For Serial Nos. 510,000 & Higher Part No. 103-9832 Rev.
WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in place and in proper working condition. ♦ Stop engine and wait for all moving parts to stop. Remove spark plug wire(s) or remove key before adjusting, servicing, or performing maintenance.
EXMARK PARTS PLUS® PROGRAM EFFECTIVE DATE: September 1, 1995 Program If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in stock for a "down" unit at the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus® shipment of six (6) line items or less. 2.
CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of troublefree operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
TABLE OF CONTENTS PAGE 1. SAFETY 1.1 1.2 1.3 1.4 1.5 1.6 Safety Alert Symbol .................................................................................... 1 Training....................................................................................................... 1 Preparation .............................................................................................. 1-3 Operation.................................................................................................
1. SAFETY This lawn mower meets or exceeds the CPSC blade safety requirements for walkbehind rotary mowers and the B71.4 specifications of the American National Standards Institute in effect at the time of production. Exmark designed and tested this lawn mower to offer reasonably safe service; however, failure to comply with the following instructions may result in personal injury. 1.
1.3.3 While mowing, always wear substantial footwear and long trousers. Do not operate equipment when barefoot or when wearing open sandals. 1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison.
DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline vapors. A fire or explosion from gasoline can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD ♦ Purchase and store gasoline only in an approved container. ♦ Always place gasoline containers on the ground away from your vehicle before filling.
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 guards, shields and safety devices in place and working. ♦ Keep hands, feet, hair, jewelry, or clothing away from rotating parts. 1.4.1 Give complete, undivided attention to the job at hand. 1.4.
1.4.8 Do Not change the engine governor settings or overspeed the engine. Operating an engine at excessive speed may increase the hazard of personal injury. 1.4.9 Never attempt to make wheel height adjustments while the engine is running. 1.4.10 Start the engine carefully according to instructions with feet well away from the blades. 1.4.11 Keep hands, feet, and clothing away from rotating parts while the mower is being operated. Keep clear of the discharge opening at all times. 1.4.
1.5.8 Keep all guards, shields and safety devices in place and in safe working condition. 1.5.9 Frequently check for worn or damaged components that could create a hazard. 1.5.10 All replacement parts must be the same as or equivalent to the parts supplied as original equipment. 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.
PART NO.: 1-213240 LOCATION: On Rear Discharge Chute Cover PART NO.: 103-6329 LOCATION: Top Surface of Shifter Control PART NO.: 103-6328 LOCATION: Top Surface of Throttle Control 2. SPECIFICATIONS 2.1 MODEL NUMBER: M266KASPC 2.2 ENGINE 2.2.1 Engine Specifications: See your engine owner's manual. 2.2.2 RPM (No Load): 3600 rpm 2.3 FUEL SYSTEM 2.3.1 Capacity: 4 qt. (3.8 liter) 2.3.2 Type of Fuel: Use only clean, fresh, regular grade, unleaded gasoline with the pump sticker octane rating of 87 or higher.
3. ASSEMBLY INSTRUCTIONS NOTE: Determine the left and right sides of the machine from the normal operating position. 3.1 Installing the Handle 1. Mount the handle to the outside of the lawn mower housing on each side as shown Fig. 1). NOTE: You can adjust the handle height for comfortable operation. Stand behind the handle to determine the height. Loosen the lower mounting bolt, adjust the handle height as desired, and re-tighten lower bolts. 2.
6. Secure the fuel line in place with the fuel line clamp (Fig. 3). FIGURE 3 3.3 Service the Engine 3.3.1 Filling the Crankcase with Oil Initially, fill the crankcase with 30 ounces (0.88 liters) of oil. Use only high-quality SAE 30 or SAE 10W-30 weight detergent oil that has the American Petroleum Institute (API) service classification SF, SG, SH, or SJ. Oil Capacity With Oil Filter 30 ounces (0.88 L) Before each use, ensure that the oil level is between the Add and Full marks on the dipstick (Fig. 8).
FIGURE 5 4.1.3 Self-Propel Drive Bail: Located on the upper handle as shown in Figure 5. When the self-propel drive bail is squeezed, the unit will move forward at the speed set on the speed control lever. When this bail is released the unit will stop moving. 4.1.4 Throttle-Choke Control: The throttle-choke control is located on the left side of the handles as shown in Figure 6. The lever is used to control engine speed.
4.2 PRE-START 4.2.1 Refer to Section 5 Maintenance and perform all of the necessary inspection and maintenance steps. 4.2.2 Fill the Fuel Tank with Gasoline See Section 1.3 Preparation section for safety information regarding the proper way to handle gasoline. For best results, use clean, fresh, lead free gasoline with an octane rating of 87 or higher. To ensure freshness, purchase only the quantity of gasoline that you expect to use in 30 days.
2. 3. FIGURE 8 Open the fuel valve. The fuel valve is located at the lower left edge of the fuel tank. Rotate the valve counter-clockwise to turn on fuel. (Fig. 9) FIGURE 9 Move the throttle-choke control to the (Choke) position. NOTE: Do not use the choke when the engine is warm. 4. Pull the starter handle lightly until you feel resistance, then pull it sharply. Allow the rope to return slowly. 5.
speed. Move the ground speed control to the Neutral position when you use the lawn mower for trimming or whenever you leave the lawn mower. 4.3.5 Operating the Blade Control Lever: 1. Start the engine. 2. Squeeze the blade control bail against the handle (Fig. 5). 3. Move the blade control lever to the full forward Latch position. Blades should engage (Fig. 6). 4. Release the blade control bail to disengage the blades.
14. Pull the lawn mower away from the newspaper. If the newspaper ball unravels or is shredded, the blade has not properly stopped, resulting in an unsafe operating condition. Contact an Authorized Service Dealer. DANGER POTENTIAL HAZARD ♦ If the blade brake clutch system is inoperative, the blade will continue to rotate when you release the blade control bail. WHAT CAN HAPPEN ♦ Contact with the blade could occur, causing serious injury. HOW TO AVOID THE HAZARD ♦ Check the BBC operation before each use.
Front wheel height adjustment: 1. Pull the wheel height adjustment lever toward the wheel (Fig. 11) and move it to the desired setting. 2. FIGURE 11 Release the wheel height adjustment lever and set it securely in the notch. 3. Adjust both front wheels to the same cutting height setting. Rear wheel height adjustment: 1. Pull the rear wheel height adjustment lever outward towards left wheel and move it to the same cutting height setting as the front wheels. 2.
3. FIGURE 13 Set the bag frame onto the bag support tabs. 4. Lower door onto bag. Mowing with the Grass Bag WARNING POTENTIAL HAZARD ♦ A worn grass bag could allow small stones and other similar debris to be thrown in the operator’s or bystander’s direction. WHAT CAN HAPPEN ♦ Thrown objects can result serious personal injury or death to the operator or bystanders. HOW TO AVOID THE HAZARD ♦ Check the grass bag frequently. If it is damaged, install a new Exmark replacement bag.
4.3.10 Operating Tips • Review the Safety Instructions (Section 1) and read this manual carefully before operating the lawn mower. • Set the engine speed to the fastest position for the best cutting results. • Maintain a sharp blade throughout the cutting season. Periodically file down nicks on the blade. Replace the blade when necessary with an original Exmark replacement blade. • Clean the air filter frequently.
5. MAINTENANCE NOTE: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Service Interval Each Use 5 Hours 50 Hours 75 Hours 100 Hours 300 Hours Storage 1 Maintenance Procedure • Check the engine oil level. • Check the stopping time of the blade brake. The blade must stop within 3 seconds of releasing the bail; if it does not; contact an Authorized Service Dealer for repair. • Remove grass clippings and dirt from under the housing.
5.2 Checking the Blade Brake Clutch Refer to Section 4.3.6 Checking the Blade Brake Clutch. 5.3 Cleaning the Underside of the Lawn Mower Housing. To ensure the best performance, keep the underside of the lawn mower housing clean (Fig. 14). Washing Method FIGURE 14 1. Position the lawn mower on a flat concrete or asphalt surface near a garden hose. 2. Start the engine. 3. Hold the running garden hose a handle level and direct the water to flow on the ground just in front of the right rear tire (Fig.
4. Remove the dirt and grass clippings with a hardwood scraper. Avoid burrs and sharp edges. 5. Turn the lawn mower upright. 6. Fill the fuel tank. 7. Connect the wire to the spark plug. 5.4 Cleaning the Discharge Tunnel Service Interval: After each use. Always be sure that the discharge tunnel door closes securely when you remove the bag. If the debris prevents the discharge door form closing securely, clean the inside of the discharge tunnel and the door thoroughly.
Paper Air Filter Foam Pre Cleaner G0216 Figure 17 NOTE: Do not try to clean a paper air filter. 6. Remove the foam pre-cleaner and wash it with a mild detergent and water, then blot it dry (Fig 17). 7. Saturate the pre-cleaner with clean engine oil, then squeeze it (do not twist) to remove the excess oil. 8. Install the foam pre-cleaner. 9. Install the new paper air filter. 10. Install the cover and secure it with the screw. 5.6 Maintaining the Blade Always mow with a sharp blade.
Sail Sail Flat Sail Wear G0219 Slot FIGURE 19 NOTE: For the best performance, install a new blade before the cutting season begins. During the year, file down any small nicks to maintain the cutting edge. DANGER POTENTIAL HAZARD ♦ A worn or damaged blade can break. WHAT CAN HAPPEN ♦ A piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death. HOW TO AVOID THE HAZARD ♦ Inspect the blade periodically for wear or damage.
9. Re-install a sharp balanced Exmark blade, spacer, washer, and blade bolt. The sail of the blade must point toward the top of the lawn mower housing for proper installation. Torque the blade bolt to 75-85 ft-lb (102-115 N-m). 10. Return the lawn mower to its upright position. 11. Close fuel valve and refuel. 12. Connect the wire to the spark plug. 5.7 Cleaning Under the Cover: 1. Stop the engine and wait for all moving parts to stop. 2. Disconnect the wire from the spark plug (Fig. 8). 3.
2. Locate the grease fitting on the underside of the mower deck. Wipe the grease fittings with a clean rag (Fig. 23). FIGURE 23 3. Install a grease gun onto the fitting and gently apply 2 or 3 pumps of #2 multipurpose lithium base grease (Fig. 23). NOTE: Excessive grease pressure may damage the seals. 5.10 Adjusting the Self-Propel Drive: If the lawn mower does not self-propel or has a tendency to creep forward when the control bar is released, adjust the transmission cable on the deck. 1.
0.030 in. (0.76 mm) FIGURE 25 6. Install the spark plug and the gasket seal. 7. Torque the plug to 17 ft-lb (23 N-m). 8. Connect the wire to the spark plug. 5.12 Changing the Engine Oil: Service Interval: Change the oil after the first 5 operating hours (or the first month) Then after every 50 operating hours (or every 6 months) 1. Run the engine to warm the engine oil. NOTE: Warm oil flows better and carries more contaminates. WARNING POTENTIAL HAZARD ♦ Oil may be hot after engine has been run.
WARNING POTENTIAL HAZARD ♦ Oil may be hot after engine has been run. WHAT CAN HAPPEN ♦ Contact with hot oil can cause severe personal injury. HOW TO AVOID THE HAZARD ♦ Avoid contacting the hot engine oil when you drain it. 2. Stop the engine and wait for all moving parts to stop. 3. Disconnect the wire from the spark plug (Fig. 8). 4. Drain the engine oil. 5. Place a rag under the oil filter to catch any oil that may leak out as you remove the filter. 6. Remove the oil filter. 7.
FIGURE 28 4. Gently apply one to two pumps of #2 multi-purpose lithium-base grease. 5. Re-install gear case access cover. 6. Install the grass bag. 5.15 Adjusting the Blade Brake Cable: Service Interval: Adjust whenever a new blade brake cable assembly it installed 1. Stop the engine and wait for all moving parts to stop. 2. Disconnect the wire from the spark plug (Fig. 8). 3. Remove belt cover 4. Loosen the blade brake cable nuts until the cable conduit slides (Fig. 29) FIGURE 29 5.
FRONT WHEEL ASSEMBLY FIGURE 30 REAR WHEEL ASSEMBLY FIGURE 31 Assembling the Wheels 1. Re-install wheel assembly as shown in Figures 30 or 31. 2. Connect the wire to the spark plug. 6. STORAGE 6.1 Preparing the fuel system. To prepare the lawn mower for off season storage, perform the recommended maintenance procedures. Store the lawn mower in a cool, clean, dry place. Cover the lawn mower to keep it clean and protected.
3. Using an oil can, add about one tablespoon of oil to the crankcase through the spark plug hole. 4. Slowly rotate the engine several times, using the starter rope, to distribute the oil. 5. Install the spark plug but do not connect the wire to the spark plug. 6.3 General Storage Information 1. Clean the lawn mower housing. Refer to Section 5.3 Cleaning the Underside of the Lawn Mower Housing. 2. Clean any dirt and chaff from the cylinder, cylinder head fins, and blower housing. 3.
8. TROUBLESHOOTING Exmark designed and built your lawn mower for trouble free operation. Check the following components and items carefully, and refer to Section X Maintenance for more information. If a problem continues, contact an Authorized Service Dealer. Problem Engine does not start Engine starts hard or loses power Engine runs rough Possible Causes Corrective Action 1. The fuel tank is empty or the fuel system contains stale fuel. 1. Drain and/or fill the fuel tank with fresh gasoline.
Problem Lawn mower or engine vibrates excessively Uneven cutting pattern Mower doesn’t cut grass Discharge chute plugs Lawn mower does not selfpropel Possible Causes Corrective Action 1. The blade is bent or is out of balance. 1. Balance the blade. If the blade is bent, replace it. 2. The blade mounting bolt is loose. 2. Tighten the blade mounting bolt. 3. The underside of the lawn mower deck contains clippings and debris. 3. Clean the underside of the lawn mower deck. 4.
9. 2-Year Limited Warranty Exmark Turf Equipment (For units purchased on or after October 1, 2004) Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part manufactured by Exmark and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of two years.
NOTES - 33 -
SERVICE RECORD Date Description of Work Done Service Done By - 34 -
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT MICRO-MULCH SYSTEM ROLL OVER PROTECTION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONTAINER TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO-MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER EZ-RIDER Check us out on the Web: www.exmark.
