Exmark FMD524 User Manual

For Turf Tracer

Serial Nos. 510,000 & Higher

and

FMD524 & FMD604

Serial Nos. 510,000 & Higher

Part No. 103-9190

WARNING

POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating pr actices 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 condit ion.
♦ Stop engine and wait for all moving parts to stop. Remove spark

plug wire(s) or remove key before adjust ing, servicing, or

performing maint enance.
♦ If mower deck becomes clogged, stop engine and wait for all

moving parts to stop. Remove spark plug wire(s) or r em ove k ey

before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts .
♦ Keep off mower unless seat platf o r m is pr ovided.
♦ Keep others off mower.

WARNING

POTENTIAL HAZARD
♦ Gasoline is harmful or f at a l if swallowed. Long-term exposure to

vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN
♦ Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD

♦ Avoid prolonged breathing of vapors.
♦ Keep face away from nozzle and gas tank/container opening.
♦ Keep away from eyes and skin.
♦ Never siphon by mouth.

IMPORTANT

When the mower is used or oper ated on any California forest, brush or grass covered land, a working
spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442
Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.

This spark ignition system complies with Canadian ICES-002
Ce système d’allumage par ètincelle de vèhicule est conform e à la norme NMB-002 du Canada

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and the California Emission Control Regulation
of emission systems, maintenance and warranty.

Keep this engine Owner’s M anual with your unit. Should this engi ne O wner’s Manual
become damaged or illegible, replace immediately. Replacements may be ordered
through the engine manufacturer.

Exmark reserves the right to make changes or add improvements to its products at any time
without incurring any obligation to make such chang es to products manufactured previously.
Exmark, or its distributors and dealer s, accept no responsibility for variations which may be
evident in the actual specifications of its pr oducts and the statements and descriptions
contained in this publication.

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

2. Distributor ships part(s) to dealer or customer, as

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

5. The customer pays for the part

6. Who pays for the part
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

The following restrictions apply
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is only available
in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United
States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the
Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday
delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by 3:00 p.m., central time. Orders
must be six (6) line items or less. Exclusions from the Exmark Parts Plus
entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or
hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight
restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or
Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered
for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

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.

requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.

®

order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus

®

order of six (6) line items or less.

distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable.

and freight if it is shipped under the Exmark Parts Plus® and if it arrives in

accordance to the program.

and freight if it fails to arrive overnight in accordance to the program?

1. The dealer not submitting the Exmark Parts Plus

®

order to his Exmark distributor by 1:00 p.m., the dealer

pays for the part and freight.

®

order

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

Exmark pays for the part and freight.

pays for the part.

-- The Exmark Parts Plus® Program is available only through participating Exmark

®

Program are: Any wholegood or accessory in its

- i -

CONGRATULATIONS on the purchase of your Exmark Mower. This product has been
carefully designed and manufactur ed to give you a maximum amount of dependability and
years of trouble-free oper at ion.

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.

By following the operating, maintenance, and safety instructions, you will prolong the lif e

of your mower, maintain its maximum ef ficiency, and promote safe operation.
If additional information is needed, or should you require trained mechanic ser vice,

contact your authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and dist r ibut or s ar e kept informed of the latest methods

of servicing and are equipped to provide prompt and efficient service in the f ield or at their
service stations. They carry ample stock of ser vice parts or can secur e t hem promptly for you
from the factor y.

All Exmark parts are thoroughly tested and inspected before leaving the factory,
however, attention is required on your part if you are t o obt ain the fullest measure of
satisfaction and performance.

- ii -

TABLE OF CONTENTS

1. SAFETY.............................................................................................PAGE

1.1 Safety Alert Symbol...................................................................................... 1

1.2 Training........................................................................................................ 1

1.3 Preparation................................................................................................1-3

1.4 Operation..................................................................................................4-6

1.5 Maintenance & Storage.............................................................................6-7

1.6 Riding Attachments......................................................................................7

1.7 Safety Signs........................................................................................ .....7-9

2. SPECIFICATIONS

2.1 Model Number............................................................................................ 10

2.2 Engine........................................................................................................ 10

2.3 Fuel System............................................................................................... 10

2.4 Electrical System........................................................................................ 10

2.5 Steering/Brake Control............................................................................... 10

2.6 Transmission.............................................................................................. 10

2.7 Wheel Drive System................................................................................... 10

2.8 Tires........................................................................................................... 11

2.9 Deck........................................................................................................... 11

2.10 Dimensions ............................................................................................... 11

2.11 Torque Requirements................................................................................11

3. ASSEMBLY INSTRUCTIONS

3.1 to 3.12 Assembly...................................................................................12-15

4. OPERATION INSTRUCTIONS

4.1 Controls.................................................................................................15-17

4.2 Pre-Start..................................................................................................... 17

4.3 Operation Instructions...........................................................................17-19

4.4 Transporting ............................................................................................... 20

5. MAINTENANCE & ADJUSTMENTS

5.1 Periodic Maintenance............................................................................20-29

5.2 Adjustments..........................................................................................30-35

6. WASTE DISPOSAL

6.1 Motor Oil Disposal......................................................................................35

6.2 Battery Disposal......................................................................................... 35

7. TROUBLE SHOOTING

7.1 Mower Tracks Left or Right........................................................................35

7.2 Mower Cuts Unevenly ................................................................................ 36

7.3 Engine Will Not Start.............................................................................36-37

8. HYDRAULIC SCHEMATIC........................................................................... 38

9. WIRING DIAGRAM....................................................................................... 39

10. WARRANTY................................................................................................. 40

- iii -

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the machine to

identify important safety messages which must be followed to avoid accidents. This
symbol means:

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The safety alert symbol appears above information which alerts you to unsafe actions or

situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lettering / Red background. I ndicates an imminently hazardous situation

which, if not avoided, WILL result in death or serious injur y.

WARNING: Black lettering / O r ange background. Indicates a pot ent ially hazardous

situation which, if not avoided, COULD result in deat h or serious injury.

CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous

situation which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to
all who operate this unit.

1.2.2 Read the instructions carefully. Familiar ize yourself with the cont r ols and t he
proper use of the equipment. If the operator(s) or m echanic(s) can not read
English, it is the owner’s responsibility to explain this mater ial t o 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. Keep in mind
that the operator or user is responsible for accidents or hazards occurring to other
people or their property.

1.3 PREPARATION

1.3.1 Evaluate the terrain to determine what accessories and attachm ents are needed to
properly and safely perform the job. Only use accessories and attachments
approved by Exmark.

1.3.2 The use of personal protective equipment, such as (but not limited to) pr ot ection
for the eyes, ears, feet , and head is r ecom mended.

CAUTION

POTENTIAL HAZARD
♦ This machine produces sound levels in excess of 85

dBA at the operator’s ear when in operation.

WHAT CAN HAPPEN
♦ Exposure to sound levels of 85 dBA or above for

extended periods of time can cause hearing loss.

HOW TO AVOID THE HAZARD
♦ Wear hearing protection when operating this machine.

1.3.3 While mowing, always wear substantial footwear and long trousers. Do not
operate equipment when barefoot or when wearing open sandals.

- 1 -

1.3.4 Thoroughly inspect the area where the equipment is t o be used and r emove all
stones, sticks, wires, bones, and other foreign objects which may damage the
equipment or cause personal injury to the operat or or bystander s.

WARNING

POTENTIAL HAZARD
♦ Engine exhaust contains carbon monoxide, which is

an odorless deadly poison.

WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.

HOW TO AVOID THE HAZARD
♦ Do not run engine indoors or in a small confined area

where dangerous carbon monoxide fumes can collect.

DANGER

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flamm able

and highly explosive.

WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can bur n you, ot hers,

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 m ay 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 start ing the engine. Never remove the

cap of the fuel tank or add fuel when engine is running
or when the engine is hot.

♦ Never fill the fuel tank so t hat the gasoline level rises

above a level that is 1/2” below the bottom of the filler
neck to allow for gasoline expansion and prevent fuel
spillage.

♦ If fuel is spilled, DO NOT attempt to start the engine.

Move away from the area of the spill and avoid
creating any source of ignition unt il fuel vapors have
dissipated.

♦ Do not operate without entire exhaust system in place

and in proper working condition.

- 2 -

DANGER

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flamm able

and highly explosive.

WHAT CAN HAPPEN
♦ A static charge can ignite g asoline 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 f illing.

♦ Do not fill gasoline containers inside a vehicle or on a

truck or trailer bed because interior car pet s or plastic
truck bed liners may insulate the container and slow
the loss of any static charge.

♦ When practical, r emove gas-powered equipment from

the truck or trailer and r efuel the equipment with its
wheels on the ground.

♦ If this is not possible, 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 or hot
engine/exhaust components.

WHAT CAN HAPPEN
♦ Explosion and fire may occur, resulting in proper t y

damage, personal injury, and/or death.

HOW TO AVOID THE HAZARD
♦ Provide adequate ventilation of any enclosed trailer to

prevent build up of gasoline vapors, especially at floor
level.

♦ Refuel only outdoors, never inside an enclosed trailer.
♦ Be sure all fuel tanks and gasoline st or age containers

have proper caps installed to prevent spillage and
minimize vapor escaping into the trailer.

♦ Do not place any equipment that is leaking gasoline in

an enclosed trailer.

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1.4 OPERATION

Although hazard control and accident prevention are parti al l y dependent upon the
design and configuration of the equipment, these factors are also dependent upon
the awareness, concern, prudence, and proper training of t he personnel i nvolved in
the operation, transport, maintenance, and st orage of t he equipment. It is essential
that all Operator Safety Mechanisms be connect ed and i n operat i ng condition prior
to use for mowing.

POTENTIAL HAZARD
♦ Operating engine parts, especially the m uffler, become

extremely hot.

WHAT CAN HAPPEN

♦ Severe burns can occur on contact.
♦ Debris, such as leaves, grass, brush, etc. can cat ch fire.

HOW TO AVOID THE HAZARD
♦ Allow engine parts, especially the muff ler , to cool before

touching.

♦ Remove accumulated debris from muffler and engine area.
♦ Install and maintain in working order a spar k arrester before

using equipment on forest - covered, grass-covered, or
brush-covered unimproved land.

WARNING

WARNING

POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories can become

entangled in rotating part s.
WHAT CAN HAPPEN
♦ Contact with rotating parts can cause traum at ic am putation

or severe lacerations.
HOW TO AVOID THE HAZARD
♦ Do not operate the machine without guards, shields, and

safety devices in place and working properly.
♦ Keep hands, feet, hair, je welry, or clot hing away from

rotating parts.

1.4.1 Give complete, undivided attention to the job at hand.

1.4.2 Mow only in daylight or in good artif icial light, keeping away from holes and hidden
hazards. DO NOT operate the mower when children or others are in the area.

1.4.3 When f easible, avoid operating the equipment in wet grass.

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr action

and/or tip-over could occur. The operator is r esponsible for safe operation on
slopes.

- 4 -

DANGER

POTENTIAL HAZARD
♦ Mowing on wet grass or steep slopes can cause sliding and

loss of control.

WHAT CAN HAPPEN
♦ Loss of control and/or loss of operator’s footing could result

in a fall with an arm or leg getting under the mower or
engine deck, which may result in serious injury or death.

HOW TO AVOID THE HAZARD

♦ Mow across slopes, never up and down.
♦ Do not mow slopes when grass is wet.
♦ Do not mow near drop-offs or near water.
♦ Do not mow slopes greater than 20 degrees.
♦ Reduce speed and use extreme caution on slopes.
♦ Avoid sudden turns or rapid speed changes.

• See inside the back cover to determine the approximate slope angle of the

area to be mowed.

• Progressively 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.

• 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
and steering.

• Watch for ditches, holes, rocks, dips, and r ises t hat change the operating
angle, as rough terrain could overtur n the machine.

• Remove or mark obstacles such as rocks, t r ee lim bs, etc. from the mowing
area. Tall grass can hide obstacles.

• Use extreme care with grass catchers or attachments. These can change the
stability of the machine and cause loss of control.

1.4.5 Use EXTREME caution when backing up. LOOK BEHI ND YO U!!

1.4.6 Stop the blades when crossing surfaces other than grass, if mower must be tilted
for transportation, and when transpor t ing the mower to and from the area to be
mowed.

1.4.7 Never operate the mower with defective guards, shields, or covers. Always have
safety shields, guards, switches, and other devices in place and in proper work ing
condition.

1.4.8 Do Not change the engine governor set t ings or over speed the engine. Operating
an engine at excessive speed may increase the hazard of personal injury.

1.4.9 Place speed control lever in neutral, lock drive levers in neutra l, disengage PTO,
and engage park brake before starting engine.

1.4.10 Start the engine carefully with feet well away from the blades.

1.4.11 Keep hands, feet, and clothing away from rotating part s while the mower is being
operated.

1.4.12 Stop the engine, wait for all moving parts to stop, and r em ove plug wire(s) or key:

• Before checking, cleaning or work ing on the mower.

• After striking a foreign object (inspect the m ower for damage and make

repairs before restart ing and operating the mower).

• Before clearing blockages.

• Whenever you leave the mower.

- 5 -

1.4.13 Stop the engine and wait f or all moving parts to stop:

• Before removing grass catcher.

• Before refueling.

• Before making heig ht adjustments.

1.4.14 Before stopping the engine, place the throttle cont r ol midway between the “slow”
and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds, then stop
the engine.

1.4.15 The fuel system is pr ovided with a shut-off valve. The fuel shut-off valve is used
to shut off the fuel:

• When the machine will not be used for a few days.

• During transport to and f r om the job.

• When parking inside a building.

1.4.16 This mower was designed fo r one oper at or only. Keep all others away from

mower during operation.

1.4.17 Do NOT mow with the discharge deflector raised, r em oved or altered unless

there is a grass collection system or mulch k it in place and work ing properly.

1.4.18 Be aware of the mower discharge and direct discharge away from ot her s.

1.4.19 Do NOT operate the mower under the influence of alcohol or drugs.

1.4.20 Use extra care when approaching blind corners, shrubs, trees, or ot her objects

that may obscure vision.

1.4.21 If jump star ting is required:
a) Connect the positive (+) power cable from t he positive post on the booster

battery to the positive terminal post on the star ter solenoid switch (this post
has the positive battery cable attached to it).

b) Connect the negative or ground cable (-) from the negative post on the

booster battery to the engine block as far away from the battery as
possible.

c) Disconnect battery cables in the reverse order after starting.

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maintenance, follow the engine m anufacture’s recommendations
precisely as stated in the engine manual.

1.5.2 Disconnect the battery from t he negative battery post when the unit will be
allowed to sit for more than 30 days without use.

1.5.3 Allowing batteries to stand for an extended period of time without recharging
them will result in reduced performance and ser vice life. To preserve optimum
battery performance and lif e, recharge batteries in storage when the open circuit
voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, bat t er y should be fully charged before

putting away for winter storage.

1.5.4 Keep engine and engine area free from accumulation of grass, leaves, excessive
grease or oil, and other debris which can accumulate in these areas. These
materials can become combustible and may result in a fir e.

1.5.5 Store f uel in a container specifically designed for t his pur pose in a cool, dry place.

1.5.6 Keep the mower and fuel container in locked storage to prevent children from
playing or tampering with them.

- 6 -

1.5.7 Gasoline powered equipment or fuel containers should not be stored in a

d

basement or any enclosed area where open pilot lights or heat appliances are
present.

1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly maintaine
and operated correctly.

1.5.9 Check all bolts freq uently to maintain proper tightness.

1.5.10 Keep all guards, shields, and all safety devices in place and in safe working
condition.

1.5.11 Frequently check for worn or deteriorating components that could create a hazard.

1.5.12 All replacement parts must be the same as or eq uivalent t o the parts supplied as
original equipment.

WARNING

POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure can penetrat e

skin and cause injury.

WHAT CAN HAPPEN
♦ Fluid accidentally injected into the skin must be

surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene ma y result .

HOW TO AVOID THE HAZARD
♦ Make sure all hydraulic fluid hoses and lines are in

good condition an all hydraulic connections and fittings
are tight before applying pressure to hydraulic system.

♦ Keep body and hands away from pinhole leaks or

nozzles that eject high pressure hydraulic fluid.

♦ Use cardboard or paper, not your hands, to f ind

hydraulic leaks.

♦ Safely relieve all pressure in the hydraulic system by

locking drive levers in neutral and shutting off the
engine before perfor ming any work on the hydraulic
system.

1.6 RIDING ATTACHMENTS

Use only Exmark riding attachments. The use of other than Exmark riding at tachments

may create a hazardous condition resulting in injury.

1.7 SAFETY SIGNS

1.7.1 Keep all safety signs legible. Remove all gr ease, dirt, and debris from safety
signs and instructional labels.

1.7.2 Safety sign s m ust be replaced if they are missing or illegible.

1.7.3 When new components are installed, be sur e that current safety signs are
affixed to the replaced components.

1.7.4 New safety signs may be obtained from your authorized Exmark equipment
dealer or distributor or fr om Exmar k Mfg. Co. Inc.

1.7.5 Safety signs may be affixed by peeling off the backing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.

1.7.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They
are critical to the safe operation of your Exmark commercial mower.

- 7 -

PART NO. 103-1541
LOCATION: Console

PART NO. 1-303517
LOCATION: LH Side of Rear Surface of

Engine Deck

For FMD524 & FMD604 Units with SN 540,000 & Higher
PART NO. 103-7491
LOCATION: On Top Front RH Surface of Mower Deck

PART NO. 1-303508
LOCATION: On Top RH Surface

of Mower Deck

PART NO. 1-513746
LOCATION: Surface of Engine

PART NO. 98-5954
LOCATION: Under LH, RH & Center Belt Shields

- 8 -

PART NO. 103-2242
LOCATION: LH Side of

Console

PART NO. 103-2243
LOCATION: RH Side of

Console

Type A Anti-Scalp Rollers Only – See Figure 9
PART NO. 1-323540
LOCATION: Front of Mower
Deck Top Surface

Deck Next to Muffler

PART NO. 1-403005
LOCATION: LH & RH Front Top

Surface of Mower Deck

p

PART NO. 1-403143
LOCATION: RH Rear Surface of Engine Deck

PART NO. 1-513747
LOCATION: To

Rear of Battery Cover

PART NO. 1-553049
LOCATION: On Top Front LH Surface of

Mower Deck

PART NO. 103-2239
LOCATION: Top of Mower Deck Beneath Center Shield

PART NO. 1-413214
LOCATION: Right Side of Hydro

Control Crank Arm

PART NO. 103-2432
LOCATION: Parking Brake

PART NO. 103-4935
LOCATION: Left Rear Top Corner

PART NO. 1-523552
LOCATION: On Top of

Lever

of Engine Deck

Hydraulic Tank

For FMD524 & FMD604 Units with SN 410,000 – 439,999
PART NO. 103-1077

LOCATION:

- 9 -

Front RH Side of Mower Deck

2. SPECIFICATIONS

2.1 MODEL NUMBER:

2.2 ENGINE

2.2.1 Engine Specifications: See your Engine Owner's Manual.

2.2.2 3600 RPM (No Load).

2.3 FUEL SYSTEM

2.3.1 Capacity: 5.0 gal. (18.9 L.)

2.3.2 Type of Fuel: Regular unleaded g asoline, 87 octane or higher. In countries

2.3.3 Fuel Filter: Replaceable in- line

2.3.4 Fuel Shut-Off Valve: 1/4 turn

2.4 ELECTRICAL SYSTEM:

2.4.1 Charging System: Flywheel Alternator

2.4.2 Charging Capacity: 15 amp

2.4.3 Battery Type: BCI Group U1 235 amps at O° F

2.4.4 Battery Voltage: 12 Volt; Polarity, negative ground.

2.4.5 Fuses: blade type, 20 amp to char ging circuit; 20 amp to electric clutch.

2.4.6 Safety Int er lock System: Operator must have OPC (Operator Presence Control)

Park brake must be diseng aged to move speed control out of neutral or engine

TT23KCC; TT23KAC; TT20KCC

using the research method, it should be a 90 oct ane minimum.

levers held in contact with handle grips, speed control lever in neutral, and PTO
disengaged to start eng ine. Release of OPC levers will cause the engine to stop
if speed control lever is not in neutral and/or PTO is engaged.

will kill.

2.5 STEERING CONTROL:

Fingertip drive control levers provide independent speed control, braking and neut ral

to each drive wheel for moving forward or reverse, st opping, and power turning.

2.6 TRANSMISSION:

2.6.1 Two Hydro Gear BDP-10A variable displacement piston pumps independently
coupled to two high efficiency Parker wheel drive motor s .

2.6.2 Hydraulic Oil: Use Mobil 1 15W-50 Synthet ic Motor O il.

2.6.3 Hydraulic Oil Capacity: 2.4 qt. (2. 2 L.)

2.6.3 Hydraulic Filter is replaceable cartridge type.

P/N 1-513211: 10 microns, 18 psi bypass (Summer use above 32°
P/N 1-523541: 40 microns, 18 psi bypass (Winter use below 32° F (0° C))

2.6.4 Speed Range: Forward 0 - 6.75 mph (10.9 km/h)

Reverse 0 - 2.25 mph (3.6 km/h)

2. 6. 5 Drive wheel release valves allow machine to be moved when the engine is not
running

F (0° C))

2.7 WHEEL DRIVE SYSTEM:

Drive wheels are direct coupled to Parker wheel drive motors with 1.0" (25. 4

mm) tapered shaft.

- 10 -

2.8 TIRES Drive Front Caster

Size.......................... 18 x 8.50-8..........................11 x 4.0-5

Quantity............................ 2........................................ 2

Tread........................Turf Master........................... Smooth

Ply Rating......................... 4........................................ 4

Pressure................14 psi (90 kPa)................. 16 psi (152 kPa)

2.9 MOWER DECK

2. 9. 1 Model Numbers: FMD604 and FMD524

2. 9. 2 Cutting Width: 60 in. (152.4 cm.)

52 in. (132.1 cm.)

2. 9. 3 Discharge: Right Side

2. 9. 4 Optional Mulch Kit and Bagger available.

2. 9. 5 Blade Size: 60" - (3 ea.) 20.50 in. (52.1 cm.)

52" - ( 3 ea. ) 18.00 in. (45.7 cm.)

2. 9. 6 Type of Drive: Electric clutch mounted on engine shaft. Blades driven by two

belts with self tensioning idlers.

2. 9. 7 Adjustable anti-scalp rollers (6 ea.)

2. 9. 8 Cutting Height: Adj ust s in 1/2” (1.3 cm) increments f r om 1 1/2” (3.8 cm) to 4

1/2” (11.5 cm).

2. 9. 9 Deck Mounting: Full floating deck is attached to out-fr ont support frame,

removable for service.

2.10 DIMENSIONS

2.10.1 Overall Width:

Discharge chute down
Discharge chute up

w/52” Deck w/60” Deck

64.2” (163.1 cm) 72.2” (183.4 cm)

53.4” (135.6 cm) 61.4” (156.0)

2.10.2 Overall Length:

83.4” (211.8 cm) 83.4” (211.8 cm)

w/52” Deck w/60” Deck

2.10.3 Curb Weight*:

w/52” Deck w/60” Deck

720 lbs. (327 kg) 760 lbs. (345 kg)

∗ Weights will vary slightly depending on engine and handle option.

2. 10.4 Overall Height: 45” (114.3 cm)

2. 10. 5 Tread Width (to outside of tires): 45.8” (116.3 cm)

2.11 TORQUE REQUIREMENTS

BOLT LOCATION TORQUE
Cut t er Housing Spindle Nut (secured with threadlocker) ...140-145 ft-lbs. (190-197 N-m)

Blade Mounting Bolt..................................................................55-60 ft-lbs. (75-81 N-m)

Mower Deck Support/Engine Deck Mount.................................30-35 ft-lbs. (41-47 N-m)

Ant i- Scalp Roller ( See Figure 9)

Type A – Whizlock Nut...............................................40-45 ft-lbs. (54-61 N-m)

Type B – Hex Capscrew.............................................50-55 ft-lbs. (68-75 N-m)

Type B – Nyloc Nut.....................................................30-35 ft-lbs. (41-47 N-m)

Engine Mounting Bolts ..............................................................15-20 ft-lbs. (20-27 N-m)

Wheel Lug Nuts ....................................................................90-95 ft-lbs. (122-129 N-m)

Clutch Retaining Bolt (secured with threadlocker)..................... 55- 60 ft-lbs. (75-81 N-m)

- 11 -

3. ASSEMBLY INSTRUCTIONS

p

3.1 UNCRATE UNIT

3.1.1 Remove tr act or and m ower deck from crates.

3.2 SERVICE BATTERY:

WARNING: Battery posts, terminals, and related accessor ies cont ain lead com pounds,

chemicals known to the State of California to cause cancer and re

The machine is shipped with a filled lead-acid battery.

3. 2. 1 Remove battery cover from machine.

roductive harm. Wash

DANGER

POTENTIAL HAZARD
♦ Charging the battery may produce explosive gasses
WHAT CAN HAPPEN
♦ Battery gasses can explode causing serious injury.
HOW TO AVOID THE HAZARD

♦ Keep sparks, flames, or cigarettes away from battery.
♦ Ventilate when charging or using battery in an

enclosed space.

♦ Make sure venting path of battery is always open once

battery is filled with acid.

3. 2. 2 Check the voltage of t he bat tery with a digital voltmeter. Locate the voltage r eading
of the battery in the table below and charge the bat tery for the recommended time
interval to bring the charge up t o a full charge of 12.6 volts or greater.

IMPORTANT: Make sure the negative battery cables are 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 batter y (see char t below f or r ecom mended
charger settings).

Voltage

Reading

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 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

POTENTIAL HAZARD
♦ If the ignition is in the “ ON” position there is potential

for sparks and engag em ent of components.
WHAT CAN HAPPEN
♦ Sparks could cause an explosion or moving parts

could accidentally engage causing personal injury.
HOW TO AVOID THE HAZARD
♦ Be sure ignition switch is in the “OFF” position before

charging the battery.

Percent

Charge

CAUTION

Maximum

Charger Settings

Charging Interval

3. 2. 3 Connect the negative battery cables.

- 12 -

NOTE: If the positive cable is also disconnected, connect the positive (red)

cable first, then the negat ive (black) cable. Slip insulator boot over the positive
terminal.

NOTE: If time does not permit charging the bat tery, or if charging eq uipm ent is

not available, connect the negative battery cables and run the vehicle
continuously for 20 to 30 minutes to suf ficiently charge the battery.

3.4 DRIVE WHEELS

3. 4. 1 Check air pressure in drive tires; recommended pressure is 12-16 psi. Measure
circumference of each drive tir e. Adjust tire pressure within 12-16 psi range to
try to make tire circumferences match as closely as possible.

3.5 MOWER DECK INSTALLATION

3. 5. 1 Release the wheel drive system by opening the drive wheel release valves. See
Section 4.1.11. Roll the tractor t o the mower deck assembly and allow the tractor
assembly to tip backward until the rear of t he engine deck contacts the ground.

3. 5. 2 Remove mower deck support frame from mower deck by removing t he t wo
hairpins and spacers from the f r ont deck support pins and by removing the two
hairpins and spacers from the rear deck support pins. See Figure 1.

3. 5. 3 Install mower deck support frame to tract or engine deck and secure using (8)
3/8-16 x 1 1/4” screws, (8) disc spring washers and (8) whizlock nuts from bolt
bag. See Figure 1.

NOTE: Place spring washer cone side against bolt head (cupped side away from head)

and install to outside of support frame as shown in Figure 1. Install with whizlock
nuts to the inside of engine deck . Tighten until spring washers are flat.

3. 5. 4 Position tractor with mower deck support f r am e in place, over the mower deck.

CAUTION

POTENTIAL HAZARD
♦ When mower deck is not installed or the two front

support rod hairpins are removed, the unbalanced
weight of the tractor or tractor with mounted mower
support frame may cause the f r ont of the unit to rise

suddenly.
WHAT CAN HAPPEN
♦ If the unit rises suddenly, injury may occur.
HOW TO AVOID THE HAZARD
♦ Securely hold down the front end of the unit when the

mower deck is not installed.

Align and re-install the mower deck support pins int o the support frame. Inst all

the two spacers and hairpins onto the front support pins and the two hairpins and
spacers onto the rear support pins. See Figur e 1.

- 13 -

FIGURE 1

SUPPORT PIN LOCATION

3. 5. 5 Mower Deck Stationary Idler Installation:
Locate the two holes along the back center section of the deck and install the

stationary idler and related parts (from bolt bag) in the rig ht hand hole. See
Figure 2. Be sure the coned end of the disc spring washer is against the head of
the bolt. Tighten hardware.

3/8-16 x 4 1/2

HEX CAPSCREW

FIGURE 2

STATIONARY IDLER INSTALLATION

3. 5. 6 Install the deck drive belt around the clut ch. Refer to belt routing decal. Be sure
belt is in the clutch drive sheave groove. Place the other end of t he belt into the
V-groove of the stationary idler, m ove the spr ing loaded idler outward and route
the belt around the inside of the spring loaded idler. Position the belt into the V­groove of the mower deck drive sheave. Carefully release the spring loaded
idler. Install the center belt shield.

3. 5. 7 Adjust cutting height of deck and ant i-scalp rollers. See Adjustment Section 5. 2. 1.

3.6 POSITION DISCHARGE CHUTE:

Loosen two (2) 5/16” nyloc nuts attaching discharge chute. Lower the discharge

chute into position. Retighten nyloc nuts until chut e is snug but can pivot freely.

3.7 SERVICE ENGINE: See Engine Operator's Manual.

3.8 SERVICE HYDRAULIC OIL

T he m a chine is shipped with hydraulic oil in the reservoir. Run the machine for

approximately 15 minutes to allow any extra air to purge out of t he hydraulic
system. Check hydraulic reservoir and if necessary f ill the reservoir to the
appropriate level with Mobil 1 15W-50 synthetic mot or oil. Replace hydraulic
reservoir cap and tighten until snug. Do not overt i ghten.

- 14 -

NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with the

temperature of the oil. The “HOT” level shows the level of oil when it is at 225°F
(107°C). The “COLD” level shows the level of t he oil when it is at 75° F ( 24° C). Fill
to the appropriate level depending upon the temper ature of the oil. For example: If
the oil is about 150°F (65°C), f ill to halfway between the “HOT” and “COLD” levels.
If the oil is at room t em perature (about 75°F (24°C)), fill only to the “COLD” level.

3.9 GREASE UNIT:

NOTE: UNIT IS NOT GREASED AT THE FACTORY.
Refer to Maintenance Section 5.1.14 for grease zerk locations and grease amounts.

3.10 FAMILIARIZE YOURSELF WITH THE CONTROLS.

See Controls Section 4.1.

3.11 FOLLOW PRE-START INSTRUCTIONS.

See Pre-Start Section 4.2.

3.12 PERFORM NECESSARY ADJUSTMENTS.

See Maintenance and Adjustment Section 5.

4. OPERATION INSTRUCTIONS

4.1 Controls

4.1.1 Operator Presence Control (OPC) Levers
assembly directly above the handle grips. See Figure 3. When these l evers

are depressed, the OPC system senses that the operator is in the normal
operator's position. When the levers are released, the OPC system senses
that the operator has moved from the normal operating positi on and will kill
the engine if either the speed cont rol lever is not in the neutral position or the
PTO is engaged.

4.1.2 Drive Levers
the handle grips. See Figure 3. These levers individually control the speed and
direction of each drive wheel. When the speed control lever is moved out of the
neutral position and the neutral lock lat ches are moved into the drive position, as
shown in Figure 3, and the drive levers are released, the drive wheels are
engaged in the forward direction.

Squeezing the left hand and/or right hand lever causes the left hand and/or right

hand drive wheel respectively to slow down, stop, or reverse, depending on how
far each drive lever is “squeezed”. Squeezing the drive levers beyond the neutral
position causes the drive wheels to engage in the reverse direction regardless of
the position of the neutral lock latches and the speed control lever.

4.1.3 Neutral Lock Latches
“neutral” position where the drive wheels are not engaged in either a forward or
reverse direction. See Figure 3.

: Located on each side of the upper handle assembly directly below

: These latches allow the operator to lock t he dr ive levers in a

: Located on the upper handle

- 15 -

FIGURE 3

DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION

4.1.4 PTO Engagement

: Switch is located on left side of contr ol console. The switch must
be pulled out to the ”Rotate” position to engage the blades. The switch is pushed
in to the “Stop” position to stop the blades. Operator must have operator pr esence
control levers depressed when PTO is engaged or eng ine will stop.

4.1.5 Choke Control

: Located on the control console right hand side. Choke is used to
aid in starting a cold engine. The choke control is pulled out to be in the “ON”
position and pushed in to be in the “OFF” position. DO NOT run a warm engine
with choke in the “ON” position.

4.1.6 Throttle Control

: Located on the control console’s right side. The throttle is used
to control engine speed. Moving the throttle cont r ol forward will increase engine
speed and moving it to the rear will decrease engine speed.

4. 1. 7 Speed Control Lever

: Located in middle of control console, it cont rols the maximum

forward speed and is infinitely variable from neut r al 0 mph to 6.75 mph.

Park brake must be diseng aged to move speed control out of neutral or engine

will kill.

4.1.8 Ignition Switch

: Located on the control console. The ig nit ion switch is used to st ar t
and stop the engine. The ignition switch has thr ee positions, “Off”, “On” and
“Start”. Insert key into switch and rotate clockwise to the “On” position. Rot ate
clockwise to the next position to engage the star ter (key must be held against
spring pressure in this position). Oper ator must have speed control lever in
neutral, OPC levers depressed and PTO disengaged t o st art engine. When
engine starts, release key.

4.1.9 Hour Meter

: Located on the left hand side of console j ust above the PTO switch.
The hour meter is connected to a pressur e switch installed in t he engine block
and it records the number of hour s t hat the engine has run. If ignit ion switch is
left on without engine running, hour m eter will not run.

NOTE: This switch is not a low oil sensor and will not alert the operator if the

engine oil is low.

4. 1. 10 Fuel Shut-O ff Valve

: Installed in the fuel line midway between the tank and
engine. The fuel shut-off valve is used to shut off the flow of fuel when parking
inside a building, during transporta t ion t o and from the job sites, and when the
machine will not be used for a few days.

Rotate valve 1/4 turn clockwise to shut fuel off. Rot ate valve 1/4 turn counter-

clockwise to turn fuel on.

- 16 -

4. 1.11 Drive Wheel Release Valves
pumps. Drive wheel release valves are used to release the hydro-static drive
system to allow the machine to be moved by hand without the engine running.

With a 5/8 wrench, t ur n bot h valves one turn count er - clockwise to release the

drive system.

Turn clockwise to reset the drive system. Do Not over t i ght en.

4.1.12 Tracking Adjustment Knob:
tank support. The k nob can be adjusted so that machine will “track” str aight
ahead with the drive levers released.

4. 1. 13 Park Br ake Lever
The brake lever engages the par k brake on the drive wheels.

Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the brake.
When parking on a steep slope, the wheels must be chocked or blocked in

addition to the brake being engaged. The unit must be tied down and brake
engaged when transporting,

Park brake must be diseng aged to move speed control out of neutral or engine

will kill.

4.2 PRE-START

4. 2. 1 Fill fuel tank. For best r esults use only clean fresh regular grade unleaded
gasoline with an octane rating of 87 or higher. Regular grade leaded ga soline
may also be used; however, combustion chamber and cylinder head will require
more frequent ser vice. See Engine Owner's Manual. Do not add oil to gasoline.

: Located on the left side of t he unit above the hydraulic tank.

: Located on the left rear corner of the hydrostatic

Located on the right-hand side of t he r ear of the fuel

Do Not overfill fuel tank. Never fill the fuel tank so that the f uel level rises above

a level that is 1/2” below the bottom of t he filler neck to allow for f uel expansion
and prevent fuel spillage.

4. 2. 2 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary
inspection and maintenance steps.

4. 2. 3 Make sure you understand the controls, their locations, t heir functions, and their
safety requirements.

4.3 OPERATING INSTRUCTIONS

4.3.1 Starting Engine

Operator must have Operator Presence Control (OPC) levers depressed, the

PTO disengaged and speed control lever in neutral.

On a cold engine, place the throttle midway between the “Slow” and “Fast”

positions and place the choke in the “On” position. On a warm engine, place the
throttle lever midway between “Slow” and “Fast” positions and leave the choke in
the “Off” position.

Turn ignition switch to “Start” position. Release the switch as soon as the engine

starts.

On a cold engine, gradually return choke to the “Off ” position after engine star t s

and warms up.

IMPORTANT

seconds at a time. If the engine does not start , allow a 60 second starter
cool-down period between starting attempts. Fail ure t o f ollow these
guidelines can burn out the starter motor.

: Open fuel valve.

: Do not crank the engine continuously for more than ten (10)

NOTE: It is helpful to have the left and right neut r al lock latches locked in

neutral when starting the engine, See Controls Section 4.1.3.

- 17 -

4.3.2 Stopping Engine

: Lock drive levers in neutral, disengag e PTO, move speed
control lever to neutral, and engag e par k brake. Move throttle to the “midway”
position. Allow engine to run a minimum of 15 seconds. Rotate ignition switch
to “Off” posit ion. Remove key to prevent children or other unauthorized persons
from starting engine.

Close fuel shut-off valve when machine will not be used for a few days, when

transporting, and when the unit is park ed inside a building.

4. 3. 3 Drive Lever/Neutral Lock Latch Operation

:

To lock the drive levers in “neutral lock”, squeeze the drive levers to the “neutral”

position (Do Not squeeze the drive levers all the way back as this will cause the
drive wheels to go into full reverse direct ion) . See Figure 4 (a). Place thumbs on
the inner lobe of the neutral lock latches and rotate them under the drive levers
into the “neutral lock” posit ion. See Figure 4 (b). Release the drive levers.

CAUTION

POTENTIAL HAZARD
♦ If the neutral lock latches are not completely engaged

the drive levers could unexpectedly slip into the

forward drive position.
WHAT CAN HAPPEN
♦ If the drive levers slip into the drive position t he unit

could lurch forward and cause injury or property

damage.
HOW TO AVOID THE HAZARD
♦ Be sure the drive levers are past the roller and

securely seated at the bottom of t he neut r al lock

latches.

To place the drive levers in the “forward” position, slightly sq ueeze the dr ive

levers while placing thumbs on the outer thumb lobe of t he neutral lock latches
(or the index finger on the front lobe) and rotate them from under the drive
levers. Slowly and carefully release the drive levers. See Figure 4 (c) .

To place the drive levers in the “reverse” position, squeeze the drive levers

past the neutral position. See Figur e 4 ( d).

(a) (b)

(c) (d)

FIGURE 4

DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION

- 18 -

4. 3.4 Drive Wheel Engagement/ Turning

: Wit h dr ive levers lock ed in “neutral”, shift

speed control lever to desired forward speed.

Slowly squeeze and hold both drive levers in the neutral position and rotate both

neutral lock latches fr om t he neutral lock position to the forward position.

DO NOT squeeze both drive levers all the way back, this will cause the drive

wheels to engage in the reverse direction.

For st r aight ahead motion: Smoothly release both drive levers to engage drive

wheels.

For turning: Squeeze the right hand drive lever to turn r ight and the left hand

drive lever to turn left. To m ake a “zero turn”, squeeze either the left hand or the
right hand drive lever back into the reverse posit ion while the opposit e dr ive lever

is in a forward position at an equal but opposite speed.
For reverse: Squeeze both drive levers into the reverse position.
For smooth operation of this machine, avoid quick, jerky movements of the drive

levers. Move the drive levers smoothly and deliberately.

4.3.5 To Stop

: Squeeze drive levers back to the “neutral” position. Move the neutral
lock latches into the “neutral lock” position and release drive levers. Move the
speed control lever to the neutral position.

4.3.6 PTO Engagement

:

DANGER

POTENTIAL HAZARD
♦ 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 t he mower or mower

deck when the PTO is engaged.

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 occur.
WHAT CAN HAPPEN
♦ Thrown objects or blade contact can cause serious

injury or death.
HOW TO AVOID THE HAZARD
♦ Never operate the mower with the discharge deflector

raised, removed, or altered unless there is a g r ass

collection system or mulch kit in place and working

properly.

DANGER

The PTO switch engages the cutting blades. Be sur e that all persons are clear of

mower deck and discharge area before engaging the PTO.

Set throttle to “midway” position. The switch must be pulled out to the “Rotate’

position to engage the blades. Accelerate to full throttle to begin mowing.

4.3.7 PTO Disengagement

: Push in on the switch to the “Stop” position to stop the

blades.

- 19 -

4.4 TRANSPORTING

WARNING

POTENTIAL HAZARD
♦ Loading the mower onto a trailer without strong

enough or properly supported ramps could be

dangerous.
WHAT CAN HAPPEN
♦ The ramps could collapse causing the unit to fall,

which could cause injury.
HOW TO AVOID THE HAZARD
♦ Use proper ramps that are secured to the t ruck or

trailer.
♦ Keep feet and legs out f r om under the unit when

loading and unloading.
♦ If necessary, use assistance when loading.

Be sure the fuel shut-off valve is closed.
Use a heavy duty trailer to transport the machine. Eng age neutral lock latches

and park brake, then block wheels.
Securely fasten the machine to the trailer with str aps, chains, cables, or ropes.
Do not rely solely on the parking brake to hold the machine on the trailer.
Be sure that the trailer has all necessary light ing and marking as req uir ed by law

and use a safety chain.

5. MAINTENANCE & ADJUSTMENTS

WARNING

POTENTIAL HAZARD
♦ While maintenance or adjustments are being made,

someone could start the engine.
WHAT CAN HAPPEN
♦ Accidental starting of the engine could seriously injure

you or other bystanders.
HOW TO AVOID THE HAZARD
♦ Remove the key from the ig nit ion switch and pull the

wire(s) off the spark plug(s) before you do any

maintenance. Also push the wire(s) aside so it does

not accidentally contact the spark plug( s) .

WARNING

POTENTIAL HAZARD
♦ The engine can become very hot.

WHAT CAN HAPPEN
♦ Touching a hot engine can cause severe burns.
HOW TO AVOID THE HAZARD
♦ Allow the engine to cool completely before service or

making repairs around the eng ine area.

- 20 -

5.1 PERIODIC MAINTENANCE

5.1.1 Check engine oil level

Service Interval: See Engine Owner's Manual
a) Stop engine, wait for all moving parts t o stop and make sure unit is on a

level surface.
b) Check with engine cool.
c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinser t the

dipstick. DO NOT screw into place. Remove dipstick and check oil level.
d) If the oil level is low, add oil as specified in the Engine Owner’s Manual to bring

the oil level up to the “FULL” mark on t he dipst ick. DO NOT OVERFILL.

IMPORTANT: DO NOT operate the engine with oil level below the “LOW”

(or “ADD”) mark or over the “FULL” mark.

5. 1. 2 Clean engine air cooling system
Service Interval: Daily or more often in dry conditions.

CAUTION

POTENTIAL HAZARD
♦ Excessive debris can cause the engine and hydraulic

system to overheat.
WHAT CAN HAPPEN
♦ Excessive debris around the engine cooling air intake

and around the hydraulic pumps can create a fire

hazard.
HOW TO AVOID THE HAZARD
♦ Clean all debris from around the eng ine and hydraulic

pumps daily.

.

.

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Clean all debris from engine air intake screen, around engine shrouding,

and around the hydraulic pumps.

5. 1. 3 Clean grass build-up under deck

.

Service Interval: Daily
a) Stop engine, wait for all moving parts t o stop, and remove key.
b) Raise deck to the highest position. Lift the front of unit and support unit

using jack stands or equivalent support .

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or m aint enance

relying solely on mechanical or hydraulic jacks could be

dangerous.
WHAT CAN HAPPEN

♦ The mechanical or hydraulic jacks may not be enough

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 st ands or equivalent support.

c) Clean out any gr ass build- up from underside of deck and in dischar ge chute.

- 21 -

5. 1. 4 Check mower blades

.
Service Interval: Daily
a) Stop engine, wait for all moving parts t o stop, and remove key.
b) Lift deck and secure in raised position as stat ed in Sect ion 5.1.3.
c) Inspect blades and shar pen or r eplace as r equired.

For Serial Nos. 510,000 – 539,999:

d) Re-install the blades (if they were removed) by placing a block of wood

between the front or rear baffles and the blade then torquing t he blade bolts
to 115-120 ft. lbs. (156- 163 N- m ) . Be sure the spring disk washer cone is
installed toward the bolt head. See Figure 5.

CAUTION

POTENTIAL HAZARD
♦ Operating a mower deck with loose or weakened blade

bolts can be dangerous.
WHAT CAN HAPPEN
♦ A loose or weakened blade bolt could allow a blade

rotating at a high speed to come out from under the

deck, causing serious injury or property damage.
HOW TO AVOID THE HAZARD
♦ Replace the blade bolt after striking a foreign object .

(Use only Exmark replacement parts PN 103-0862 –

blade bolt and PN 103-0865 – spring disc washer).
♦ DO NOT lubricate the thr eads of the bolt or spindle

before assembly.
♦ Torque the blade bolt to 115-120 ft. lbs. (156-163 N-m)

DO NOT USE WRENCH HERE.

FOR BLADE INSTALLATION MAINTAIN

140-145 ft-lbs. (190-197 N-m) ON THIS NUT

FIGURE 5
BLADE BOLT INSTALLATION

For Serial Nos. 540,000 and Higher:
d) Re-install the blades (if they were removed) in the f ollowing or der ( See Figure 6):

1) Install bushing through blade with bushing flange on bottom (grass)
side of blade.

2) Install bushing/blade combo into spindle.

3) Install blade bolt and spring disc washer. Be sure the spring disc
washer cone is installed towards the bolt head. Place a block of wood
between front or rear baffles and the blade then torque the blade bolts
to 55-60 ft-lbs. (75-81 N- m).

- 22 -

FIGURE 6

BLADE BOLT INSTALLATION

IMPORTANT: DO NOT use components other than the original blade, blade
bushing, spring disc washer, and blade bolt supplied with the unit. Failure t o use
all original components and assembled as shown will increase the risk of a blade
bolt becoming loose or weak after striking a foreign object.

CAUTION

POTENTIAL HAZARD
♦ Operating a mower deck with loose or weakened blade

bolts can be dangerous.
WHAT CAN HAPPEN
♦ A loose or weakened blade bolt could allow a blade

rotating at a high speed to come out from under the deck,

causing serious injury or property damage.
HOW TO AVOID THE HAZARD
♦ Always re-install original Exmark blades, blade bushings,

spring disc washers, and blade bolts in the correct

positions as shown.

5. 1. 5 Check safety interlock system.
Service Interval: Daily
a) Check starting circuit . St arter should crank with: Operator Presence

Control levers depressed, speed control lever in neutral, and PTO
disengaged.

Try to start the engine with OPC levers disengaged, speed cont rol lever in

neutral and PTO disengaged - starter MUST NOT crank.

Try to start with, OPC levers depressed, speed control lever in any speed

but neutral and PTO disengaged - starter M UST NOT crank .

Try to start with OPC levers depressed, speed control lever in neutral and

PTO engaged - starter MUST NOT crank.

b) Check OPC circuits. Clear the area. Run engine at one-third throttle, then,

with drive levers and neutral lock latches in neutral lock position, move the
speed control lever out of neutral and release OPC levers engine MUST
stop. Again, run engine at one- t hird throttle, move the speed control lever
to neutral, engage PTO and re lease O PC levers - engine MUST stop.

NOTE: Park brake must be disengaged before the speed control lever is

moved out of neutral or eng ine will kill.

- 23 -

c) If machine does not pass any of these tests, DO NOT operate. Contact

your authorized EXMARK SERVICE DEALER.

IMPORTANT: It is essential that all Operator Safety Mechanisms, be in

place and in proper operating condition prior to mowing.

5. 1. 6 Check for loose hardware.
Service Interval: Daily
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten hardware or correct the problem before operating .

5. 1. 7 Service air cleaner

.

Service Interval: 50 hrs.

more often under severe conditions.
See Engine manual for addi t i onal information.

a) Stop engine, wait for all moving parts t o stop, and remove key.

b) Loosen retaining clips and remove air cleaner compartment cover.
c) Remove paper element. Check the condition of the inner element.

Replace if dirty, bent or damag ed.

d) Check the condition of the inner element. Replace whenever it appears dir t y,

typically every other time the paper element is replaced. Clean the base

around the inner element before r em oving, so dir t does not get into the engine.
e) DO NOT wash or use pressurized air to clean paper element or inner elem ent .
f) Reinstall elements. Position the cover so that the rubber dust ejector is

pointing downward and secure with retaining clips.

5.1.8 Change engine oil.
Service Interval: See Engine Owner's Manual

NOTE: Change oil after first five (5) hours of operati on. Follow engine

manufacturers recommendations for future oil changes.

a) Stop engine, wait for all moving parts t o stop, and remove key.
b) Drain oil while engine is warm from oper at ion.
c) Oil drain valve is located on the right hand side of Kohler engines and the left

hand side for Kawasaki engines. Place pan under machine to catch oil and

open valve with a 10 mm wrench. Allow oil to drain then close the valve.
d) Replace the oil filter as per Engine Owner's Manual. Clean around oil filter

and unscrew filter to remove. Bef o r e r e inst alling new filter, apply a thin

coating of oil on the surface of the rubber seal. Tur n filter clockwise until

rubber seal contacts the filter adapter, then tighten filter an additional 2/3 to

3/4 turn.
e) Clean around oil fill cap and remove cap. Fill to the specified capacity and

replace cap. Use oil as specified in Engine Owners Manual. Do not overfill.

f) Start the engine and check for leaks. St op engine and recheck oil level.

5.1.9 Check the battery charge

.

Allowing the batteries to stand for an extended per iod without r echar ging them will
result in reduced performance and ser vice 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.

- 24 -

Check the voltage of the bat tery with a digital voltmeter. Locate the voltage reading
of the battery in the table below and charge the bat tery for the recommended time
interval to bring the charge up t o a full charge of 12.6 volts or greater.

IMPORTANT: Make sure the negative battery cables are 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 batter y (see char t below f or r ecom mended
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 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

5. 1. 10 Check hydraulic oil level.
Service Interval: 40 hr.
a) Stop engine and wait for all moving parts t o st op.
b) Clean area around hydraulic reservoir cap and remove cap.
c) Check hydraulic reservoir and if necessary fill t he r eser voir t o the

appropriate level with Mobil 1 15W-50 synthetic motor oil. Replace

hydraulic reservoir cap and tighten until snug. Do not overt ighten.
NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with the

temperature of the oil. The “HOT” level shows the level of oil when it is at

225°F (107°C). The “COLD” level shows the level of the oil when it is at 75°F

(24°C). Fill to the appropriate level depending upon the temperature of the

oil. For example: If the oil is about 150° F (65°C), fill halfway between the

“HOT” and “COLD” levels. If the oil is at room temperature (about 75°F

(24°C)), fill only to the “COLD” level.

5. 1. 11 Change hydraulic system filter

.
Service Interval: After First 250 hrs, then yearly thereafter.
Note: Use only Exmark P/N 1-513211 for Summ er use above 32°

1-523541 for Winter use below 32°

F (0° C). (Refer t o Sect ion 2.6.2 for filter

F (0° C) or P/N

specifications)

a) Place unit on a level surface. Stop engine, wait f or all moving parts to stop,

and remove key.

b) Carefully clean area around filter. It is important that no dirt or

contamination enters the hydraulic system.
c) Unscrew filter to remove and allow oil to drain from reservoir.
IMPORTANT: Before re-inst alling new filter, fill it com pletely with Mobil 1

15W-50 and apply a thin coat of oil on the surface of t he r ubber seal. Turn

filter clockwise until rubber seal contact s t he filter adapter. Do not tighten yet.
d) Fill reservoir as stated in Section 5.1.10.
e) Loosen filter 1/2 turn and allow a small amount of oil to leak from the oil

filter (this allows air to be purged from the oil filt er and supply hose from the

hydraulic reservoir). Turn filter clockwise until rubber seal contacts the filter

adapter. Then tighten t he filter an additional 2/3 to 3/4 turn.

- 25 -

f) Raise the rear of the machine up onto j ack stands high enough to raise the

drive wheels off of the gr ound. Run machine to allow any other air to be

purged from the hydraulic system and r echeck the oil level.
g) If either drive wheel does not rotate, one or both of the charge pumps

(located on the top of the main pump as shown in Figur e 7) m ay have lost

their “prime”. Ref er t o Sect ion 5. 1.12.
h) Do not change hydraulic system oil (except what can be drained when

changing filter) unless it is felt t hat oil has been contaminated.

Changing oi l unnecessarily could damage the hydraulic system by

introducing contaminates into the system.

5. 1. 12 Hydraulic system air purg e pr ocedur e

.

Air must be purged from the hydraulic system when any hydraulic components,

including oil filter, are r em oved or any of the hydraulic lines are disconnected.

The critical area for purging air from the hydraulic system is between the oil

reservoir and each charge pump located on the top of each variable
displacement pump. See Figure 7. Air in ot her parts of the hydraulic system will
be purged through normal operat ion once the charge pump is “primed”.

FI GURE 7
CHARGE PUMP LOCATION

a) Stop engine and wait for all moving parts to stop. Raise the rear of the machine

up onto jack stands high enough t o r aise t he drive wheels off the ground.
b) Check oil level as stated in Sect ion 5. 1.10.
c) Star t engine and move throttle control ahead to full throttle position. Move

the speed control lever to the middle speed position and place the drive

levers in the “drive” position.
If either drive wheel does not rotate, it is possible t o assist the purging of

the charge pump by carefully rotating the tire in the forward position.
NOTE: It is necessary to lightly touch the charge pump cap with your hand

to check the pump temperature. If the cap is too hot to touch, turn off
engine. The pumps may be damaged if the pump becomes too hot.

If either drive wheel still does not rotate continue with step (d).
d) Thoroughly clean the area around each of the charge pump housings.
e) To “prime” charge pump, loosen two hex socket head capscrews (shown in

Figure 7) 1-1/2 turns only. Make sure engine is not runni ng. Lift the

charge pump housing upward and wait for a steady flow of oil t o flow out

from under the housing. Ret ighten the capscrews. Do this for both pumps.
Note: Hydraulic reservoir can be pressurized up to 5 psi to speed this process.

- 26 -

f) If either drive wheel still does not rotate, stop and repeat steps (d) and (e)

above for the respective pump. If wheels rotate slowly, the system may

prime after additional running. Check oil level as stated in Section 5.1.10.

g) Allow unit to r un several m inut es after the charge pumps are “ pr im ed” with

drive system in the full speed position. Check oil level as stat ed in Sect ion

5.1.10.

h) Check hydro drive linkage adjustment as stated in Section 5.2.5.

5. 1. 13 Check tire pressures
Service Interval: 40 hrs.
a) Stop engine, wait for all moving part s to stop, and remove key. Check air

pressure in tires; recommended tire pressur e is: rear, 12-14 psi; front

casters, 15-17 psi.
b) Inflate tires to pressures stated above. Measure circumference of each

drive tire. Adjust tire pressures within the above range to t ry to make tire

circumferences match as closely as possible.
Note: Front cast er t i res have permanent ti re sealant installed.

5. 1. 14 Inspect Belt wear
Service Interval: 40 hrs.
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Remove the three mower deck belt shields to check mower primary and

secondary belt condition.
c) Look under engine deck t o check the pump drive belt condition.
d) Check all idler ar m s t o be sure they pivot freely.

5.1.15 Lubrication
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Lubricate fittings with one to two pumps of NG LI grade #2 multi-purpose

Refer to the following chart for fitting locations and lubrication schedule.

gun grease.

.

.

1. Caster Wheel Bearings *0 2 *Yearly

2. Caster Pivots *0 2 *Yearly

3. Idler Pivots (Mower Deck) 1 2 Yearly

4. Idler Pivot (Pump Drive) 2 1 Yearly

5. Hydro Control Arm Support Bushings

∗ See 5.1.15 Section c) f or special lubrication instructions on the front caster pivots and

Section 5.1.16 for special lubrication inst r uctions on the front caster wheel hubs.

No. 4 (Idler Pivot (Pump Drive))
Located Under Engine Deck

LUBRICATION CHART

FITTING

LOCATIONS

INITIAL

PUMPS

2 2 40 hours

No. of

PLACES

SERVICE

INTERVAL

- 27 -

c) Lubricat e front caster pivots once a year. Remove hex plug and cap. Thread

grease zerk in hole and pump with grease until it oozes out around top
bearing. Remove grease zerk and thr ead plug back in. Place cap back on.

5.1.16 Lubricate caster wheel hubs:

Service Interval: Once Yearly
a) Stop eng ine, wait for all moving parts to stop,

and remove key.
b) Remove caster wheel from caster forks.
c) Remove seal guards fr om 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 to

lock the spacer nuts to the axle. Remove

the axle (with the other spacer nut still

assembled to it) from t he wheel assembly.

CASTER WHEEL ASSEM BLY

FIGURE 8

e) Pry out seals, and inspect bearing s for wear or damage and replace if necessary.
f) Pack the bearings with a NGLI grade #1 multi-purpose grease.
g) Insert (1) bear ing, (1) new seal into the wheel.
NOTE: Seals (Exmark PN 103-0063) must be replaced.
h) If the axle assembly has had both spacer nut s r emoved (or broken loose),

apply a thread locking adhesive to (1) spacer nut and thr ead onto the axle

with the wrench flats facing outward. Do not thr ead spacer nut all of the way

onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer

surface of the spacer nut to the end of the axle inside the nut.
i) Insert the assembled nut and axle into the wheel on the side of the wheel

with the new seal and bearing.
h) With the open end of the wheel facing up, fill the area inside the wheel

around the axle full of NGLI grade #1 multi-purpose grease.
i) Insert the second bearing and new seal into the wheel.

nd

j) Apply a thread locking adhesive to the 2

spacer nut and thread onto the axle

with the wrench flats facing outward.
k) Torque the nut to 75- 80 in-lbs. (8-9 N-m), loosen, then r e- t orque to 20-25 in-

lbs. (2-3 N-m). Make sure axle does not extend beyond either nut.
l) Re-install the seal guards over the wheel hub and insert wheel into caster

fork. Re-install cast er bolt and tighten nut fully.
IMPORTANT: To prevent seal and bearing damage, check the bearing

adjustment often. Spin t he caster tire. The tire should not spin freely (more

than 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 dr ag. Re-apply

threadlocking adhesive.

5. 1. 17 Check spark plugs

.
Service Interval: 160 hrs.
a) Remove spark plugs, check condition and adjust plug gap or replace with

new plugs. See Engine Owner's Manual.

5. 1. 18 Remove engine shrouds and clean cooling fins

.
Service Interval: 80 hrs.
a) Stop engine, wait for all moving parts t o stop, and remove key.

- 28 -

b) Remove cooling shroud cleanout covers (Kohler) or cooling shrouds

(Kawasaki) from engine and clean cooling fins. Also clean dust, dirt, and
oil from external surfaces of engine which can cause improper cooling.

c) Make sure cooling shr oud cleanout covers or cooling shrouds are properly

reinstalled. Operating the engine without cooling shroud cleanout covers or
cooling shrouds will cause engine damage due to overheating.

5. 1. 19 Change fuel filt er

.
Service Interval: As Required
a) A fuel filter is installed in the fuel line between the fuel tank and the engine.

Replace when necessary.

For Kohler engines use Kohler P/N 2405002
For Kawasaki engines use Kawasaki P/N 49019-7001

5.1.20 Wheel hub

- slotted nut torque specification.

When tightening the slot t ed nut on the wheel motor tapered shaft:
a) Torque the slotted nut to 100 ft. lbs. (136 N-m).
b) Further tighten the nut until t he next set of slots line up with the cross hole

in the shaft.
c) Replace cott er pin.
Note: Do not use anti-seize compound on the wheel hub.

5. 1. 21 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut-Type”

are used on the following fasteners:
a) Pump drive sheave setscrews.
b) Square head setscrews on Hydro pump control arms.
c) Shoulder bolt s in ends of speed control crank.
e) OPC lever setscrews.
f) Electric clutch retaining bolt.
g) Pump drive idler pivot bolt.
h) Fuel tank bulkhead fitting t h r eads.
i) Thumb latch screw threads on handles.
j) Cast er wheel spacer nuts. ( Reference Section 5.1.16)
h) Cutter housing spindle nut.

Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro Pro-Lock Retaining I

or Retaining II” are used on the following:
a) OPC lever hubs and cross-shaft
NOTE: Care must be used

not to bond the bearing, next to each OPC
hub, to the cross shaft whi ch could cause binding of the OPC levers
and erratic operation.

b) Fuel tank studs where studs are inserted into tank.

NOTE: When installing the nuts onto the fuel tank studs, fully tighten the

nyloc nut and back off 1/2 tu r n. This allows for normal fuel tank expansion
and contraction with changes in temperature and fuel levels.

5.1.22 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.

5.1.23 Dielectric grease

is used on all blade type electrical connections to prevent

corrosion and loss of contact.

- 29 -

5.2 ADJUSTMENTS

IMPORTANT: Disengage PTO, shut off engine, wait for all moving part s t o st op,

and remove key before servicing, cleaning, or making adjustments to the unit.

5.2.1 Cut t ing height and anti-scalp roller adjust m ent

.

CAUTION

POTENTIAL HAZARD
♦ When mower deck is not installed or the two front

support rod hairpins are removed, the unbalanced
weight of the tractor or tractor with mounted mower
deck support frame may cause the front of the unit to

rise suddenly.
WHAT CAN HAPPEN
♦ If the unit rises suddenly, injury may occur.
HOW TO AVOID THE HAZARD
♦ Securely hold down the front end of the unit when the

mower deck is not installed or front support rod

hairpins are removed.

a) Stop engine and wait for all moving parts t o st op.
b) Install hairpin clips in the holes for the desir ed cut t ing height. See Figure 9.
IM PORTANT: To maintain correct cutting height and rake, check t he f ol lowing

for proper adjustment.

1. The front and rear hairpins are in t he sam e holes with the proper spacers
under the hair pins. See Figure 8.

2. The t ire pr essur es are set as directed in Section 5.1.13.

3. The length of the rear deck suppor t link assemblies should average 6.89”
(approximately 6 7/8” (17.5 cm)) from the center of the balljoint to the
center of the far t hest hole. See Figure 9.

NOTE: All (4) pins must eq ually support the weight of the deck.

Adjustment in the length of the rear deck support assemblies may be
necessary. If one side is longer than 6.89” ( 17.5 cm), than the opposite
side must be shorter by the same amount.

LEFT HAND

SIDE SHOWN

FIGURE 9

CUTTING HEIGHT ADJUSTMENT

- 30 -

c) Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one

of the positions shown in Figure 10. Rollers will maintain 3/4 in. (19 mm)
clearance to the ground to minimize gouging and roller wear or damage.

For Maxi mum Deck Fl ot ation, place rollers one hole position lower. Rollers

should maintain 1/4 in. (6.4 mm) clear ance to ground. Do Not adjust rollers
to support the deck. Be sure roller bolt s and nut s ar e installed with the spring
disc washer between head of the bolt and mounting bracket .

Two types of anti-scalp roller assemblies are available. See Figure 10 t o

determine which assembly has been installed on the unit. Torque
hardware as specified, or loss of roller m ay result .

Type A – Torque the 3/8 whizlock nut to 40-45 ft-lbs. (54-61 N-m)
Type B – Torque the 3/8 nyloc nut to 30-35 ft-lbs. (41-47 N-m)
Torque the 3/8-24x2 Gr 8 hex capscrew to 50-55 ft-lbs (68-75 N-m)

FIGURE 10
ANTI-SCALP ROLLER INSTALLATION
AND CUTTING HEIGHT ADJUSTMENT

d) When operating in extr emely rough conditions it may be necessary to

position the anti-scalp rollers one or two holes higher than described in "c"
to prevent damage to the rollers and/or bolt failure. See Figur e 10.

NOTE: When anti- scalp r oller s ar e placed in t hese positions, reduced deck

flotation will result.

5. 2. 2 Pump drive belt tension adjustment

:

No adjustment necessary.

5. 2. 3 Mower deck drive belt

:

No adjustment necessary.

5. 2. 4 Blade drive belt tension

:

No adjustment necessary.

5. 2. 5 Hydro Drive Linkage Adjustment

:

a) Adjust Speed Control Linkage and Neutral Safety Switch

1. Stop engine and wait for all moving part s to stop.

2. Move speed control lever (located on console) t o t he full forward position
and check orientation of tabs on t he ends of the speed control crank. See
Figure 11. These tabs should be pointing straight down at the 6 o’clock
position or slightly forward. Adjust t hreaded yoke at the bottom of speed
control linkage until tabs ar e posit ioned cor rectly. See Figure 11.

3. Pull speed contr ol lever back to neutral. Check that the neutral safety
switch actuating tab has depressed the plunger of the switch so that
there is about 5/16” between the tab and the switch. See Figur e 11. If
necessary, move the switch fore and aft.

- 31 -

FIGURE 11

NEUTRAL SAFETY SWITCH ADJUSTMENT

b) Adjust Neutral Control Linkages

1. Raise the r ear of the machine up onto jack stands high enough to raise
the drive wheels off of the g r ound.

2. Star t the engine and move the throttle ahead to t he full throttle position.
Place the neutral lock latches in the “forward” position as shown in Figure
4 and move the speed control lever to the “mid-speed” position.

Note: The park brake must be disengaged and the OPC levers m ust

be held down whenever the speed control lever is out of the neutral
position or the engine will kill.

3. Squeeze the respective drive lever until an increased resistance is felt;
this is where neutral should be.

For Standard Pistol Grip Models: Make sure you have not reached the end

of the neutral lock latc h slot . If you have, shorten the drive lever linkage.

If the wheel turns while holding the drive lever in neutral, the neut r a l

control linkages need to be adjusted. I f wheels stop then go to step 7.

FIGURE 12

HYDRO DRIVE LINKAGE ADJUSTMENT

4. Loosen the nut ag ainst the neutral control linkage yok e as shown in
Figure 12.

5. Adjust t he neut ral control linkage until the respective drive wheel stops
when the lever is pulled against the neutral spring (neut r al position).
Turn the adjusting bolt appr oximat ely 1/4 t ur n clockwise if the wheel is
turning in reverse or turn the bolt approximately 1/4 turn counter­clockwise if the wheel is turning for ward. Release the drive lever to the
forward drive position and squeeze back into the neutr al position.
Check to see if the wheel stops. If not, repeat the above adjustment
procedure.

6. Make this adjustm ent on both sides.

- 32 -

7. Aft er adjustments are made and the wheels stop when the drive lever is
in the neutral position, tighten t he nut against the yokes.

c) Adjust Hydro Control Linkage:

1. Place the speed control lever in t he “ neutral” position. This adjustment
is again made with rear of machine on jack st ands and engine running
at full throttle. O PC levers will have to be held down whenever speed
control lever is moved out of neutral position.

Note: The neut r al lock latches should still be “unlocked” and in the

“forward” position.

2. Loosen the front nut on left hydro control link as shown in Figure 12. Turn

the rear control linkage adjusting nut counter-clockwise until wheel rotates
forward. Turn the rear nut of left control link clockwise 1/4 of a turn at a
time, stopping to move the speed contr ol forward and back to neutral, until
left wheel stops rotating forward. Turn the nut an additional 1/2 turn and
tighten the front jam nut making sure not t o put a bind on t he linkage.
Make sure flat part of linkage is perpendicular to pin part of swivel. See
Figure 13.

FIGURE 13

HYDRO CONTROL LINKAGE/SWIVEL ADJUSTMENT

After adjusting t he left hydro control linkage, m o ve the speed cont r ol

lever to the mid-speed position and then back to t he neutral position.
Recheck the left drive wheel rotation to see if further adjustm ent is
necessary - be sure the speed control lever is in the neutral position.

If inconsistent neutral occurs, check to be sure bot h spri ngs are

properly tightened on the speed control lever under the console -
especially the rear pivot spring.

Repeat above adjustments if necessary.

3. Place the speed cont rol lever in neutral. Adjust the right side linkage by
turning the quick t r ack knob counter-clockwise until the tire begins to
rotate forward. Begin to r et ighten the knob clockwise about 1/4 turn at
a time, stopping to move the speed control forward and back to neutral.
Recheck the drive wheel rotation to see if f urther adjustment is
necessary.

4. The spring that keeps tension on the knob should normally not need
adjustment. However, if adjustm ent is needed, adjust to where length
of spring is about 1” (2.5 cm) between washers. Adjust spring length by
turning nut at fr ont of spring.

d) Drive Lever Linkage Adjustment

1. With rear of machine st ill on jack stands and engine running at full
throttle, move the speed control lever to t he m idway position. Move the
respective drive lever upward until it reaches the neutral position and
engage neutral lock latches. See Figure 14. If the tire rotates in either
direction, the length of the drive lever linkage will need to be adjusted.

2. Adjust the linkage length by loosening the jam nuts at both ends of the
linkage and rotating the linkage in the ball joints. Lengthen the linkage

- 33 -

if the tire is turning in reverse and shorten the linkage if the tire is
creeping forward. Tight en the jam nuts at both ends. Release and re­engage the neutral lock checking that the tire stops. Continue t his
process until the tire is at a dead stop.

FIGURE 14

DRIVE LEVER AND LATCH IN NEUTRAL POSITION

3. Make this adjustment for bot h sides.

e) Tracking Adjustment

1. St op engine and wait for all moving parts to stop. Raise rear of machine,
remove jack stands, and caref ully lower machine to the ground.

2. Check t he dr ive tire pr essur es and tire circumferences. See 5.1.13.

3. Run t he unit and obser ve the t racking on a level, smooth, hard surface
such as concrete or asphalt.

4. I f the unit tracks to one side or the other, turn the quick track knob.
Turn the knob right to “steer” right, t ur n the knob left to “steer ” left.

5. 2. 6 Hydro Pump Spring Tension Setting

a) For medium or heavy duty drive conditions such as operation with a sulky

on steep slopes, a higher spring f or ce may be required on the hydro pump
control arms to prevent the drive system f r om stalling.

b) For a heavier drive setting, relocate the spring anchor link as shown in

Figure 15. The spring anchor links are located under the engine deck on
the left and right hand sides.

Note: In “medium” or “heavy duty” positions, the drive lever forces at t he

upper handle will also be increased.

FIGURE 15
HYDRO PUMP SPRING TENSION SETTING

5. 2. 7 Throttle Control Adjust m ent

a) Loosen cable clamp on engine and position throttle cont r ol (at the control

console) within 1/4" (6 mm) from the upper end of the slot. Pull on cable
assembly at lower end where it attaches to the engine until the throttle
control arm contacts the stop screw. Secure cable with cable clamp.

b) Tension in throttle lever can be adjusted by adjusting t he tightness of the

lever pivot bolt, which is located under the console. See Figure 16.

- 34 -

FIGURE 16

THROTTLE TE NSION

5. 2. 8 Electric Clutch Adjustment

No adjustment necessary.

5.2.9 Park Brake Adjustment

a) Shut off engine and wait f or all moving parts to stop.
b) Disengage the park brak e.
c) Remove the hair pin in t he park brake linkage. Turn the linkage in the yoke

until there is 3/16” (.48 cm) t o 1/ 4” (.64 cm) clearance between the park brake
tire bars and the tires with the park brake disengaged. Re-install the hairpin.

:

6. WASTE DISPOSAL

6.1 MOTOR OIL DISPOSAL

Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil

at a certified recycling center or according to your state and local regulations.

6.2 BATTERY DISPOSAL

DANGER

POTENTIAL HAZARD
♦ Battery electrolyte contains sulfuric acid, 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 elect r olyte.
♦ Do not swallow electrolyte.

Federal law states that batteries should not be placed in the garbage. Management

and disposal practices must be within relevant federal, state, or local laws.

If a battery is being replaced or if the unit containing the battery is no longer operating

and is being scrapped, take the battery to a local certified recycling center. I f no local
recycling is available return the battery to any certified battery reseller.

7. TROUBLE SHOOTING

7.1 MOWER TRACKS TO LEFT OR RIGHT.

a) Check the drive tire pressur es and t ir e cir c um ferences. See 5.1.13.
b) Turn knob on t he right hydro control linkage in the dir ect ion that the mower needs

to be adjusted to. Turn the knob in 1/4 turn increments until the m ower tr acks
correctly.

- 35 -

7.2 MOWER CUTS UNEVENLY.

a) Check the drive tire pressures and tire circumferences. See 5. 1.13. A more

uniform cutting heig ht may be obtained with higher tire pressure on rough terr ain.
A lower tire pressure provides more flotation.

b) Check deck support pins. Hairpin clips must be in the same hole position on each

support pin. See Section 5.2.1.

c) Check deck support alignment and check mounting brackets to be sure all bolts

are tight.

d) Check blades tip to tip for straightness. (They should be within 3/16”, or one

blade width from being in line.)

7.3 ENGINE WILL NOT START.

a) Make sure battery has a f ull char ge.
b) Check that t he t hrottle control is midway between “slow” and “fast” positions, and

choke is in “on” position for a cold engine or “off” posit ion for a warm engine.
c) Make sure the speed control lever is in the “t r ue neutral” position. See Section 5.2.5.
d) Check that t he PTO is disengaged.
e) Make sure the "OPC" levers ar e depr essed.
f) Check that there is fuel in the tank and that t he fuel valve is open.
g) Check that t he spar k plug wires are properly connected.
h) Check for loose or faulty wiring connections. If it is necessary to disconnect wire

connectors, Do Not pull on the wires.
i) Check for corr osion at all wiring connections. Even minor corrosion may cause a

faulty connection. Clean connector terminals thoroughly, apply dielectric grease

and reconnect.
IMPORTANT: It is essential that all operator safety mechanisms be connected

and in proper operating condition prior to mower use.

NOTE: After caref ully check ing the above steps, attempt to start t he engine. If it does

not start, contact your authorized Exmark ser vice dealer.

ENGINE TROUBLESHOOTING

When a problem occurs, do not overlook the simple causes. For example, starting

problems could be caused by an empty fuel tank. T he following tables list some of the
common causes of trouble. Do not at t em pt to service or replace major items or any
items that call for special timing or adjustment procedures (such as valves, governor,
etc.). Have this work done by your Engine Service Dealer.

- 36 -

PROBLEM

Will not start
Hard starting

ENGINE TROUBLESHOOTING TABLE

NO

FUEL

X

IMPROPER

FUEL

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

X X X X X

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

X X X X X X X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

AIR

SCREEN

Stops suddenly
Lacks power
Operates erratically
Knocks or pings
Skips or misfires
Backfires
Overheats

High fuel
consumption

X

X X X X X X X X
X X X X X X X
X
X X X X X

X X X X X X

X X

X X X X X
X X X X X

X X X X

- 37 -

8. HYDRAULIC SCHEMATIC

- 38 -

9. WIRING DIAGRAM

- 39 -

10. 2-Year Limited Warranty

Exmark Turf Equipment

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.

This warranty applies to Exmark turf equipment purchased on
or after October 1, 2004 sold in the US or Canada. This
warranty may only be assigned or transferred to a second (or
third) owner by an authorized Exmark dealer. The warranty
period commences upon the date of the original retail
purchase.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet. We are not authorized
to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

• Any damage or deterioration due to normal use, wear

• Cost of regular maintenance service or parts, such as

• Any product or part which has been altered or misused

• Any repairs necessary due to use of parts, accessories

All warranty work must be performed by an authorized Exmark
Service Dealer using Exmark approved replacement parts.

1. Contact any Exmark Service Dealer to arrange service at
their dealership. To locate a dealer convenient to you,
access our website at www.exmark.com. U.S. Customers
may also call 402-223-6375.

2. Bring the product and your proof of purchase (sales
receipt) to the Exmark Service Dealer.

If for any reason you are dissatisfied 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
[e-mail]

Warranty Period

Items and Conditions Not Covered

Exmark Service Dealer.
and tear, or exposure.
filters, fuel, lubricants, tune-up parts, and adjustments.
or required replacement or repair due to normal wear,

accidents, or lack of proper maintenance.
or supplies, including gasoline, oil or lubricants,

incompatible with the turf equipment or other than as
recommended in the operator's manual or other
operational instructions provided by Exmark.

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

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 extends only to
turf equipment operated under normal conditions. You
must properly service and maintain your Exmark product
as described in the operator’s manual. Such routine
maintenance, whether performed by a dealer or by you, is
at your expense.

As a condition to this warranty, customer shall have read
the operator's manual and shall have completed and
submitted to Exmark Warranty Company, within the
prescribed time, the Exmark warranty registration.

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement
as set forth herein. Neither Exmark nor Exmark Warranty

Company shall have any liability for any other cost, loss
or damage, including but not limited to, any incidental
or consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge relating to
repairs or replacements outside of normal business
hours at the place of business of the authorized
Exmark service dealer.

• Rental of like or similar replacement equipment
during the period of any warranty, repair or
replacement work.

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that

covered by the terms of this warranty.

• Any claims for lost revenue, lost profit or additional
cost as a result of a claim of breach of warranty.

• Attorney's fees.

No Claim of breach of warranty shall be cause for
cancellation or rescission of the contract of sale of any
Exmark mower.

There are no understandings, agreements, representations,
or warranties, express or implied, including but not limited to
any regarding the merchantability (that product is fit for
ordinary use) or fitness for use (that product is fit for a
particular purpose), not specified herein, respecting the
equipment which is the subject of this warranty.

Some states do not allow exclusions of incidental or
consequential damages, or limitations on how long an
implied warranty lasts, so the above exclusions and
limitations may not apply to you.

This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.

- 40 -

SERVICE RECORD

Date Description of Work Done Service Done By

- 40 -

ALIGN THIS EDGE WITH A VERTICAL SURFACE

(TREE, BUILDING, FENCE POST, POLE ETC.)

T
H

I

S

I

S
A
5

°

S
L
O

P
E

T

H

I

S

I

S

A

1

0

°

S
L
O

P

E

T

H

I

S

I

S

A

1

5

°

S

L

O

P

E

E

T

HI

S

I

S

A

2

0

°

S

L

O

P

FOLD ALONG APPROPRIATE LINE

EXAMPLE: COMPARE

SLOPE WITH FOLDED

EDGE.

- 41 -

M

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

Check us out on the Web:

www.exmark.com

WARNING

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects, or

other reproductive harm.

©1997-2005 EXMARK MFG. CO. INC. PART NO. 103-9190
INDUSTRIAL PARK BOX 808 [phone]
BEATRICE, NE 68310 FAX [phone]

ALL RIGHTS RESERVED PRINTED IN U.S.A.

FG. CO. INC.

®