Exmark 135-5271 User manual

135-5271
OPERATORCONTROLLED
DISCHARGE-HAND
StarisE-SeriesModels
SerialNo.404,314,159&Higher
PartNo.4504-477Rev.B

WARNING
CALIFORNIA
Proposition65Warning
Useofthisproductmaycauseexposure
tochemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2019ExmarkMfg.Co.,Inc.
2101AshlandAve
Beatrice,NE683102
Contactusatwww.Exmark.com.
PrintedintheUSA
AllRightsReserved

Introduction
CONGRATULATIONSonthepurchaseofyour
Exmarkequipment.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
equipment.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,and
safetyinstructions,youwillprolongthelifeofyour
equipment,maintainitsmaximumefciency,and
promotesafeoperation.
Important:Tomaximizesafety,performance,
andproperoperationofthismachine,itis
essentialthatalloperatorscarefullyreadand
fullyunderstandthecontentsoftheOperator’s
manualprovidedwiththeproduct.Safe
operationofExmarkequipmentisessential.
Failuretocomplywiththeoperatinginstructions
orreceivepropertrainingmayresultininjury.
Gotohttps://www.Exmark.comforadditional
safeoperationinformation,suchassafetytips,
trainingmaterials,andOperator’smanuals.
Ifadditionalinformationisneeded,orshould
yourequiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Forcompletewarrantydetails,see
https://www.Exmark.com.Youmayalsocall
us402-223-6375torequestawrittencopyofthe
product’swarranty.
3

Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
GeneralSafety.................................................5
SafetyandInstructionalDecals.......................6
Setup......................................................................7
ProductOverview.................................................10
Operation..............................................................11
BeforeOperation...........................................11
OperationInstructions...................................11
DuringOperationSafety.................................11
AfterOperation..............................................13
Maintenance..........................................................14
MaintenanceSafety.............................................14
RecommendedMaintenanceSchedule(s)............14
PeriodicMaintenance........................................14
CheckforLooseHardware.............................14
CheckDischargeGateClosure........................14
Adjustments......................................................15
HandleAdjustment........................................15
DischargeGateAdjustment............................15
Troubleshooting....................................................17
CaliforniaProposition65Warning
Information...............................................18
4

Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure1)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents.
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
g000502
Figure1
SafetyAlertSymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Indicatesanimminentlyhazardous
situationwhich,ifnotavoided,Willresultindeathor
seriousinjury.
WARNING:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Couldresultindeath
orseriousinjury.
CAUTION:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Mayresultinminor
ormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
GeneralSafety
Exmarkdesignedandtestedthisaccessorytooffer
reasonablysafeservice;however,failuretocomply
withsafetyinstructionsmayresultininjuryordeath.
•Read,understand,andfollowallinstructions
andwarningsinthemowerandthisaccessory
Operator’sManualsandothertrainingmaterial,
onthemachine,engine,andattachments.All
operatorsandmechanicsshouldbetrained.If
theoperator(s)ormechanic(s)cannotreadthis
manual,itistheowner’sresponsibilitytoexplain
thismaterialtothem;otherlanguagesmaybe
availableonourwebsite.
•Onlyallowtrained,responsible,andphysically
capableoperatorsthatarefamiliarwiththesafe
operation,operatorcontrols,andsafetysignsand
instructionstooperatethemachine.Neverlet
childrenoruntrainedpeopleoperateorservice
theequipment.Localregulationsmayrestrictthe
ageoftheoperator.
•DoNotputyourhandsorfeetnearmoving
componentsofthemachine.
•Neveroperatethemachinewithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
•Stopthemachine,shutofftheengine,andremove
thekeybeforeservicing,fueling,orunclogging
themachine.
5

Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
decal126-8164
126-8164
1.Close2.Open
decal116-8559
116-8559
1.Warning–stayawayfrommovingparts;keepallguards
inplace.
decal133-8061
133-8061
6

Setup
Setup
InstallingOperatorControlledDischarge
AccessoryonMowerDeck
For44inchmodels:Useahammerandchiselto
knockoutthestandardtab,asshowninFigure2,
beforestartingtheinstallationinstructions.Knocking
outthetaballowstheOperatorControlledDischarge
accessoryframetotproperlytothesedecks.
Checkthelocationofthemountingpinasshownin
Figure2.Ifnecessary,removetheboltandmounting
pinandplaceitintothecorrectlocation.Reinstallthe
bolttosecurethemountingpin.
g285508
Figure2
1.Latchpositionfor32inchmodels
2.Additionallatchposition
3.Standardknockouttabfor44inchmodel
4.Extendedknockouttabfor44inchmodel
5.Bolt
6.Pinlocationfor36inchmodels
7.Pinlocationfor32inchmodels
8.Mountingpin
9.Breakofftabs/Blockergatetrim
1.Installthebracketontotherightframeusingthe
hardwareshowninFigure3.
g285558
Figure3
1.Bracketfor32and36
inchmodels
3.1/4-20x1inchcarriage
bolt
2.Bracketfor44inch
model
4.1/4inchnylocanged
nut
2.Flipuptheexistingdischargedeector.
Important:TheOperatorControlled
Dischargeaccessorycomeswithitsown
dischargedeector.WhenusingtheOperator
ControlledDischargeaccessory,Exmark
recommendstheoriginaldischargedeector
toremaininstalledonthemachineandinthe
ippedupposition.Therearesomeinstances
wheretheexistingdischargedeectormust
beremovedwheninstallingtheOperator
ControlledDischargeaccessory.Ifthe
originaldischargedeectorisremovedduring
theOperatorControlledDischargeaccessory
installation,retainthedischargedeector
anditshardwareforreinstallationoncethe
OperatorControlledDischargeaccessoryis
removed.
3.InstalltheOperatorControlledDischarge
accessoryassembly.
•For44inchmodel:Insertthemountingpin
intothetubeweldedtotherearcornerofthe
deck.
7

Setup
g285870
Figure4
1.Flipupdischarge
deector
3.OperatorControlled
Dischargeaccessory
assembly
2.Mountingpininserted
intodecktube
4.Rotate
•For36and32inchmodels:Installthe
AdapterKitpriortoinstallingtheOperator
ControlledDischargeaccessoryassembly.
–For36inchmodel:UseP/N116-7043
–For32inchmodel:UseP/N135-5313
(seeFigure5).
g285557
Figure5
1.Flipupdischarge
deector
3.OperatorControlled
Dischargeaccessory
assembly
2.Adapterkit
4.Pivottheassemblytowardsthedeck.Thefront
pinshouldengageintotheslotinthedeckor
adapterasshowninFigure6.
g285600
Figure6
1.Frontpinandslot
2.Latch
3.OperatorControlledDischargeaccessoryassembly
4.Cablebulkheadjamnuts
•Ifthefrontpindoesnotengageintheslot
inthedeckoradapter,loosenorcompletely
removethehardwareinthegatelinkframe
asshowninFigure7.Positionthegatelink
framesothatthefrontpinalignswiththeslot.
Reinstallhardware,ifremoved,andtighten.
Pivottheassemblytowardsthedeckand
engagethefrontpinintotheslot.
8

Setup
g285747
Figure7
1.Gatelinkframe4.Shim(storageposition)
2.Adjustmentslots5.Pivotmountassembly
3.Hardware6.Shim(installedposition)
•Duetomanufacturingvariance,thegate
linkframemaynotcloseandhavecomplete
contactallaroundthedischargeopening.
Anygapsaretobeminimized.Iftherearof
thegatelinkframecontactsthemowerdeck
whilerotatingittowardsthedeckcreatinga
gapatthefront,usethestepsbelowtoinstall
ashim.Ifthegatelinkframehascomplete
contactallaroundthedischargeopening,the
shimisnotnecessary.Itcanremaininthe
storagepositionforpotentiallateruseon
othermowerdecks.
A.Removetheshimlocatedonthefrontof
thegatelinkframeandlooselyreinstallthe
nut.
B.Loosenthenutontheleftadjustmentslot
ofthegatelinkframe.
C.Installtheshimbetweenthegatelink
frameandthepivotmountassembly.
Positionthecentertaboftheshim
betweenthetwomountingboltsasshown
inFigure7.
D.Tightenhardware.
5.Rotatethelatchdownwardtolocktheassembly
inthisposition(referenceFigure6).Adjustthe
tensiononthelatchtoholdtheassemblyupto
thedeck,yetallowforreleasebyhand.Tension
canbeadjustedbytighteningorlooseningthe
hardwarethatretainsthelatch.
6.Loosenoneofthejamnuts.Mountthecable
throughthebracketandtightenthejamnuts.
Ifthedischargegatedoesnotcloseatagainst
thedischargeopening,seetheDischargeGate
AdjustmentsectioninAdjustments.
7.InstallthemountingbrackettotheLHsideof
themachine.
g285098
Figure8
1.Mountingbracket4.Handleassembly
2.5/16-18x5/8inch
carriagebolt
5.Clevispin
3.5/16inchnylocnut6.Hairpin
A.Orientthemountingbracketsothewide
openingispointedupwardtowardsthe
controlpanel.Alignthetwoholesinthe
mountingbracketandinstall5/16-18x5/8
inchcarriageboltand5/16inchnylocnuts
asshowninFigure8.
B.Insertthehandleassemblyintothemounting
bracket.
C.Inserttheclevispinthroughthehandle
assemblyhole,intotheleftholeofthe
mountingbracket,andthroughthepanelof
themachine.Securethehandleassemblywith
hairpinasshowninFigure8.
9

ProductOverview
8.Attachthecenterfrontcablebrackettotheframe.
g285735
Figure9
1.Frontbracket
9.Routethecableunderthehoodshield,alongthe
leftsideofthemachine,andunderthefrontpanel
andframeasshowninFigure10.Usevelcro
strapstosecure.
g285266
Figure10
1.Velcrostrap
ProductOverview
g285613
Figure11
1.Handle
2.Dischargegate(underdischargedeector)
3.Dischargedeector
10