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For Serial Nos.

540,000 & Higher

Part No. 103-9170

Содержание Lawn Tractor

Страница 1: ...For Serial Nos 540 000 Higher Part No 103 9170 ...

Страница 2: ...from eyes and skin Never siphon by mouth IMPORTANT When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES...

Страница 3: ...bmitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 If the part does not arrive overnight due to the shipper UPS the shipper pays for the freight and Exmark pays for the part The following res...

Страница 4: ...wer maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service st...

Страница 5: ...NS 3 1 Uncrate Mower 13 3 2 Install Rollover Protection System roll bar 13 15 3 3 Service Battery 15 16 3 4 Install Drive Wheels 17 3 5 Check Tire Pressure 17 3 6 Install Seat 17 3 7 Install Motion Control Levers 17 3 8 Position Discharge Chute 18 3 9 Service Engine 18 3 10 Service Hydraulic Oil 18 4 OPERATION INSTRUCTIONS 4 1 Controls 18 20 4 2 Pre Start 20 4 3 Operating Instructions 20 22 4 4 Tr...

Страница 6: ...perator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 2 4 Avoid mowing while people especially children or pets are nearby Ke...

Страница 7: ...can burn you others and cause property damage HOW TO AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only outdoors Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when t...

Страница 8: ...e then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignited by electrical sparks ...

Страница 9: ...and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guard...

Страница 10: ...rogressively greater care is needed as the slope increases Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Avoid sudden starts when mowing uphill Mower may tip backwards Be aware that loss of traction may occur going downhill Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking ...

Страница 11: ... place and in proper working condition 1 4 9 DO NOT change the engine governor settings or overspeed the engine Operating an engine at excessive speed may increase the hazard of personal injury 1 4 10 Disengage PTO before starting engine 1 4 11 Start the engine carefully with feet well away from the blades 1 4 12 Keep hands feet and clothing away from rotating parts while the mower is being operat...

Страница 12: ...f time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage 1 5 4 Keep engine engine area and pump drive belt compartment free from accumu...

Страница 13: ...control levers in neutral and shutting off the engine before performing any work on the hydraulic system 1 6 SAFETY SIGNS 1 6 1 Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels 1 6 2 Safety signs must be replaced if they are missing or illegible 1 6 3 When new components are installed be sure that current safety signs are affixed to the rep...

Страница 14: ...303508 LOCATION RH Side on Top Rear of Mower Deck PART NO 1 513742 LOCATION Top of Mower Deck Belt Shields Left and Right Sides PART NO 1 523552 LOCATION Top of Hydraulic Reservoir Under the Seat PART NO 1 513748 LOCATION Bottom Side of Floorpan PART NO 103 3997 LOCATION RH Side of Console PART NO 103 6319 LOCATION Bottom Side of Floor Pan PART NO 107 2102 LOCATION Inside Surface of Upper Roll bar...

Страница 15: ... PART NO 1 643339 LOCATION Top of Right Engine Baffle PART NO 1 633922 LOCATION Front Center on Top of Mower Deck PART NO 103 0262 LOCATION Center Front of Console PART NO 103 7491 LOCATION LH Side on Top Front of Mower Deck PART NO 103 3270 LOCATION On Engine PART NO 98 5954 LOCATION Under Mower Deck Belt Shield s PART NO 107 2112 LOCATION Top Center of Floorpan PART NO 103 9256 LOCATION Top of c...

Страница 16: ...engaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged 2 5 OPERATOR CONTROLS 2 5 1 Steering and Motion Control Separate levers on each side of the console control speed and direction of travel of the respective drive wheels Steering is controlled by varying the positi...

Страница 17: ... type P N 1 513211 10 microns 18 psi bypass Summer use above 32 F 0 C P N 1 523541 40 microns 18 psi bypass Winter use below 32 F 0 C 2 7 6 Speeds 0 9 0 mph 14 5 km hr forward 0 5 8 mph 9 3 km hr reverse 2 7 7 Drive wheel release valves allow machine to be moved when engine is not running 2 8 TIRES 2 9 CUTTING DECK 2 9 1 Cutting Width 52 in 132 1 cm 60 in 152 4 cm 2 9 2 Discharge Side 2 9 3 Blade ...

Страница 18: ... 55 60 ft lbs 75 81 N m Engine Deck Front Frame Mount Bolts 30 35 ft lbs 41 47 N m Anti Scalp Roller Nuts 40 45 ft lbs 54 61 N m Engine Mounting Bolts 30 35 ft lbs 41 47 N m Wheel Lug Nuts 90 95 ft lbs 122 129 N m Wheel Motor Mounting Bolts 72 77 ft lbs 98 104 N m Wheel Hub Slotted Nut minimum125 ft lbs 169 N m Rollover Protection System Roll Bar Mounting Bolts 30 35 ft lbs 41 47 N m Deck Drive Ja...

Страница 19: ...ands or equivalent support 3 2 3 Remove the wheel nuts from both sides of the unit and retain for later use 3 2 4 Install the two lower roll bar tubes a Locate the left and right lower roll bar tubes b Align lower roll bar tubes along the rear engine frame as shown in Figure 2 c LOOSELY install the lower roll bar hardware four 3 8 16 x 1 capscrews four spring disk washers and four 3 8 16 whizlock ...

Страница 20: ...y Notes Make sure the capscrew and nuts are installed with the nut to the inside of the roll bar Make sure the tab on the lanyard washer is installed as shown and points toward the front of the unit d Raise the roll bar into the upright position and secure with the latch pin assemblies on each side Install latch pin from outer surface of roll bar assembly and secure with the hairpin to the inside ...

Страница 21: ... No Charging Required 12 4 12 6 75 100 16 volts 7 amps 30 Minutes 12 2 12 4 50 75 16 volts 7 amps 1 Hour 12 0 12 2 25 50 14 4 volts 4 amps 2 Hours 11 7 12 0 0 25 14 4 volts 4 amps 3 Hours 11 7 or less 0 14 4 volts 2 amps 6 Hours or More CAUTION POTENTIAL HAZARD If the ignition is in the ON position there is potential for sparks and engagement of components WHAT CAN HAPPEN Sparks could cause an exp...

Страница 22: ...shafts a Install the left motion control lever onto the control arm shaft See Figure 4 on the left side of the console Place the lever with the mounting plate towards the rear on the outside of the control arm shaft and secure with the bolts and washers Position the lever so the bolts are in the center of the slots on the lever mounting plate and tighten until snug Repeat on opposite side of unit ...

Страница 23: ... F 24 C fill only to the COLD level 4 OPERATION INSTRUCTIONS 4 1 CONTROLS 4 1 1 Familiarize yourself with all controls before operating the mower 4 1 2 Motion Control Levers Located on each side of the console The left lever controls the flow of hydraulic oil from the left hydrostatic pump to the left drive wheel motor The right lever controls the flow of hydraulic oil from the right hydrostatic p...

Страница 24: ...tracking knob Rotate the knob clockwise as viewed from the rear of the machine to cause the machine to track more to the right and counterclockwise to cause the machine to track more to the left Adjust in quarter turn increments until the machine tracks straight Check that the machine does not creep when in neutral with the park brakes disengaged IMPORTANT Do not rotate the knob too far as this ma...

Страница 25: ...11 Drive Wheel Release Valves Located on the top left front corner of hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running Unhook seat latch and tilt seat up to gain access to pumps With a 5 8 wrench turn both valves one turn counter clockwise to release drive system Turn clockwise to reset system...

Страница 26: ...ARD The rotating blades under the mower deck are dangerous WHAT CAN HAPPEN Blade contact can cause serious injury or kill you HOW TO AVOID THE HAZARD DO NOT put hands or feet under the mower or mower deck when the blades are engaged DANGER POTENTIAL HAZARD An uncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occu...

Страница 27: ...ights reflective markings or a slow moving vehicle emblem These items are required to drive on a public street or roadway WHAT CAN HAPPEN Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets an...

Страница 28: ...s possible DO NOT attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward 5 MAINTENANCE ADJUSTMENTS WARNING POTENTIAL HAZARD While maintenance or adjustments are being made someone could start the engine WHAT CAN HAPPEN A...

Страница 29: ...e disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Voltage Reading Percent Charge Maximum Charger Settings Charging Interval 12 6 or greater 100 16 volts 7 amps No Charging Required 12 4 12 6 75 100 16 volts 7 amps 30 Minutes 12 2 12 4 50 75 16 volts 7 amps ...

Страница 30: ...gh support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support c Clean out any grass build up from underside of deck and in discharge chute 5 1 5 Check mower blades Service Interval Daily a Stop engine wait for all moving parts to stop and remove ...

Страница 31: ...Daily a Check starting circuit Starter should crank with parking brake engaged PTO disengaged and motion control levers moved out in the neutral lock position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must not crank Try to start with opera...

Страница 32: ... before operating 5 1 9 Service air cleaner Service Interval 50 hrs More often under severe conditions See Engine manual for additional information a Stop engine wait for all moving parts to stop and remove key b Loosen wing nut and remove air cleaner compartment cover c Remove foam pre cleaner element and wash in warm water with detergent Rinse until all traces of detergent are eliminated and squ...

Страница 33: ... the COLD level 5 1 13 Check tire pressures Service Interval 40 hrs a Stop engine wait for all moving parts to stop and remove key b Check tire pressure in drive tires c Inflate drive tires to 13 psi 90 kPa d Check tire pressure in Caster tires e Inflate caster tires to 13 psi 90 kPa NOTE Do not add any type of tire liner or foam fill material to the tires Excessive loads created by foam filled ti...

Страница 34: ...ring Remove grease zerk and thread plug back in Place cap back on 5 1 16 Lubricate caster wheel hubs Service Interval Once Yearly a Stop engine wait for all moving parts to stop and remove key b Remove caster wheel from caster forks c Remove seal guards from the wheel hub d Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied t...

Страница 35: ...n 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Re apply threadlocking adhesive 5 1 17 Lubricate seat switch actuator Service Interval 160 hrs a Stop engine wait for all moving parts to stop and remove key b Unhook seat latch and tilt seat up c Lubricate switch actuator rod with spray type lubricant or light oi...

Страница 36: ...PORTANT Before reinstalling new filter fill it with Mobil 1 15W 50 and apply a thin coat of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn e Fill reservoir as stated in Section 5 1 12 f Raise the rear of machine up and support with jack stands or equivalent support just high enough to a...

Страница 37: ...I or Retaining II are used on the following a Fuel tank studs where studs are inserted into tank 5 1 28 Mobil HTS grease or food grade antisieze is used in the following locations a Between the cutter housing spindle and bearings b Between the cutter housing spindle and sheave c Under top cutter housing bearing guard d Between jackshaft and bearings and jackshaft and sheaves 5 1 29 Dielectric grea...

Страница 38: ...pressure in drive tires Proper inflation pressure for tires is 13 psi 90 kPa Adjust if necessary Check tire pressure in Caster tires Proper inflation pressure for tires is 13 psi 90 kPa d Set anti scalp rollers to top holes or remove them completely for this adjustment e Raise the deck to the 4 5 11 4 height position also transport position and take all force off of the two large deck lift springs...

Страница 39: ... will be slightly lower than the rear of the deck 5 2 3 Pump Drive Belt Tension Self tensioning No adjustment necessary 5 2 4 Mule Drive Belt Tension Adjustment Self tensioning idler adjust as follows a Stop engine wait for all moving parts to stop and remove key b Check to make sure the center of the bolt head in the center of the spring loaded pulley on left side engine deck support is positione...

Страница 40: ...either the brake disengaged or the PTO engaged the engine should stop after 1 2 second has elapsed b To adjust seat switch actuator rod length loosen lock nut on bottom of the actuator rod 5 16 x 7 bolt and adjust the nuts to move the actuator plate washer up or down on the rod then retighten 5 2 7 Belt Guide Adjustment a Stop engine wait for all moving parts to stop and remove key b Remove the be...

Страница 41: ...ectly below the yoke Turn the bottom nut below washer until the correct measurement is obtained See Figure 14 turn nut clockwise to lengthen the gap screws rod into yoke and turn counter clockwise to shorten the gap screws rod out of yoke Tighten nut against yoke and check opposite side of unit repeat if necessary 5 2 10 Adjust Throttle Lever Tension a Stop engine wait for all moving parts to stop...

Страница 42: ...OR ADJUSTMENT 5 2 13 Motion control linkage adjustment WARNING POTENTIAL HAZARD Engine must be running and drive wheels must be turning so motion control adjustment can be performed WHAT CAN HAPPEN Contact with moving parts or hot surfaces may cause personal injury HOW TO AVOID THE HAZARD Keep fingers hands and clothing clear of rotating components and hot surfaces CAUTION POTENTIAL HAZARD Raising...

Страница 43: ...e Section 5 2 12 NOTE The motion control lever needs to be in neutral while making any necessary adjustments The left rod assembly controls the left wheel and the right rod assembly controls the right wheel h Bring the LH motion control lever into the neutral position Adjust LH pump control rod length by rotating the double nuts on the rod in the appropriate direction until the wheels slightly cre...

Страница 44: ...cid which is poisonous and can cause severe burns WHAT CAN HAPPEN Swallowing electrolyte can be fatal or if it touches skin can cause severe burns HOW TO AVOID THE HAZARD Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do not swallow electrolyte Federal law states that batteries should not be placed in the garbage Management and disposal ...

Страница 45: ...is open d Be sure the seat switch is properly adjusted See Section 5 2 6 e Make sure the parking brake is set and motion control levers are moved out neutral lock position f Check that the PTO is disengaged g Check that the spark plug wires are properly connected h Check for loose or faulty wiring connections i Check for corrosion at all wiring connections Even minor corrosion may cause a faulty c...

Страница 46: ...UEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN INSUFFICIENT BATTERY CHARGE Will not start X X X X X X X Hard starting X X X X X X X Stops suddenly X X X X X X X Lacks power X X X X X X X X Operates erratically X X X X X X X Knocks or pings X X X Skips or misfires X X X X X Backfires X X X X X Overheats X X X X X High fuel consumption X X X X ...

Страница 47: ... 42 8 ELECTRICAL DIAGRAM ...

Страница 48: ... 43 9 HYDRAULIC DIAGRAM ...

Страница 49: ...with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extend...

Страница 50: ... 45 SERVICE RECORD Date Description of Work Done Service Done By ...

Страница 51: ... 46 ...

Страница 52: ...EM ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 2004 EXMARK MFG CO INC PART NO 103 9170 INDUSTRIAL PARK BOX 808 402 223 6300 BEATRICE NE 68310 FAX 402 223 54...

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