TURF TRACER®
X-SERIES LP
ForSerialNos.
920,000&Higher
PartNo.4500-714Rev.A
Thissparkignitionsystemcomplieswiththe
CanadianstandardICES-002.Cesystèmed’allumage
parètincelledevèhiculeestconformeàlanorme
NMB-002duCanada
KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2010ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
Contactusatwww.Exmark.com.
2
PrintedintheUSA
AllRightsReserved
Introduction
CONGRATULATIONS onthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency ,andpromotesafe
operation.
Figure1
1.Modelandserialnumberlocation
ModelNo.
Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
Exmarkpartsmanualsareavailableonlineat
http://www.exmark.com/manuals.htm
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready .
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
SerialNo.
3
Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.....................11
Specications.......................................................14
ModelNumbers............................................14
Systems.........................................................14
Dimensions...................................................15
TorqueRequirements....................................16
ProductOverview................................................16
Operation.............................................................17
Controls........................................................17
Pre-Start........................................................18
OperatingInstructions..................................19
Transporting.................................................23
Maintenance.........................................................24
RecommendedMaintenanceSchedule(s)...........24
PeriodicMaintenance.......................................25
CheckEngineOilLevel.................................25
CheckBatteryCharge....................................25
CheckMowerBlades.....................................27
CheckSafetyInterlockSystem.......................27
CheckforLooseHardware............................28
ServiceAirCleaner........................................28
ChangeEngineOil........................................28
CheckHydraulicOilLevel.............................28
CheckTirePressures.....................................28
CheckConditionOfBelts..............................29
LubricateGreaseFittings...............................29
LubricateCasterWheelHubs........................29
RemoveEngineShroudsandCleanCooling
Fins...........................................................30
CheckSparkPlugs.........................................30
CheckLPGTank...........................................30
CheckLPGFuelDeliverySystem..................31
ChangeHydraulicSystemFilter.....................31
WheelHub-SlottedNutTorque
Specication..............................................33
ThreadLockingAdhesives.............................34
MobilHTSGrease(OrFood-Grade
Anti-seize).................................................34
Copper-BasedAnti-seize..............................34
DielectricGrease...........................................34
Adjustments.....................................................35
DeckLeveling...............................................35
PumpDriveBeltTension...............................35
DeckBeltTension.........................................35
BladeDriveBeltTension..............................35
ParkBrakeAdjustment..................................35
HydroDriveLinkageAdjustment..................35
TrackingAdjustment.....................................37
HydroPumpSpringTensionSetting..............37
ElectricClutchAdjustment............................37
LPGRegulator.............................................38
Cleaning...........................................................38
CleanGrassBuild-UpUnderDeck................38
WasteDisposal..............................................38
Troubleshooting...................................................40
Schematics...........................................................43
4
Safety
Safety
SafetyAlertSymbol
ThislawnmowermeetsorexceedstheB71.4
specicationsoftheAmericanNationalStandards
Instituteineffectatthetimeofproduction.
Exmarkdesignedandtestedthislawnmowertooffer
reasonablysafeservice;however,failuretocomply
withthefollowinginstructionsmayresultinpersonal
injury.
ThisSafetyAlertSymbol(
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents.
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
1.Safetyalertsymbol
Figure2)isusedbothin
Figure2
aliquidfuelthatisstoredinatankunderpressure.
Beforetheliquidleavesthetank,itisconvertedinto
avapor.SinceLPGisstoredasbothliquidandgas,
itmayleakfromjointsorconnectionsthatarenot
sealedproperly.LPGbecomesammablewhenitis
mixedwithair.
TheLPGinformationinthisOperator’smanualis
providedonlyasaguide.ConsulttheNFPA58:
LiqueedPetroleumGasCode,2008Editionfor
additionalsafetyinformation.ThisNationalFire
ProtectionAssociation(NFPA)codepertainstothe
handling,storing,transporting,andusageofLPG.
• ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.
• Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
• Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
• Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.
WARNING :Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.
CAUTION :Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
WhatisLPG?LPGstandsforliqueedpetroleum
gasandismorecommonlycalledpropane.LPGis
• Onlyadultsandmatureteenagersshouldoperate
amower,andevenmatureteenagersshouldhave
adultsupervision.Besureateenager:
1.hasreadandunderstandstheOperator’s
Manualandrecognizestherisksinvolved;
2.issufcientlymaturetousecaution;and
3.isofsufcientsizeandweighttooperate
thecontrolscomfortablyandtomanagethe
mowerwithouttakingrisks.
• Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
• Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
• Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.
5
Safety
CAUTION
Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.
Wearhearingprotectionwhenoperatingthis
machine.
• Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
DANGER
LPGfuelisextremelyammableandvapors
areexplosive.
AreorexplosionfromLPGfuelcanburn
you,others,andcausepropertydamage.
• Neversmokearoundtank(s)andstay
awayfromanopenameorwherefumes
maybeignitedbyaspark.
DANGER
LPGfuelisextremelyammableandvapors
areexplosive.
• Incaseofretakethefollowingsteps:
1.Ifyoucansafelydoso,stoptheowof
gasasquicklyaspossible.Neverput
outameunlessgascanbeshutoff.
2.NotifytheFireDepartmentandclear
immediateareaofallpeople.
3.Whengasowisstopped,putoutthe
re.Usuallywhenowofgasiscutoff,
rewillautomaticallystop.
4.Ifgasowcannotbeimmediately
stopped,directwaterontankstokeep
themcool,butDoNotputoutre.
• Storagelocationsandtrailersshould
beequippedwithatleastoneapproved
portablereextinguisherhavinga
minimumcapacityof18lb(8.2kg)dry
chemicalwithaB:Crating.DoNot
useCarbonTetrachlorideextinguishers
(Pyreneetc.).
• Extinguishallsourcesofsparkorame
whenapproachingLPGtanksormowers.
Thehazardincreasesforenclosedtrailers
orstoragelocationswherevaporleakage
mayoccurandcollect.
• LPGisheavierthanairandmay
accumulateinlowlyingareas,suchas
ditches,drains,orpits.
• LPGtank(s)shouldbelledbytrained
andqualiedpersonnelONLY .
• Nevertamperwithorrepairthetank(s);
contacttrainedandqualiedpersonnel.
• DoNotchangethetank(s)whenthe
engineisrunning.
• Beforedisconnectingthehose(s),purge
allLPGvaporsfromthesystem,by
closingthefuelvalve(s)onALLtanksand
allowingtheenginetorununtilitstops.
• Storethetank(s)awayfromheat,sparks,
oropenames.
• DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
DANGER
LPGvaporsandliquidescapingfromthetank
maycauseseriousinjuryordeath.Vapors
orliquidmaycausesuffocation,freezingof
tissue,orfrostbite.
• Storeandservicethemowerinawell
ventilatedarea.
• AnapprovedLPGdetectorinstalledin
trailersandstorageareasisrecommended.
• LPGisheavierthanairandmay
accumulateinlowlyingareas,suchas
ditches,drains,orpits.
• Avoidbreathingofvapors.
• Keepawayfromventvalve.
• Keepawayfromeyesandskin.
• Contacttrainedandqualiedpersonnelif
tankshowssignsoffrostedareas,makesa
hissingsound,oremitsafoulodor.
• Obtainimmediatemedicalattentionif
contactoccurswithvaporsorliquid.
• Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
6
Safety
functioningproperly .DoNotoperateunlessthey
arefunctioningproperly.
Inspection
ItisveryimportanttochecktheLPGtankand
componentsforwearorleaks.
Important: Nevercheckforleaksusinganopen
ame.
Important: Neverusebarehandswhen
checkingthettingorvalve.EscapingLPG
vaporandliquidfreezesskinoncontact.
Important: Onlyhandtightentankconnection
tting.Overtighteningbytheuseoftoolsmay
causedamage.Ifhandtighteningdoesnotstop
aleak,contacttrainedandqualiedpersonnel
immediately.
•Beforeeachuse:
–Visuallyinspectthetank,hose,andttingand
bealerttoafoulodorcomingfromthetank.
–TheLPGtankshouldbefreeofdentsor
damage.Ifthetankshowsignsofdentsor
damage,replaceitimmediately.
–Checkthevalveandttingopeningsfordirt
anddebris.
–Slowlyopenthevalveallthewayandlisten
foracontinuoushissfromtheregulator,it
mayindicatealeak.
–LPGhasarotteneggorskunksmelladded
toittohelpdetectagasleak.Ifyoudetect
agasleak:
◊TurnofftheLPGvalveifyoucansafely
doso.
◊Leavethearea.
–InspecttheLPGtankandthefuelconnection
jointforleaks.Usethefollowingprocedure
belowtodetectleaks:
◊Applyanapprovedleakdetectorsolution,
obtainedfromatrainedandqualied
LPGdistributor,orathicknon-ammonia
soapywatersolution(50%non-ammonia
soapand50%water).(Aleakdetector
solutionthatcontainsammoniawillcause
thettingstocorrodeandleak.)
◊Usingasmallbrushorspraybottle,apply
thesolutionaroundallthettingsofthe
LPGtankandthefuelconnectionjoint.
◊Slowlyopenthegasvalveahalf-turn.
◊Ifbubblesaredetected,thejointortting
hasaleak.Shutoffthevalve,tighten
theleakingconnection,andslowlyopen
thevalveagain.Ifbubblesstillappear,
DoNotusethetank.Ifitissafetodo
so,removethetankfromyourmower;
otherwise,contacttrainedandqualied
personnelimmediately.
◊Ifnobubblesaredetected,theLPGtank
maybeused.
•Weekly:
–ChecktheentireLPGfueldeliverysystemfor
damageordeterioration.
–ChecktheentireLPGfueldeliverysystemfor
leaksatalljointsusingthesamemethodas
describedintheprevioussection.
–Followalltheinspectionchecksasspecied
inthetwopreviousinspectionsections.
•TankRequalication:
◊Contacttrainedandqualiedpersonnel
immediately.
–DoNotuseifthehosesareabraded,damaged,
kinked,orattened.
–Makesurethetankissecurelymountedto
themower.Ifthetankisloose,thehoseor
ttingsmayleak.
•Witheachtankchange:
–Checkallgauges,ttings,andvalvesfor
damage.
–Lookfordeterioration,damagedormissing
o-ringsontankconnectiontting.
–USDOT(UnitedStatesDepartmentof
Transportation)regulationsrequireLPG
tankstobeinspected,requalied,andmarked
within12yearsofthemanufacturedateand
onaregularbasisthereafter.Typicallythis
occurswhenthetankisrelled;contacta
trainedandqualiedLPGtankproviderfor
moredetails.
–DoNotlltheLPGtankifitisbeyondthe
requalicationperiod.
–DoNotlldamagedorrustedLPGtanks.
7
Safety
Operation
WARNING
Operatingengineparts,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.
• Allowengineparts,especiallythemufer,to
coolbeforetouching.
• Removeaccumulateddebrisfrommufer
andenginearea.
• Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcankill
you.
DoNotrunengineindoorsorinasmallconned
areawheredangerouscarbonmonoxidefumes
cancollect.
• Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
• Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.
• Neverraisedeckwithbladesrunning.
• Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
• Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.
• DoNotchangetheenginegovernorsettingor
overspeedtheengine.
• Parkmachineonlevelground.Stopengine,wait
forallmovingpartstostop,removekeyand
engageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
• Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:
–Beforechangingtanks.
–Beforedumpingthegrasscatcher.
–Beforemakingheightadjustments.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
• DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.
• Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
•DONOToperatethemowerwhenpeople,
especiallychildren,orpetsareinthearea.
• Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.
• Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
• Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
• DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
• Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
• Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
8
Safety
DANGER
Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Lossofcontrol
and/orlossofoperator’sfootingcouldresultina
fallwithanarmorleggettingunderthemower
orenginedeckwhichmayresultinserious
injury,deathordrowning.
• Mowacrossslopes,neverupanddown.
• DoNotmowslopeswhengrassiswet.
• DoNotmowneardrop-offsornearwater.
• DoNotmowslopesgreaterthan20degrees.
• Reducespeedanduseextremecautionon
slopes.
• Avoidsuddenturnsorrapidspeedchanges.
• Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
• Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
• Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
• Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.
• Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.
• Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
• Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
• Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.
MaintenanceandStorage
• Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.
• Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.
• LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
• Storemowerinawellventilatedoutdoorshelter,
building,ortrailer.
• Closefuelvalvewhenmowerisnotinuse,
includingwhilestoringortransporting.
• Theemptytank(s)shouldbetreatedasifitwas
full.
• Storethetank(s)outsideofbuildingsinanopen
wellventilatedarea,awayfromsparkandames.
• DoNotstorethetank(s)ormachinewith
tank(s)inanareawherethetemperaturecanrise
above120°F(49°C).Ifthetemperatureexceeds
approximately160°F(71°C),thetankwillrelease
highlyammablepropanevapor.SeePreparation
intheSafetySection.
• Storethetank(s)inuprightpositionorwith
pressurereliefvalvetowardsthetop.
• DoNotdrag,drop,orabusethetank(s).
• Storageoftheemptytank(s)shouldfollowlocal
andstateregulations.
• Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
• Usejackstandstosupportcomponentswhen
required.
• Carefullyreleasepressurefromcomponentswith
storedenergy.
• Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
• Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.
• Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.
• Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
9
Safety
DANGER
Chargingorjumpstartingthebatterymay
produceexplosivegases.Batterygasescan
explodecausingseriousinjury.
• Keepsparks,ames,orcigarettesaway
frombattery.
• Ventilatewhenchargingorusingbattery
inanenclosedspace.
• Makesureventingpathofbatteryis
alwaysopenoncebatteryislledwith
acid.
• Alwaysshieldeyesandfacefrombattery.
DANGER
Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.
• Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.
• DoNotswallowelectrolyte.
• Intheeventofanaccident,ushwith
waterandcalladoctorimmediately.
WARNING
Removingstandardoriginalequipmentparts
andaccessoriesmayalterthewarranty,traction,
andsafetyofthemachine.Failuretouseoriginal
Exmarkpartscouldcauseseriousinjuryor
death.Makingunauthorizedchangestothe
engineorfuelsystem,mayviolateEPAand
CARBregulations.
Replaceallpartsincluding,butnotlimitedto,
tires,belts,blades,andfuelsystemcomponents
withoriginalExmarkparts.
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbyadoctor
familiarwiththisformofinjuryorgangrenemay
result.
• Ifequipped,makesureallhydraulicuid
hosesandlinesareingoodconditionandall
hydraulicconnectionsandttingsaretight
beforeapplyingpressuretohydraulicsystem.
• Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagement
ofcomponents.Sparkscouldcausean
explosionormovingpartscouldaccidentally
engagecausingpersonalinjury.
Besureignitionswitchisinthe“OFF”
positionbeforechargingthebattery.
• Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
• Checkallboltsfrequentlytomaintainproper
tightness.
• Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
• Usecardboardorpaper,notyourhands,to
ndhydraulicleaks.
• Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrollevers
inneutralandshuttingofftheenginebefore
performinganyworkonthehydraulicsystem.
10
SafetyandInstructionalDecals
Safety
• Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
• Replaceallworn,damaged,ormissingsafety
signs.
• Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
• Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
1-303517
• Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
• Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
• Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
1-403143
103–2242
1-413214
103-2076
11
Safety
109-9849
103–2243
109-9875
103-2432
103-4935
116-0404
12
Safety
116-4257
1.Fast
2.Slow
109-9906
13
Specications
Specications
ModelNumbers
SerialNos:920,000andHigher
TTX24PKAE
Systems
Engine
• EngineSpecications:SeeyourEngineOwner’s
Manual
• EngineOilType:Exmark4–CyclePremium
EngineOil
• RPM:FullSpeed:3600(NoLoad)
Idle:1550RPM
TankTypeandRelling
Important:TheLPGtankusedonthismower
isaspecialtankwithinternalbafesdesigned
forthisapplication.
• HorizontalTankSpecications:
–TankMaterial:Aluminum
–Capacity:33.5lb
–DisconnectCoupling:LHACMEThreaded
–FuelWithdrawal:Vapor
–FuelShut-OffValve:Rotateclockwiseto
close.
• TypeofFuel:HD5gradepropane
• Newtanksmustbeproperlylledbytrainedand
qualiedpersonnel.
• OnlyusetanksrecommendedbyExmark.Failure
todosowillresultinimproperoperationofthe
fuelsystem.
CAUTION
Note:Useofa“forklift”typeliquidwithdrawaltank
willresultinicingorfreezingoftheLPGregulator
andpreventtheenginefromoperating.Thismay
alsoresultinpermanentfuelsystemdamageandthe
releaseofhighlyammablepropaneliquidorvapor.
ElectricalSystem
• ChargingSystem:FlywheelAlternator
• ChargingCapacity:15amps
• BatteryType:BCIGroupU1235amps0°F
• BatteryVoltage:12Volt
• Polarity:NegativeGround
• Fuses:Twobladetype,20amptochargingcircuit;
20amptoelectricclutch
SafetyInterlockSystem:
• OperatormusthaveOPC(OperatorPresence
Control)leversheldincontactwithhandle
grips,speedcontrolleverinneutral,andPTO
disengagedtostartengine.ReleaseofOPClevers
willcausetheenginetostopifspeedcontrollever
isnotinneutraland/orPTOisengaged.
• Parkbrakemustbedisengagedtomovespeed
controloutofneutralorenginewillkill.
OperatorControls
SteeringControl:Fingertipdrivecontrollevers
provideindependentspeedcontrol,brakingand
neutraltoeachdrivewheelformovingforwardor
reverse,stopping,andpowerturning.
Undernocircumstancesshouldpropane
tankslledbeyond80%capacitybeusedin
service.
Theuseofoverlledtanksmayresultinthe
releaseofhighlyconcentratedandextremely
ammableliquidpropane.RefertotheSafety
section.
Transmission
• TwoHydroGearvariabledisplacementpiston
pumpsindependentlycoupledtotwohigh
efciencyParkerwheeldrivemotors.
• HydraulicOil:UseExmarkPremiumHydroOil.
• HydraulicOilCapacity:2.4qt.(2.2L)
14
Specications
• HydraulicFilterisreplaceablecartridgetype.
P/N109–4180:25microns,10psibypass
(Summeruseabove32°F(0°C))
P/N1–523541:40microns,18psibypass(Winter
usebelow32°F(0°C))
• Speeds:
–0-6.75mph(10.9km/hr)forward.
–0-2.25mph(3.6km/hr)reverse.
• Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
WheelDriveSystem
DrivewheelsaredirectcoupledtoParkerwheeldrive
motorswith1inch(25.4mm)taperedshaft.
Tires&Wheels
Drive FrontCaster
Pneumatic
(Air-Filled)
Quantity
Tread
Size 18x8.50-8 11x4.00-5
PlyRating
Pressure
2 2
TurfMaster Smooth
4
14psi(96kPa)
SemiPneumatic
–Bladesdrivenbytwobelts(w/self-tensioning
idlers).
• Deck:
Fulloatingdeckisattachedtoout-frontsupport
frame,removableforservice.Anti-scalprollers
providemaximumturfprotection.Deckdesign
allowsforbagging,mulchingorsidedischarge.
• DeckDepth:
–52inchDeck:5.5inches(14.0cm)
–60inchDeck:5.5inches(14.0cm)
• CuttingHeightAdjustment:
Adjustsfrom11/2inches(3.8cm)to41/2
inches(11.4cm)in1/2inch(1.3cm)increments.
• MulchingKit:Optional
• Bagger:Optional
Dimensions
OverallWidth:
52inchDeck 60inchDeck
DeectorUp 53.4inches
(135.6cm)
DeectorDown 64.8inches
(164.6cm)
61.4inches
(156.0cm)
73.0inches
(185.4cm)
CuttingDeck
• ModelNumbers:
–FMD524
–FMD604
• CuttingWidth:
–52inch(132.1cm)
–60inch(152.4cm)
• Discharge:Side
• BladeSize:(3ea.)
–52inchDeck:18.00inches(45.7cm)
–60inchDeck:20.50inches(52.1cm)
• BladeSpindles:Solidsteelspindleswith1inch
(25.4mm)I.D .bearings.
• DeckDrive:
–Electricclutchmountedonengineshaft.
OverallLength:
52inchDeck 60inchDeck
83.4inches(211.8cm) 83.4inches(211.8cm)
OverallHeight:
52inchDeck 60inchDeck
45inches(114.3cm) 45inches(114.3cm)
TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)
52inchDeck 60inchDeck
45.8inches(116.3cm) 45.8inches(116.3cm)
15
ProductOverview
WheelBase:(CenterofCasterTireto
CenterofDriveTire)
52inchDeck 60inchDeck
43.3inches(110.0cm) 43.3inches(110.0cm)
CurbWeight:
52inchDeck 60inchDeck
740lb(336kg) 780lb(354kg)
TorqueRequirements
BoltLocation
CutterHousingSpindle
Nut
BladeMountingBolt
(lubricatewithanti-seize)
EngineDeck/Mower
DeckSupportMount
Bolts
Torque
140–145ft-lb(190–197
N-m)
55-60ft-lb(75-81N-m)
30-35ft-lb(41-47N-m)
ProductOverview
Figure3
1.Controls
2.LPGFuelT ank 4.Height-of-CutPins
3.ParkBrakeLever
Anti-ScalpRollerNyloc
NutSee
Anti-ScalpRollerWhizlock
NutSeeFigure9
EngineMountingBolts
WheelLugNuts
WheelHubSlottedNuts
(StyleA)
WheelHubSlottedNuts
(StyleB)
ClutchRetainingBolt
(securedwiththreadlocker)
WheelMotorMounting
Bolts
Figure9
30-35ft-lb(41-47N-m)
30-35ft-lb(41-47N-m)
15-20ft-lb(20-27N-m)
90-95ft-lb(122-129N-m)
140-155ft-lb(190-210
N-m)
minimum100ft-lb(136
N-m)
55-60ft-lb(75-81N-m)
30-35ft-lb(41-47N-m)
16
Operation
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
OperatorPresenceControl(OPC)
Levers
Locatedontheupperhandleassemblydirectlyabove
thehandlegrips.
Whentheseleversaredepressed,theOPCsystem
sensesthattheoperatorisinthenormaloperator’ s
position.Whentheleversarereleased,theOPC
systemsensesthattheoperatorhasmovedfromthe
normaloperatingpositionandwillkilltheengineif
eitherthespeedcontrolleverisnotintheneutral
positionorthePTOisengaged(see
Figure4).
asshowninFigure4,andthedriveleversarereleased,
thedrivewheelsareengagedintheforwarddirection.
Squeezingthelefthandand/orrighthandlever
causesthelefthandand/orrighthanddrivewheel
respectivelytoslowdown,stop,orreverse,depending
onhowfareachdriveleveris“squeezed”.Squeezing
thedriveleversbeyondtheneutralpositioncauses
thedrivewheelstoengageinthereversedirection
regardlessofthepositionoftheneutrallocklatches
andthespeedcontrollever.
NeutralLockLatches
Locatedontheupperhandleassemblyontheends
ofthehandlegrips.
Theselatchesallowtheoperatortolockthedrive
leversina“neutral”positionwherethedrivewheels
arenotengagedineitheraforwardorreverse
direction.
ThrottleControl
Figure4
1.OPCLever
2.Rotateneutrallocklatch
downwardforneutral
lockposition
3.NeutralLockLatch
4.DriveLeverinneutral
position
DriveLevers
Locatedoneachsideoftheupperhandleassembly
aheadofandbelowthehandlegrips.
Theseleversindividuallycontrolthespeedand
directionofeachdrivewheel.Whenthespeedcontrol
leverismovedoutoftheneutralpositionandthe
neutrallocklatchesaremovedintothedriveposition,
Locatedonthecontrolconsole’ srightside.
Thethrottleisusedtocontrolenginespeed.Moving
thethrottlecontrolforwardwillincreaseengine
speedandmovingittotherearwilldecreaseengine
speed.Movingthethrottleforwardintothedetent
isfullposition.
SpeedControlLever
Locatedinmiddleofcontrolconsole.
Thespeedcontrollevercontrolsthemaximum
forwardspeedandisinnitelyvariablefromneutral
0–6.75mph(10.9km/hr).
Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.
BrakeLever
Locatedontheleftsideoftheunit.
Thebrakeleverengagestheparkbrakeonthedrive
wheels.
Pulltheleverupandrearwardtoengagethebrake.
Pushtheleverforwardanddowntodisengagethe
brake.
Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
17
Operation
engaged.Theunitmustbetieddownandbrake
engagedwhentransporting.
Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.
IgnitionSwitch
Locatedontheleftsideofthecontrolconsole.
Theignitionswitchisusedtostartandstopthe
engine.Theignitionswitchhasthreepositions,
“Off”,“On”and“Start”.Insertkeyintoswitch
androtateclockwisetothe“On”position.Rotate
clockwisetothenextpositiontoengagethestarter
(keymustbeheldagainstspringpressureinthis
position).Operatormusthavespeedcontrolleverin
neutral,OPCleversdepressedandPTOdisengaged
tostartengine.Whenenginestarts,releasekey .
HourMeter
Locatedonthefrontlefthandsideofconsolejust
abovethePTOswitch.
Thehourmeterisconnectedtoapressureswitch
installedintheengineblockanditrecordsthe
numberofhoursthattheenginehasrun.Ifignition
switchisleftonwithoutenginerunning,hourmeter
willnotrun.
Witha5/8wrench,turnbothvalvesoneturn
counterclockwisetoreleasethedrivesystem.
Turnclockwisetoresetthedrivesystem.DoNot
overtighten.
TrackingAdjustmentKnob
Locatedontheright-handsideoftherearofthefuel
tanksupport.
Theknobcanbeadjustedsothatmachinewill
“track”straightaheadwiththedriveleversreleased.
PTOEngagementSwitch
Switchislocatedonleftsideofcontrolconsole.
Theswitchmustbepulledouttothe“Rotate”
positiontoengagetheblades.Theswitchispushed
intothe“Stop”positiontostoptheblades.Operator
musthaveoperatorpresencecontrolleversdepressed
whenPTOisengagedorenginewillstop.
LPGCylinderBrackets
Thebracketsarelocatedontheenginedeck.
TheLPGcylinderbracketsareusedtofastenthe
removableLPGtanktothemower.
Note: Thisswitchisnotalowoilsensorandwillnot
alerttheoperatoriftheengineoilislow.
FuelValve
LocatedontheLPGfueltank.
Thefuelvalveisusedtoopenandclosethefuel
supplywhenthemachineisnotinuse,during
transporttoandfromthejobsite,andwhenparked
insideawell-ventilatedbuilding.
Rotatethefuelvalveclockwisetoturnoffthefuel.
Rotatefuelvalvecounter-clockwisetoturnonthe
fuel.
DriveWheelReleaseValves
Locatedontheleftrearcornerofthehydrostatic
pumps.
Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
movedbyhandwithouttheenginerunning.
FuelGauge
LocatedontheLPGfueltank.
ThisgaugemonitorstheamountofliquidLPGin
thefueltank.
SafetyPressureReliefValve
LocatedontheLPGfueltank.
Thesafetypressurereliefvalverelievestheexcess
pressureintheLPGtank.
Important: Thisvalvehasaprotectiveplastic
capthatshouldNEVERberemoved.Ifthe
capisdamagedormissing,contacttrainedand
qualiedpersonnelimmediately.
Pre-Start
LPGtankssuppliedfromExmarkDoNotcontain
LPGfuelforshippingreasonsandsafety.Havethe
18
Operation
LPGtankslledbytrainedandqualiedpersonnel.
Forbestresults,useclean,freshHD5gradepropane.
DoNotallowtheLPGtankstobeoverlled.
OverllingLPGtanksbuildsexcesspressurewithin
thetankwhichcausesthereliefvalvetoopen.
Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.
RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.
OperatingInstructions
Important:Ifatanytimeyousensesomething
iswrongwiththeLPGequipment,stopthe
mowerinasafelocationandturnthemoweroff.
Ifyoucansafelydoso,closethefuelvalveand
trytondthecause;otherwise,getawayfrom
themowerandcontacttrainedandqualied
personnelimmediately.
Note: Itishelpfultohavetheleftandright
neutrallocklatcheslockedinneutralwhen
startingtheengine.RefertoNeutralLock
Latches sectioninControls.
EngagingthePTO
DANGER
Therotatingbladesunderthemowerdeckare
dangerous.Bladecontactcancauseserious
injuryorkillyou.
DoNotputhandsorfeetunderthemoweror
mowerdeckwhenthebladesareengaged.
DANGER
Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.
OpentheFuelValve
1.Slowlyopenthefuelvalvetoequalizethepressure
inthetank.ThefuelvalveislocatedontheRH
sideoftheLPGtank.Ifthefuelvalveisopened
tooquickly,thepressurereliefvalveisequipped
withabackpressurecheckvalvethatwillshutoff
thefuelsupply.Ifthishappens,closethefuel
valvecompletelyandwaitveseconds.Slowly
openthefuelvalve.
2.Rotatethefuelvalvecounter-clockwisetoturnon
thefuel.Ifleaksaredetected,refertotheleak
informationintheInspectionsectioninSafety .
StartingtheEngine
1.PushinonthePTOswitchtothe“STOP”
position.
2.Placethethrottleinthe“SLOW”position.
3.Turnignitionswitchto“Start”position.Release
theswitchassoonastheenginestarts.
Important: DoNotcranktheengine
continuouslyformorethantensecondsat
atime.Iftheenginedoesnotstart,allowa
60secondstartercool-downperiodbetween
startingattempts.Failuretofollowthese
guidelinescanburnoutthestartermotor.
Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunlessthere
isagrasscollectionsystemormulchkitinplace
andworkingproperly.
ThePTOswitchengagesthecuttingblades.Besure
thatallpersonsareclearofmowerdeckanddischarge
areabeforeengagingthePTO.
1.Setthrottleto“MIDW AY”position.
2.PullthePTOswitchoutwardtothe“ROTATE”
positiontoengagetheblades.
3.Placethethrottleinthe“FAST”positiontobegin
mowing.
DisengagingthePTO
1.Setthethrottletothe“MIDWAY”position.
2.PushthePTOswitchintothe“STOP”position
todisengagetheblades.
StoppingtheEngine
1.Bringthemowertoafullstop.
2.Lockdriveleversinneutral.
3.DisengagethePTO.
19
Operation
4.Movespeedcontrollevertoneutral.
5.Engagetheparkingbrake.
6.Placethethrottleinthe“SLOW”position.
7.Turnoffthefuelvalve(s)andallowtheengineto
runoutoffuel.Failuretodothismaycausethe
engineto“ood”whenre-starting.
8.Turntheignitionswitchtothe“OFF”position
oncetheenginehasstopped.
9.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.
Important: ThereareNOadjustments
necessaryfortheLPGmower.DoNotmakeany
adjustmentstotheregulatororcarburetor.If
theengineisnotrunningproperly,contactan
AuthorizedServiceDealer.
DrivingtheMachine
DriveLever/NeutralLockLatchOperation
Tolockthedriveleversin“neutrallock”,squeezethe
driveleverstothe“neutral”position(DoNotsqueeze
thedriveleversallthewaybackasthiswillcausethe
drivewheelstogointofullreversedirection).See
Figure5position1.Placethumbsontheinnerlobe
oftheneutrallocklatchesandrotatethemunder
thedriveleversintothe“neutrallock”position.See
Figure5position2.Releasethedrivelevers.
CAUTION
Iftheneutrallocklatchesarenotcompletely
engagedthedriveleverscouldunexpectedlyslip
intotheforwarddriveposition.Ifthedrivelevers
slipintothedrivepositiontheunitcouldlurch
forwardandcauseinjuryorpropertydamage.
Besurethedriveleversarepasttherollerand
securelyseatedatthebottomoftheneutrallock
latches.
Toplacethedriveleversinthe“forward”position,
slightlysqueezethedriveleverswhileplacingthumbs
ontheouterthumblobeoftheneutrallocklatches
(ortheindexngeronthefrontlobe)androtatethem
fromunderthedrivelevers.Slowlyandcarefully
releasethedrivelevers.See
Toplacethedriveleversinthe“reverse”position,
squeezethedriveleverspasttheneutralposition.See
Figure5position4.
Figure5position3.
Figure5
1.DriveLeverinneutral
position
2.DriveLeverlockedin
neutralposition
3.DriveLeverinforward
position
4.DriveLeverinreverse
position
DrivingForward
1.Releasetheparkingbrake.
2.Withdriveleverslockedin“neutral”,shiftspeed
controllevertodesiredforwardspeed.
3.Slowlysqueezeandholdbothdriveleversin
theneutralpositionandrotatebothneutrallock
latchesfromtheneutrallockpositiontothe
forwardposition.
Note: DoNotsqueezebothdriveleversallthe
wayback.Thiswillcausethedrivewheelsto
engageinthereversedirection.
4.Tomoveforwardinastraightline,smoothly
releasebothdriveleverstoengagedrivewheels.
Toturnleftorright,squeezetherighthanddrive
levertoturnrightandthelefthanddrivelever
toturnleft.
Tomakea“zeroturn”,squeezeeithertheleft
handortherighthanddriveleverbackintothe
reversepositionwhiletheoppositedriveleverisin
aforwardpositionatanequalbutoppositespeed.
Note: Forsmoothoperationofthismachine,
avoidquick,jerkymovementsofthedrivelevers.
Movethedriveleverssmoothlyanddeliberately.
Tostop,squeezedriveleversbacktothe“neutral”
position.Movetheneutrallocklatchesintothe
“neutrallock”positionandreleasedrivelevers.
Movethespeedcontrollevertotheneutral
position.
20
DrivinginReverse
Tomoverearwardinastraightline,squeezedrive
leversintothereverseposition.
Toturnleftorright,squeezetherighthanddrivelever
toturnleftandthelefthanddrivelevertoturnright.
Tomakea“zeroturn”,squeezeeitherthelefthand
ortherighthanddriveleverbackintothereverse
positionwhiletheoppositedriveleverisinaforward
positionatanequalbutoppositespeed.
Note: Forsmoothoperationofthismachine,avoid
quick,jerkymovementsofthedrivelevers.Movethe
driveleverssmoothlyanddeliberately.
Tostop,squeezedriveleversbacktothe“neutral”
position.Movetheneutrallocklatchesintothe
“neutrallock”positionandreleasedrivelevers.Move
thespeedcontrollevertotheneutralposition.
AdjustingtheCuttingHeight
WARNING
Whenthetwofrontsupportrodhairpinsare
removedfromthemowerdeck,theweightofthe
tractorsectionmaycausethefrontframeofthe
unittorisesuddenly.Iftheunitrisessuddenly,
injurymayoccur.
Securelyholddownthefrontoftheunitwhenthe
frontsupportrodhairpinsareremoved.
Operation
Figure6
1.Decksupportpin
B.Thetirepressuresaresetasdirectedin Check
TirePressuresintheMaintenancesection.
C.Thelengthofthereardecksupportlink
assembliesaverage6.89inches(approximately
67/8inches)(175.01mm)fromthecenterof
theballjointtothecenterofthefarthesthole.
Figure7.
See
Note: Allfourpinsmustequallysupportthe
weightofthedeck.Adjustmentinthelength
ofthereardecksupportassembliesmaybe
necessary.Ifonesideislongerthan6.89
inches(approximately67/8inches)(175.01
mm),thantheoppositesidemustbeshorter
bythesameamount.
2.CuttingHeight
Thecuttingheightofthemowerdeckisadjusted
from11/2to41/2inches(3.81cmto11.4cm)in
1/2inchincrements.
1.Stopthemachineandmovethedriveleverstothe
neutrallockedposition.
2.DisengagethePTO.
3.Engagetheparkbrake.
4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.
5.Installhairpinclipsintheholesforthedesired
cuttingheight.See
Figure6.
Important: T omaintaincorrectcutting
heightandrake,checkthefollowingfor
properadjustment.
A.Thefrontandrearhairpinsareinthesame
holeswiththeproperspacersunderthehair
pins.See
Figure6.
21
Operation
Figure8
Forcuttingheightsabove3.5inches(90mm)usethe
bottomhole.Therollerswillstillbeeffectiveagainst
scalping.
Figure7
LeftHandSideShown
AdjustingtheAnti-ScalpRollers
Itisrecommendedtochangetheanti-scalproller
position,whentheheightofcuthaschanged.
1.Stopthemachineandmovethemotioncontrol
leversoutwardtotheneutrallockedposition.
2.DisengagethePTO.
3.Engagetheparkbrake.
4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.
5.Afteradjustingtheheightofcut,adjustthe
anti-scalprollersbyremovingthewhizlocknut
andspringdiscwasher.
6.Adjusttheanti-scalprollersforNormalOperating
Conditions.Placetherollersinoneofthe
positionsshown(
3/4inch(19mm)clearancetothegroundto
minimizegougingandrollerwearordamage.
Figure8).Rollerswillmaintain
1.Anti-scalproller
mountingbracket
2.Cuttingheight
ForMaximumDeckFlotation, placetherollers
oneholepositionlower.Rollersshouldmaintain
1/4inch(6.4mm)clearancetotheground.Do
Not adjusttherollerstosupportthedeck.
7.Besurethewhizlocknutsareinstalledwiththe
springdiscwasherbetweentheangeofthenut
andthemountingbracket.
8.Torquethe3/8–16whizlocknutto30-35ft-lb
(41-47N-m)(
Figure9).
9.Ifthe3/8nylocnuthasbeenremoved,reinstall
andtorqueto30–35ft-lb(41-47N-m).
Figure9
1.Springdiscwasher
(conetowardsnut)
2.Frontrightanti-scalp
bracketshown
3.3/8nyloc-torqueto30-35
ft-lb(41-47N-m)
4.3/8-16whizlocknut
torqueto30-35ft-lb
(41-47N-m)
22
Operation
Transporting
TransportingaUnit
WARNING
Loadingthemowerontoatrailerwithoutstrong
enoughorproperlysupportedrampscouldbe
dangerous.Therampscouldcollapsecausing
theunittofall,whichcouldcauseinjury.
• Useproperrampsthataresecuredtothe
truckortrailer.
• Keepfeetandlegsoutfromundertheunit
whenloadingandunloading.
• Ifnecessary,useassistancewhenloading.
ConsulttheNFPA58:LiqueedPetroleumGas
CodeforadditionalinformationregardingLPG
transportation.
• Besurethefuelvalveisclosed.
• PlacespareLPGtank(s)inaDOTapproved
storagecage.
• Securelyfastenthemachinetothetrailerwith
straps,chains,cables,orropes.
• DoNotrelysolelyontheparkingbraketohold
themachineonthetrailer.
• Besurethatthetrailerhasallnecessarylighting
andmarkingasrequiredbylawanduseasafety
chain.
–Transporttanksinanupright,verticaland
securepositiontominimizemovement,
tipping,orphysicaldamagerelativetoother
tanksortothestoragecagewhileintransit.
–Placetankssothatvalves,ttings,orgauges
areprotectedfromphysicaldamageduring
transport.
• Placetank(s)inawell-ventilatedtrailer.
• DoNotstorethetank(s)ormachinewith
tank(s)inanareawherethetemperaturecanrise
above120°F(49°C).Ifthetemperatureexceeds
approximately160°F(71°C),thetankwillrelease
highlyammablepropanevapor.SeePreparation
intheSafetySection.
• DoNottransportLPGtank(s)inthepassenger
spaceofavehicle.
• DoNottransportleakingfueltanks.
• Trailersmusthaveappropriatemarkingsto
transportLPG.
• FollowNFPA58andstateandlocalregulations
fortransportingLPG.
• Useaheavydutytrailertotransportthemachine.
Engageneutrallocklatchesandparkbrake,then
blockwheels.
23
Maintenance
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
WARNING
Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecouldseriously
injureyouorotherbystanders.
Removethekeyfromtheignitionswitch,engage
parkingbrake,andpullthewire(s)offthespark
plug(s)beforeyoudoanymaintenance.Also
pushthewire(s)asidesoitdoesnotaccidentally
contactthesparkplug(s).
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst5hours
Aftertherst100hours
Aftertherst250hours
Beforeeachuseordaily
MaintenanceProcedure
•Changetheengineoil.
•Checkwheelhub-slottedtorquespecication.
•Changethehydrauliclter.
•Checktheengineoillevel.
•Checkthemowerblades.
•Checkthesafetyinterlocksystem.
•Checkforloosehardware.
•ChecktheLPGtankandcomponents.
•Cleanthegrassbuild-upfromunderthedeck.
WARNING
Theenginecanbecomeveryhot.Touchingahot
enginecancausesevereburns.
Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheenginearea.
Every40hours
Every80hours
Every100hours
Every160hours
Every250hours
Every500hours
•Checkthehydraulicoillevel.
•Checkthetirepressures.
•Checktheconditionofthebelts.
•Greasethehydrocontrolarmsupportbushings.
•ChecktheentireLPGfueldeliverysystem.
•Removeengineshroudsandcleancoolingns.
•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)
•Checkthesparkplugs.
•Replacetheprimaryaircleanerelement—checksecondaryaircleanerelement;replaceif
dirty.(Mayneedmoreoftenundersevereconditions.SeetheEnginemanualforadditional
information.)
•Replacethesecondaryaircleanerelement.(Mayneedmoreoftenundersevereconditions.
SeetheEnginemanualforadditionalinformation.)
•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)
•Checkwheelhub-slottedtorquespecication.
24
Maintenance
MaintenanceService
Interval
Monthly
Yearly
MaintenanceProcedure
•Checkthebatterycharge.
•Greasethefrontcasterwheelhubs.
•Greasefrontcasterpivots.
•Greasetheidlerpivots(MowerDeck).
•Greasetheidlerpivot(PumpDrive).
•Lubricatethecasterwheelhubs.
PeriodicMaintenance
CheckEngineOilLevel
ServiceInterval:Beforeeachuseordaily
1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.
2.Checkwithenginecold.
3.Cleanareaarounddipstick.Removedipstickand
wipeoiloff.Reinsertthedipstickandpushitall
thewaydownintothetube.DoNotscrewinto
place.Removethedipstickandreadtheoillevel.
4.Iftheoillevelislow ,wipeofftheareaaroundthe
oilllcap,removecapandlltothe“FULL”
markonthedipstick.Exmark4-CyclePremium
EngineOilisrecommended;refertotheEngine
Owner’smanualforanacceptablealternative.Do
Not overll.
Important: DoNotoperatetheenginewiththe
oillevelbelowthe“LOW”(or“ADD”)markon
thedipstick,oroverthe“FULL”mark.
CheckBatteryCharge
ServiceInterval:Monthly
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandlead
compounds,chemicalsknowntotheStateof
Californiatocausecancerandreproductive
harm.Washhandsafterhandling.
batteryperformanceandlife,rechargebatteriesin
storagewhentheopencircuitvoltagedropsto12.4
volts.
Note: Topreventdamageduetofreezing,battery
shouldbefullychargedbeforeputtingawayfor
winterstorage.
Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebatteryin
thetableandchargethebatteryfortherecommended
timeintervaltobringthechargeuptoafullcharge
of12.6voltsorgreater.
Important: Makesurethenegativebatterycable
isdisconnectedandthebatterychargerusedfor
chargingthebatteryhasanoutputof16voltsand
7ampsorlesstoavoiddamagingthebattery(see
chartforrecommendedchargersettings).
Voltage
Reading
12.6or
greater
12.4–12.6 75–100%
12.2–12.4 50–75%
12.0–12.2 25–50%
11.7–12.0 0–25%
11.7orless
Percent
Charge
100%
0%
Maximum
Charger
Settings
16volts/7
amps
16volts/7
amps
16volts/7
amps
14.4volts/4
amps
14.4volts/4
amps
14.4volts/2
amps
Charging
Interval
No
Charging
Required
30Minutes
1Hour
2Hours
3Hours
6Hoursor
More
Allowingbatteriestostandforanextendedperiodof
timewithoutrechargingthemwillresultinreduced
performanceandservicelife.Topreserveoptimum
25
Maintenance
RecommendedJump
StartingProcedure
ServiceInterval:Asrequired
1.Checktheweakbatteryforterminalcorrosion
(white,green,orblue“snow”),itmustbecleaned
offpriortojumpstarting.Cleanandtighten
connectionsasnecessary.
CAUTION
Corrosionorlooseconnectionscancause
unwantedelectricalvoltagespikesatanytime
duringthejumpstartingprocedure.
DoNotattempttojumpstartwithlooseor
corrodedbatteryterminalsordamagetothe
enginemayoccur.
DANGER
Jumpstartingaweakbatterythatiscracked,
frozen,haslowelectrolytelevel,oran
open/shortedbatterycell,cancausean
explosionresultinginseriouspersonalinjury.
WARNING
Batteriescontainacidandproduceexplosive
gases.
• Shieldtheeyesandfacefromthebatteries
atalltimes.
• DoNotleanoverthebatteries.
Note: Besuretheventcapsaretightandlevel.
Placeadampcloth,ifavailable,overanyvent
capsonbothbatteries.Besurethevehiclesdo
nottouchandthatbothelectricalsystemsare
offandatthesameratedsystemvoltage.These
instructionsarefornegativegroundsystemsonly .
3.Connectthepositive(+)cabletothepositive(+)
terminalofthedischargedbatterythatiswiredto
thestarterorsolenoidasshowninFigure10.
DoNotjumpstartaweakbatteryifthese
conditionsexist.
2.Makesuretheboosterisagoodandfullycharged
leadacidbatteryat12.6voltsorgreater.Use
properlysizedjumpercables(4to6A WG)with
shortlengthstoreducevoltagedropbetween
systems.Makesurethecablesarecolorcodedor
labeledforthecorrectpolarity.
CAUTION
Connectingthejumpercablesincorrectly
(wrongpolarity)canimmediatelydamagethe
electricalsystem.
Becertainofbatteryterminalpolarityand
jumpercablepolaritywhenhookingup
batteries.
Note: Thefollowinginstructionsareadapted
fromtheSAEJ1494Rev .Dec.2001–Battery
BoosterCables–SurfaceVehicleRecommended
Practice(SAE–SocietyofAutomotive
Engineers).
Figure10
1.Positive(+)cableondischargedbattery
2.Positive(+)cableonboosterbattery
3.Negative(–)cableontheboosterbattery
4.Negative(–)cableontheengineblock
5.Boosterbattery
6.Dischargedbattery
7.Engineblock
4.Connecttheotherendofthepositivecabletothe
positiveterminaloftheboosterbattery.
5.Connecttheblacknegative(–)cabletotheother
terminal(negative)oftheboosterbattery.
6.MAKETHEFINALCONNECTIONON
THEENGINEBLOCKOFTHESTALLED
VEHICLE(NOTTOTHENEGATIVEPOST)
AWAYFROMTHEBATTERY .STANDBACK.
7.Startthevehicleandremovethecablesinthe
reverseorderofconnection(theengineblock
(black)connectionisthersttodisconnect).
26
Maintenance
CheckMowerBlades
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Liftdeckandsecureinraisedpositionasstated
intheCleanGrassBuild-UpUnderDeck
procedure.
3.Inspectbladesandsharpenorreplaceasrequired.
4.Reinstallblades(iftheywereremoved)inthe
followingorder:
A.Installbushingthroughbladewithbushing
angeonbottom(grass)sideofblade.
Figure11
1.Installbushinginbladepriortoinstallingbushingin
spindle.
anti-seizepreferable.Greaseacceptable
substitute.Installbladeboltngertight.Place
wrenchonthetopspindlenutthentorquethe
bladeboltsto55-60ft-lb(75-81N-m).
WARNING
Incorrectinstallationofthebladeor
componentsusedtoretainthebladecan
bedangerous.Failuretousealloriginal
componentsandassembledasshowncould
allowabladeorbladecomponenttobe
thrownoutfromunderthedeckresultingin
seriouspersonalinjuryordeath.
AlwaysinstalltheoriginalExmarkblades,
bladebushings,andbladeboltsasshown.
CheckSafetyInterlock
System
ServiceInterval:Beforeeachuseordaily
1.Checkstartingcircuit.Startershouldcrankwith:
OperatorPresenceControlleversdepressed,
speedcontrolleverinneutral,andPTO
disengaged .
B.Installbushing/bladecombointospindle.
Figure12
1.Usewrenchherefor
bladeinstallation.This
nuthasbeentorquedto
90–110ft-lb(122–149
N-m)
2.Torqueto55-60ft-lb
(75-81N-m)Apply
lubricanttothreads
asneededtoprevent
seizing.Copper-based
anti-seizepreferable.
Greaseacceptable
substitute.
C.Applylubricanttothreadsofbladeboltas
neededtopreventseizing.Copper-based
TrytostarttheenginewithOPClevers
disengaged ,speedcontrolleverinneutraland
PTOdisengaged-startermustnotcrank.
Trytostartwith,OPCleversdepressed,speed
controlleverinanyspeedbutneutralandPTO
disengaged-startermustnotcrank.
TrytostartwithOPCleversdepressed,
speedcontrolleverinneutralandPTO
engaged-startermustnotcrank. .
2.CheckOPCcircuits.Clearthearea.Runengine
atone-thirdthrottle,then,withdriveleversand
neutrallocklatchesinneutrallockposition,
movethespeedcontrolleveroutofneutraland
releaseOPCleversenginemuststop.Again,
runengineatone-thirdthrottle,movethespeed
controllevertoneutral,engagePTOandrelease
OPClevers-enginemuststop.
Note: Parkbrakemustbedisengagedbeforethe
speedcontrolleverismovedoutofneutralorengine
willkill.
Note: Ifmachinedoesnotpassanyofthesetests,
donotoperate.ContactyourauthorizedEXMARK
SERVICEDEALER.
27
Maintenance
Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing.
CheckforLooseHardware
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.
ServiceAirCleaner
ServiceInterval:Every250hours—Replace
theprimaryaircleaner
element—check
secondaryaircleaner
element;replaceifdirty.
(Mayneedmoreoften
undersevereconditions.
SeetheEnginemanualfor
additionalinformation.)
Every500hours—
Replacethesecondary
aircleanerelement.(May
needmoreoftenunder
severeconditions.See
theEnginemanualfor
additionalinformation.)
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.SeetheEngineOwner’ sManualformaintenance
instructions.
ChangeEngineOil
todrainandreplaceoildrainplug.Torqueplug
to20-24ft-lb.
4.Replacetheoilltereveryotheroilchange.Clean
aroundoillterandunscrewltertoremove.
Beforereinstallingnewlter,applyathincoating
ofExmark4–CyclePremiumEngineOilonthe
surfaceoftherubberseal.Turnlterclockwise
untilrubbersealcontactsthelteradapterthen
tightenlteranadditional1/2to3/4turn.
5.Cleanaroundoilllcapandremovecap.Fillto
speciedcapacityandreplacecap.
6.UseoilrecommendedintheCheckEngineOil
Level section.DoNotoverll.Starttheengine
andcheckforleaks.Stopengineandrecheckoil
level.
CheckHydraulicOilLevel
ServiceInterval:Every40hours
1.Stopengineandwaitforallmovingpartstostop,
andremovekey.Engageparkingbrake.
2.Cleanareaaroundhydraulicreservoircapand
removecap.Oillevelshouldbetothetopofthe
bafeinsidethetank.Ifnot,addoil.UseExmark
PremiumHydroOil.Replacehydraulicreservoir
capandtightenuntilsnug.DoNotovertighten.
Note: Thebafeislabeled“HOT”and
“COLD”.Theoillevelvarieswiththe
temperatureoftheoil.The“HOT”levelshows
thelevelofoilwhenitisat225°F(107°C).The
“COLD”levelshowstheleveloftheoilwhen
itisat75°F(24°C).Filltotheappropriatelevel
dependinguponthetemperatureoftheoil.For
example:Iftheoilisabout150°F(65°C),llto
halfwaybetweenthe“HOT”and“COLD”levels.
Iftheoilisatroomtemperature(about75°F
(24°C)),llonlytothe“COLD”level.
ServiceInterval:Aftertherst5hours
Every100hours(May
needmoreoftenunder
severeconditions.)
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Drainoilwhileengineiswarmfromoperation.
3.Theoildrainhoseislocatedontherighthand
side.Placepanundermachinetocatchoil.
Removeplugfromendofdrainhose.Allowoil
CheckTirePressures
ServiceInterval:Every40hours
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Checktirepressureindrivetires.
3.Inatedrivetiresto12–14psi(83–97kPa).
4.Inatetirestopressuresstatedabove.Measure
thecircumferenceofeachdrivetire.Adjusttire
28
Maintenance
pressureswithintheaboverangetotrytomake
tirecircumferencesmatchascloselyaspossible.
Semi-pneumaticcastertiresdonotneedtobe
inated.
Note: DoNotaddanytypeoftirelinerorfoam
llmaterialtothetires.Excessiveloadscreatedby
foamlledtiresmaycausefailurestothehydrodrive
system,frame,andothercomponents.Foamlling
tireswillvoidthewarranty.
CheckConditionOfBelts
ServiceInterval:Every40hours
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Removethethreemowerdeckbeltshields
tocheckmowerprimaryandsecondarybelt
condition.
3.Lookunderenginedecktocheckthepumpdrive
beltcondition.
LubricationChart
Fitting
Locations
4.Idler
Pivot(Pump
Drive)
5.Hydro
Control
Arm
Support
Bushings
Initial
Pumps
2 1
2 2
Numberof
Places
*Seestep3forspeciallubricationinstructionson
thefrontcasterpivotsandtheLubricateCaster
WheelHubs sectionforspeciallubrication
instructionsonthefrontcasterswheelhubs.
Service
Interval
Yearly
40Hours
4.Checkallidlerarmstobesuretheypivotfreely.
LubricateGreaseFittings
Note:Seechartforserviceintervals.
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Lubricatettingswithonetotwopumpsof
NGLIgrade#2multi-purposegungrease.
Refertothefollowingchartforttinglocations
andlubricationschedule.
LubricationChart
Fitting
Locations
1.Front
Caster
WheelHubs
2.Front
Caster
Pivots
3.Idler
Pivots
(Mower
Deck)
Initial
Pumps
*0
*0
1 2
Numberof
Places
2
2
Service
Interval
*Yearly
*Yearly
Yearly
Number4(IdlerPivot(PumpDrive)Located
UnderEngineDeck
3.Lubricatefrontcasterpivotsonceayear.Remove
hexplugandcap.Threadgreasezerkinholeand
pumpwithgreaseuntilitoozesoutaroundtop
bearing.Removegreasezerkandthreadplugback
in.Placecapbackon.
LubricateCasterWheelHubs
ServiceInterval:Yearly
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
29
Maintenance
Figure13
1.Sealguard 2.Spacernutwithwrench
ats
2.Removecasterwheelfromcasterforks.
3.Removesealguardsfromthewheelhub.
4.Removeoneofthespacernutsfromtheaxle
assemblyinthecasterwheel.Notethatthread
lockingadhesivehasbeenappliedtolockthe
spacernutstotheaxle.Removetheaxle(with
theotherspacernutstillassembledtoit)from
thewheelassembly.
5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.
6.PackthebearingswithaNGLIgrade#1
multi-purposegrease.
7.Insertonebearing,onenewsealintothewheel.
Note: Seals(ExmarkP/N103-0063)mustbe
replaced.
8.Iftheaxleassemblyhashadbothspacernuts
removed(orbrokenloose),applyathreadlocking
adhesivetoonespacernutandthreadontothe
axlewiththewrenchatsfacingoutward.Do
Notthreadspacernutallofthewayontotheend
oftheaxle.Leaveapproximately1/8inch(3mm)
fromtheoutersurfaceofthespacernuttothe
endoftheaxleinsidethenut.
9.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.
10.Withtheopenendofthewheelfacingup,ll
theareainsidethewheelaroundtheaxlefullof
NGLIgrade#1multi-purposegrease.
11.Insertthesecondbearingandnewsealintothe
wheel.
12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.
13.Torquethenutto75-80in-lb(8-9N-m),loosen,
thenre-torqueto20-25in-lb(2-3N-m).Make
sureaxledoesnotextendbeyondeithernut.
14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully .
Important: Topreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthe
castertire.Thetireshouldnotspinfreely
(morethan1or2revolutions)orhaveanyside
play.Ifthewheelspinsfreely,adjusttorqueon
spacernutuntilthereisaslightamountofdrag.
Reapplythreadlockingadhesive.
RemoveEngineShroudsand
CleanCoolingFins
ServiceInterval:Every80hours
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Removecoolingshroudsfromengineandclean
coolingns.Alsocleandust,dirt,andoilfrom
externalsurfacesofenginewhichcancause
impropercooling.
3.Makesurecoolingshroudsareproperly
reinstalled.Operatingtheenginewithout
coolingshroudswillcauseenginedamagedueto
overheating.
CheckSparkPlugs
ServiceInterval:Every160hours
Removesparkplugs,checkconditionandresetgaps,
orreplacewithnewplugs.SeeEngineOwner’s
Manualforcorrectsparkplugpartnumber.Set
thesparkpluggapto.025inch(.64mm)forLPG
poweredengine.
CheckLPGTank
ServiceInterval:Beforeeachuseordaily
ChecktheLPGtankandcomponentsforwearor
leaks.Followalltheinspectionchecksasspeciedin
theInspectionsectioninSafety.
30
CheckLPGFuelDelivery
System
ServiceInterval:Every40hours
ChecktheentireLPGfueldeliverysystemfordamage
ordeterioration.Followalltheinspectionchecksas
speciedintheInspectionsectioninSafety .
ChangeLPGTank
ServiceInterval:Asrequired
Maintenance
ChangetheLPGtanksoutdoorsinawellventilated
area.
1.Stopthemachineonlevelground,disengagethe
PTO,andengagetheparkingbrake.
2.Closethefuelvalvetothetank.
3.Purgeallvaporsfromthehose(s),byrunning
theengineuntilitstops,turnkeyto“OFF”and
removeitfromtheignition.
4.CarefullydisconnecttheLPGfuelhose.
5.Unlatchthecylinderbracketsandremovethe
tank.
WARNING
Fuelsystemcomponentsareunderhigh
pressure.Theuseofdamagedorimproper
componentscancausesystemfailure,fuel
leakage,andpossibleexplosion,whichmay
resultinseriousinjuryordeath.
• DoNotattempttorepairormodifythe
valves,ttings,orothertankcomponents.
Figure14
1.Hydraulicreservoir
2.Mountingtab
3.Tankslot
Important: Valvesandgaugesmaynot
functionproperlyiftheLPGtankisnot
installedcorrectly.
10.Latchthebracketsandmakesurethetankis
securelyfastenedtothemower.
11.Carefullyconnectthefuelhose.Makesurethe
hoseisnotkinked.
12.Slowlyopenthefuelvalvetoequalizethepressure
inthetank.Ifthefuelvalveisopenedtooquickly,
thepressurereliefvalveisequippedwithaback
pressurecheckvalvethatwillshutoffthefuel
supply.Ifthishappens,closethefuelvalve
completelyandwaitveseconds.Slowlyopen
thefuelvalve.
13.CheckforleaksasdescribedintheInspection
sectioninSafety.
4.LPGTank
5.Cylinderbracket
• ONLYusetheExmarkapprovedLPG
tank,ttings,andhosesthatwere
designedforyourmower.
6.Inspectthelledtankvalveandttingopenings
fordirt,debris,ordamage.
7.Inspectthetankhoseconnectionttingfor
damagedormissingo-rings.
8.Makesurethereplacementtanktypeandsize
matchthetankspecicationdecal.
9.Mountthetankbyaligningtheslotwiththe
mountingtabasshowninFigure14
ChangeHydraulicSystem
Filter
ServiceInterval:Aftertherst250hours
Every500hours/Yearly
(whichevercomes
rst)thereafter
(Every250hours/Yearlyif
usingMobil115W50)
Note:UseonlyExmarkPartNo.109-4180for
Summeruseabove32°F(0°C)orP/N1-523541for
Winterusebelow32°F(0°C)(RefertoTransmission
sectioninSpecicationsforlterspecications).
31
Maintenance
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Carefullycleanareaaroundlter.Itisimportant
thatnodirtorcontaminationenterhydraulic
system.
3.Unscrewltertoremoveandallowoiltodrain
fromreservoir.
Important: Beforereinstallingnewlter,
llitwithExmarkPremiumHydroOiland
applyathincoatofoilonthesurfaceofthe
rubberseal.
Turnlterclockwiseuntilrubbersealcontactsthe
lteradapter,thentightenthelteranadditional
2/3to3/4turn.
4.FillreservoirasstatedinCheckHydraulicOil
Level.
ExmarkPremiumHydroOilisrecommended.
Refertothechartforanacceptablealternative:
HydroOil
ExmarkPremiumHydro
Oil(Preferred)
Mobil115W50
ChangeInterval
500Hours
250Hours
their“prime”.RefertoHydraulicSystemAir
Purge section.
Note: DoNotchangehydraulicsystemoil(except
forwhatcanbedrainedwhenchanginglter),unless
itisfelttheoilhasbeencontaminatedorbeen
extremelyhot.
Changingoilunnecessarilycoulddamagehydraulic
systembyintroducingcontaminatesintothesystem.
HydraulicSystemAirPurge
ServiceInterval:Asrequired
Airmustbepurgedfromthehydraulicsystem
whenanyhydrauliccomponents,includingoil
lter,areremovedoranyofthehydrauliclinesare
disconnected.
Thecriticalareaforpurgingairfromthehydraulic
systemisbetweentheoilreservoirandeach
chargepumplocatedonthetopofeachvariable
displacementpump(
thehydraulicsystemwillbepurgedthroughnormal
operationoncethechargepumpis“primed”.
Figure15).Airinotherpartsof
5.Loosenlter1/2turnandallowasmallamount
ofoiltoleakfromtheoillter(thisallowsairto
bepurgedfromtheoillterandsupplyhosefrom
thehydraulicreservoir).Turnlterclockwise
untilrubbersealcontactsthelteradapter.Then
tightenthelteranadditional2/3to3/4turn.
6.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely.
CAUTION
Raisingthemowerforserviceormaintenance
relyingsolelyonmechanicalorhydraulic
jackscouldbedangerous.Themechanicalor
hydraulicjacksmaynotbeenoughsupport
ormaymalfunctionallowingtheunittofall,
whichcouldcauseinjury.
DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.
7.Ifeitherdrivewheeldoesnotrotate,oneorboth
ofthechargepumps(locatedonthetopofthe
mainpumpasshowninFigure15)mayhavelost
Figure15
1.Chargepumpcap 2.Loosen11/2turnsonly
1.Stopengineandwaitforallmovingpartstostop.
Raisetherearofthemachineupontojackstands
highenoughtoraisethedrivewheelsoffthe
ground.
32
Maintenance
2.Checkoillevelasstatedin CheckHydraulicOil
Levelsection.
3.Startengineandmovethrottlecontrolaheadto
fullthrottleposition.Movethespeedcontrol
levertothemiddlespeedpositionandplacethe
driveleversinthe“drive”position.
Ifeitherdrivewheeldoesnotrotate,itispossible
toassistthepurgingofthechargepumpby
carefullyrotatingthetireintheforwardposition.
Note: Itisnecessarytolightlytouchthecharge
pumpcapwithyourhandtocheckthepump
temperature.Ifthecapistoohottotouch,turn
offengine.Thepumpsmaybedamagedifthe
pumpbecomestoohot.
Ifeitherdrivewheelstilldoesnotrotatecontinue
withstep
4.
4.Thoroughlycleantheareaaroundeachofthe
chargepumphousings.
5.To“prime”chargepump,loosentwohexsocket
headcapscrews(showninFigure15)11/2turns
only.Makesureengineisnotrunning. Lift
thechargepumphousingupwardandwaitfor
asteadyowofoiltoowoutfromunderthe
housing.Retightenthecapscrews.Dothisfor
bothpumps.
SeeFigure16todeterminewhichslottednuthas
beeninstalledontheunit.
Figure16
1.StyleA(blacknish) 3.StyleB(yellowzinc)
2..03inch(.76mm) 4..24inch(6mm)
•StyleA(blacknish):
Torquetheslottednutto140-155ft-lb(190-210
N-m).
Note: DoNotuseanti-seizeonwheelhub.
•StyleB(yellowzinc):
1.Removeanddiscardthecotterpin.
2.Torquetheslottednutto100ft-lb(136N-m).
3.Checkdistancefrombottomofslotinnutto
insideedgeofhole.Twothreads(0.1inch)or
lessshouldbeshowing.
Note: Hydraulicreservoircanbepressurizedup
to5psitospeedthisprocess.
6.Ifeitherdrivewheelstilldoesnotrotate,stop
andrepeatsteps4and5abovefortherespective
pump.Ifwheelsrotateslowly,thesystemmay
primeafteradditionalrunning.Checkoillevel
asstatedinChecktheHydraulicOilLevel
section.
7.Allowunittorunseveralminutesafterthecharge
pumpsare“primed”withdrivesysteminthefull
speedposition.CheckoillevelasstatedinCheck
theHydraulicOilLevel section.
8.Checkhydrodrivelinkageadjustmentasstatedin
HydroDriveLinkageAdjustment sectionin
Adjustments.
WheelHub-SlottedNut
TorqueSpecication
ServiceInterval:Aftertherst100hours
Figure17
1.0.1inchmax 2.Nomorethantwo
threads(0.1inchmax)
shouldbeshowinghere.
4.Ifmorethantwothreads(0.1inch)are
showingremovenutandinstallwasher(P/N
1-523157)betweenhubandnut.
5.Torquetheslottednutto100ft-lb(136N-m).
6.Thentightennutuntilthenextsetofslotsline
upwiththecrossholeinshaft.DoNotloosen
nuttoaligntheslot.Ifrequired,tightento
thenextsetofslots.
Every500hoursthereafter
7.Installnewcotterpin(P/N1-806800).
33
Maintenance
Note:DoNotuseanti-seizeonwheelhub.
ThreadLockingAdhesives
Threadlockingadhesivessuchas“Loctite242”
or“Fel-Pro,Pro-LockNutType”areusedonthe
followingfasteners:
• Pumpdrivesheavesetscrews.
• SquareheadsetscrewsonHydropumpcontrol
arms.
• Shoulderboltsinendsofspeedcontrolcrank.
• OPCleversetscrews.
• Electricclutchretainingbolt.
• Pumpdriveidlerpivotbolt.
• Thumblatchscrewthreadsonhandles.
• Casterwheelspacernuts.
• Fueltankbulkheadttingnuts.
Adhesivessuchas“LoctiteRC/609orRC/680”or
“Fel-ProPro-LockRetainingIorRetainingII”are
usedonthefollowing:
DielectricGrease
Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.
• OPCleverhubsandcross-shaft
Note: Caremustbeusednottobondthe
bearing,nexttoeachOPChub,tothecross-shaft
whichcouldcausebindingoftheOPCleversand
erraticoperation.
• Fueltankstuds,wherestudsareinsertedintotank.
MobilHTSGrease(Or
Food-GradeAnti-seize)
MobilHTSgrease(orfood-gradeanti-seize)isused
inthefollowinglocations:
• Betweenthecutterhousingspindleandbearings.
• Betweenthecutterhousingspindleandsheave.
• Undertopcutterhousingbearingguard.
Copper-BasedAnti-seize
Copper-basedanti-seizeisusedinthefollowing
locations:
OnthreadsofBladeBoltsSerialNos.540,000and
Higher.SeeCheckMowerBladessectionfor
instructions.
34
Maintenance
Adjustments
Note: DisengagePTO,shutoffengine,waitfor
allmovingpartstostop,engageparkingbrake,and
removekeybeforeservicing,cleaning,ormakingany
adjustmentstotheunit.
DeckLeveling
SeeAdjustingtheCuttingHeightsectionin
Operation.
PumpDriveBeltTension
Self-tensioning-Noadjustmentnecessary.
DeckBeltTension
Self-tensioning-Noadjustmentnecessary.
BladeDriveBeltTension
Self-tensioning-Noadjustmentnecessary.
ParkBrakeAdjustment
1.Shutoffengineandwaitforallmovingpartsto
stop.
2.Disengagetheparkbrake.
3.Removethehairpinintheparkbrakelinkage.
Turnthelinkageintheyokeuntilthereis3/16
inch(4.8mm)to1/4inch(6.4mm)clearance
betweentheparkbraketirebarsandthetireswith
theparkbrakedisengaged.Re-installthehairpin.
Adjustthethreadedyokeatthebottomofthe
speedcontrollinkage(seeFigure18)untilthe
tabsarepositionedcorrectly.
Figure18
ViewedfromLeftSideofUnit
1.NeutralSafetySwitch 3.5/16inch(7.9mm)
2.ActuatingTabinneutral
position
3.Pullthespeedcontrolleverbacktoneutral.
Checkthattheneutralsafetyswitchactuating
tabhasdepressedtheplungeroftheswitch
sothatthereisabout5/16inch(7.9mm)
betweenthetabandtheswitch(see
Ifnecessary,movetheswitchforeandaft.
•AdjustNeutralControlLinkages:
1.Raisetherearofthemachineupontojack
standshighenoughtoraisethedrivewheels
offoftheground.
2.Starttheengineandmovethethrottleahead
tothefullthrottleposition.Placetheneutral
locklatchesinthe“forward”positionas
shownin
andmovethespeedcontrollevertothe
“mid-speed”position.
Figure4.Releasetheparkbrake
Figure18).
HydroDriveLinkage
Adjustment
• AdjustSpeedControlLinkageandNeutral
SafetySwitch:
1.Stopengineandwaitforallmovingpartsto
stop.Engageparkingbrake.Removekeyor
sparkplugwire(s).
2.Movethespeedcontrollever(locatedon
theconsole)tothefullforwardpositionand
checktheorientationofthetabsontheends
ofthespeedcontrolcrank(see
Thesetabsshouldbepointingstraightdown
atthe6o’clockpositionorslightlyforward.
Figure18).
Note: TheOPCleversmustbehelddown
andtheparkbrakemustbedisengaged
wheneverthespeedcontrolleverismoved
outofneutralortheenginewillkill.
3.Squeezetherespectivedriveleveruntilan
increasedresistanceisfelt,thisiswhere
neutralshouldbe.
Ifthewheelturnswhileholdingthedrive
leverinneutral,theneutralcontrollinkages
needtobeadjusted.Ifthewheelstopsthen
gotostep7.
35
Maintenance
Figure19
ViewedfromLeftSideofUnit
1.NeutralControlLinkage 5.SpeedControlLinkage
2.HydroControlLinkage
3.DriveLeverLinkage 7.Loosennut
4.SpeedControlCrank
6.Adjusthere-rotateat
approximately1/4
turnincrementsand
re-check.
8.Yoke
Note: Theneutrallocklatchesshouldbe
“unlocked”andintheforwardposition.
2.Loosenthefrontnutonlefthydrocontrol
linkageasshownin
Figure19.Turntherear
controllinkageadjustingnutcounterclockwise
untilwheelrotatesforward.Turntherearnut
ofleftcontrollinkageclockwise1/4ofaturn
atatime,stoppingtomovethespeedcontrol
forwardandbacktoneutral,untilleftwheel
stopsrotatingforward.
Turntherearnutanadditional1/2turnand
tightenthefrontnutmakingsurenottoput
abindonthelinkage.Makesureatpartof
linkageisperpendiculartopinpartofswivel
Figure20).
(see
4.Loosenthenutagainsttheneutralcontrol
linkageyokeasshownin
Figure19.
5.Adjusttheneutralcontrollinkageuntil
therespectivedrivewheelstopswhenthe
leverispulledagainsttheneutralspring
(neutralposition).Turntheadjustingbolt
approximately1/4turnclockwiseifthe
wheelisturninginreverseorturnthebolt
approximately1/4turncounterclockwiseif
thewheelisturningforward.Releasethe
drivelevertotheforwarddrivepositionand
squeezebackintotheneutralposition.Check
toseeifthewheelstops.Ifnot,repeatthe
aboveadjustmentprocedure.
6.Makethisadjustmentonbothsides.
7.Afteradjustmentsaremadeandthewheels
stopwhenthedriveleversareintheneutral
position,tightenthenutsagainsttheyokes.
•AdjustHydroControlLinkages:
1.Placethespeedcontrolleverinthe“neutral”
position.Thisadjustmentisagainmadewith
rearofmachineonjackstandsandengine
runningatfullthrottle.OPCleverswillhave
tobehelddownandtheparkbrakemustbe
disengagedwheneverspeedcontrolleversare
movedoutoftheneutralposition.
Figure20
1.LeftHydroControlLink
(leftsideshown)
2.Frontnut 5.Linkageinincorrect
3.Rearnut
4.Linkageisperpendicular
topin(correctposition)
position
6.Endviewofswivel
Afteradjustingthelefthydrocontrollinkage,
movethespeedcontrollevertothemid-speed
positionandthenbacktotheneutralposition.
Rechecktheleftdrivewheelrotationtoseeif
furtheradjustmentisnecessary-besurethe
speedcontrolleverisintheneutralposition.
Important: Ifinconsistentneutraloccurs,
checktobesurebothspringsareproperly
tightenedonthespeedcontrolleverunder
theconsole–especiallytherearpivot
spring.
Repeataboveadjustmentsifnecessary.
3.Placethespeedcontrolleverinneutral.Adjust
therightsidelinkagebyturningthequicktrack
knobcounterclockwiseuntilthetirebeginsto
rotateforward.Begintoretightentheknob
clockwiseabout1/4turnatatime,stopping
tomovethespeedcontrolforwardandback
36
Maintenance
toneutral.Recheckthedrivewheelrotation
toseeiffurtheradjustmentisnecessary.
4.Thespringthatkeepstensionontheknob
shouldnormallynotneedadjustment.
However,ifadjustmentisneeded,adjustto
wherelengthofspringisabout1inch(2.5cm)
betweenthewashers.Adjustspringlengthby
turningnutatfrontofspring.
•DriveLeverLinkageAdjustment:
1.Withrearofmachinestillonjackstandsand
enginerunningatfullthrottle,disengage
theparkbrakeandmovethespeedcontrol
levertothemidwayposition.Movethe
respectivedriveleverupwarduntilitreaches
theneutralpositionandengageneutrallock
latches(
direction,thelengthofthedriveleverlinkwill
needtobeadjusted.
Figure21).Ifthetirerotatesineither
2.Checkthedrivetirepressuresandtire
circumferencesasstatedinChecktheTire
Pressures sectioninMaintenance.
3.Runtheunitandobservethetrackingonalevel,
smooth,hardsurfacesuchasconcreteorasphalt.
4.Iftheunittrackstoonesideortheother,turnthe
quicktrackknob.Turntheknobrightto“steer”
right,turntheknobleftto“steer”left.
HydroPumpSpringTension
Setting
1.Formediumorheavydutydriveconditionssuch
asoperationwithasulkyonsteepslopes,ahigher
springforcemayberequiredonthehydropump
controlarmstopreventthedrivesystemfrom
stalling.
2.Foraheavierdrivesetting,relocatethespring
anchorlinkasshowninFigure13.Thespring
anchorlinksarelocatedundertheenginedeckon
theleftandrighthandsides.
Figure21
2.Adjustthelinkagelengthbylooseningthejam
nutsatbothendsofthelinkageandrotating
thelinkageintheballjoints.Lengthenthe
linkageifthetireisturninginreverseand
shortenthelinkageifthetireiscreeping
forward.Tightenthejamnutsatbothends.
Releaseandre-engagetheneutrallocklatch
checkingthatthetirestops.Continuethis
processuntilthetireisatadeadstop.
3.Makethisadjustmentforbothsides.
4.Stopengineandwaitforallmovingparts
tostop.Raiserearofmachine,removejack
stands,andcarefullylowermachinetothe
ground.
Note: In“medium”or“heavyduty”positions,
thedriveleverforcesattheupperhandlewillalso
beincreased.
Figure22
1.Heavyduty
2.Mediumduty 4.Retainingbolt
3.Standard
TrackingAdjustment
1.Stopengineandwaitforallmovingpartstostop.
ElectricClutchAdjustment
Noadjustmentnecessary.
37
Maintenance
LPGRegulator
Noadjustmentsnecessary.Iftheengineisnot
runningproperly ,contactanAuthorizedService
Dealer
Cleaning
CleanGrassBuild-UpUnder
Deck
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Raisedecktothetransport(maximumcutting
height)position.Liftthefrontofunitandsupport
unitusingjackstandsorequivalentsupport.
CAUTION
Raisingthemowerforserviceormaintenance
relyingsolelyonmechanicalorhydraulic
jackscouldbedangerous.Themechanicalor
hydraulicjacksmaynotbeenoughsupport
ormaymalfunctionallowingtheunittofall,
whichcouldcauseinjury.
DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.
3.Cleanoutanygrassbuild-upfromundersideof
deckandindischargedeector.
WasteDisposal
MotorOilDisposal
Engineoilandhydraulicoilarebothpollutantsto
theenvironment.Disposeofusedoilatacertied
recyclingcenteroraccordingtoyourstateandlocal
regulations.
BatteryDisposal
DANGER
Batteryelectrolytecontainssulfuricacid,which
ispoisonousandcancausesevereburns.
Swallowingelectrolytecanbefatalorifittouches
skincancausesevereburns.
• Wearsafetyglassestoshieldeyes,andrubber
glovestoprotectskinandclothingwhen
handlingelectrolyte.
• DoNotswallowelectrolyte.
• Intheeventofanaccident,ushwithwater
andcalladoctorimmediately.
38
Federallawstatesthatbatteriesshouldnotbeplaced
inthegarbage.Managementanddisposalpractices
mustbewithinrelevantfederal,state,orlocallaws.
Ifabatteryisbeingreplacedoriftheunitcontaining
thebatteryisnolongeroperatingandisbeing
scrapped,takethebatterytoalocalcertiedrecycling
center.Ifnolocalrecyclingisavailablereturnthe
batterytoanycertiedbatteryreseller.
Maintenance
39
Troubleshooting
Troubleshooting
Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating
conditionpriortomoweruse.
Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused
byanemptyfueltank.
Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor
itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have
thisworkdonebyyourEngineServiceDealer.
Note: WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.
Problem PossibleCause CorrectiveAction
Starterdoesnotcrank.
Enginewillnotstart,startshard,orfailsto
keeprunning.
1.PTOisengaged.
2.Speedcontrolleverisarenotinneutral
lockposition.
3.OPCleversarereleased.
4.Batterydoesnothaveafullcharge.
5.Electricalconnectionsarecorroded,loose
orfaulty.
6.Fuseisblown. 6.Replacetheblownfuse.
7.Relayorswitchisdefective. 7.ContactanAuthorizedServiceDealer.
1.Engineoillevelislow .
2.LPGtankisoverlled. 2.TaketanktoanapprovedLPGprovider
3.LPGtankisnotanExmarkapproved
vaportank.
4.Engineisooded.
5.Oilpressureswitchorfuelshut-off
solenoidmalfunction.
6.ConnectiontotheLPGtankisloose.
7.LPGfueltankisemptyorverylow . 7.ReplacetheLPGfueltank.
8.Fuelvalveisclosed.
9.Fuelvalveopenedtofast.
10.LPGtankisnotinstalledproperly .
11.LPGtankcomponentsorhosesaredirty
ordamaged.
12.Thethrottleisnotinthecorrectposition. 12.Besurethethrottlecontrolisinthe
13.Aircleanerisdirty.
14.Electricalconnectionsarecorroded,loose
orfaulty.
15.Relayorswitchisdefective. 15.ContactanAuthorizedServiceDealer.
1.DisengagethePTO .
2.Ensurethespeedcontrolleverisinthe
neutrallockposition.
3.DepressOPClevers.
4.
Chargethebattery.SeeCheck
BatteryChargeandRecommended
JumpStartingProceduresectionsin
Maintenance.
5.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.
1.Checkandaddoilifnecessary.
tobleedoffsomefuel.
3.RemovetankandreplacewithanExmark
approvedLPGvaportank.
4.Shutofffuelvalve.Letunitsetfor15-30
minutes.Withthevalvestilloffandthe
throttleinthe“SLOW”position,startthe
unit.Oncetheengineattemptstostart,
slowlyopenthefuelvalve.
5.ContactanAuthorizedServiceDealer.
6.Hand-tightenconnectortotank.
8.Slowlyopenthefuelvalve.
9.Openthefuelvalveslowlytoequalize
pressureinthetank(s).
10.ReinstalltheLPGtank.
11.ReplaceLPGtankcomponentsorhoses.
“SLOW”position.
13.Cleanorreplacetheaircleanerelement.
14.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.
40
Troubleshooting
Problem PossibleCause CorrectiveAction
16.Faultysparkplug.
17.Sparkplugwireisnotconnected.
16.Clean,adjustorreplacesparkplug.
SeeCheckSparkPlugsectionin
Maintenanceforpropersparkpluggap.
17.Checkthesparkplugwireconnection.
Enginelosespower.
Engineoverheats
Mowerpullsleftorright(withleversfully
forward).
Machinedoesnotdrive.
1.Engineloadisexcessive 1.Reducethegroundspeed.
2.Aircleanerisdirty.
3.Oillevelinthecrankcaseislow.
4.Coolingnsandairpassagesforthe
engineareplugged.
5.Dirt,water,orstalefuelisinthefuel
system.
6.Fuellevelislow. 6.ReplacetheLPGfueltank.
7.Faultysparkplug.
1.Engineloadisexcessive 1.Reducethegroundspeed.
2.Oillevelinthecrankcaseislow.
3.Coolingnsandairpassagesforthe
engineareplugged.
1.Trackingneedsadjustment. 1.Adjustthetrackingbyturningknobonthe
2.Tirepressureindrivetiresnotcorrect. 2.Adjusttirepressureinthedrivetires.
1.Bypassvalveisnotclosedtight. 1.Tightenthebypassvalve.
2.Driveorpumpbeltisworn,looseor
broken.
3.Driveorpumpbeltisoffapulley. 3.Changethebelt.
2.Cleanorreplacetheaircleanerelement.
3.Addoiltothecrankcase.
4.Removetheobstructionsfromthecooling
nsandairpassages.
5.ContactanAuthorizedServiceDealer.
7.Clean,adjustorreplacesparkplug.
SeeCheckSparkPlugsectionin
Maintenanceforpropersparkpluggap.
2.Addoiltothecrankcase.
3.Removetheobstructionsfromthecooling
nsandairpassages.
righthydrocontrollinkageinthedirection
thatthemowerneedstobeadjustedto.
Turntheknobin1/4turnincrements
untilthemowertrackscorrectly.
2.Changethebelt.
Unevencuttingheight.
Abnormalvibration
1.Blade(s)notsharp. 1.Sharpentheblade(s).
2.Cuttingblade(s)is/arebent.
3.Mowerdeckisnotlevel. 3.Levelmowerdeckfromside-to-sideand
4.Undersideofmowerisdirty. 4.Cleantheundersideofthemower.
5.Tirepressureindrivetiresnotcorrect. 5.Adjusttirepressureinthedrivetires.
6.Bladespindlebent. 6.ContactanAuthorizedServiceDealer.
7.Tipsofadjacentbladesareatanuneven
cuttingheight.Bladestipsshouldbeeven
within3/16inchwhichisapproximately
onebladethickness.
1.Cuttingblade(s)is/arebentorunbalanced.
2.Blademountingboltisloose. 2.Tightentheblademountingbolt.
3.Enginemountingboltsareloose. 3.Tightentheenginemountingbolts.
4.Looseenginepulley,idlerpulley,orblade
pulley.
5.Enginepulleyisdamaged. 5.ContactanAuthorizedServiceDealer.
6.Bladespindleisbent. 6.ContactanAuthorizedServiceDealer.
7.Beltisdamaged. 7.Installnewbelt.
2.Installnewcuttingblade(s).
front-to-rear.
7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley.
41
Troubleshooting
Problem PossibleCause CorrectiveAction
Bladesdonotrotate.
1.Drivebeltisworn,looseorbroken. 1.Checkthebelttension.
2.Drivebeltisoffpulley. 2.Checkbeltfordamage;replaceif
3.Deckbeltisworn,looseorbroken. 3.Installnewdeckbelt.
4.Deckbeltisoffpulley. 4.Installdeckpulleyandchecktheidler
5.Brokenormissingidlerspring.
6.PTOclutchdoesnotengage. 6.ContactanAuthorizedServiceDealer.
necessary.Installdrivebeltandcheck
adjustingshaftsandbeltguidesforcorrect
position.
pulley,idlerarmandspringforcorrect
positionandfunction.
5.Replacethespring.
42
Schematics
Schematics
ElectricalDiagram
43
Schematics
HydraulicDiagram
44
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 on these products 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 commercial turf equipment
sold in the U.S. 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.
Warranty Exceptions Warranty Period
• Bags, Belts and Tires 90 days
• Battery 1 Year Prorated
• Engine *
* The Engine warranty is covered by the engine manufacturer.
Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet.
This warranty only includes the cost of parts and labor.
Items and Conditions Not Covered
This warranty does not cover the following:
• Pickup and delivery charges to and from any authorized
Exmark Service Dealer.
• Any damage or deterioration due to normal use, wear and
tear, or exposure.
• Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune-up parts, and adjustments.
• Any product or part which has been altered or misused or
required replacement or repair due to normal wear,
accidents, or lack of proper maintenance.
• Any repairs necessary due to use of parts, accessories 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.
There are no other express warranties except for engine and
special emission system coverage.
All warranty work must be performed by an authorized
Exmark Service Dealer using Exmark approved replacement
parts.
Instructions for Obtaining Warranty Service
The product must be registered with original proof of purchase
by an Exmark Service Dealer before obtaining any warranty
service.
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. or Canada customers may
also call 402-223-6375.
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
service@exmark.com
Owner’s Responsibilities
If your product requires warranty service it 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 read the operator’s
manual. You must also 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.
General Conditions
The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair or replacement of
defective components as set forth herein. Neither Exmark
nor Exmark Warranty Company shall be liable for any
incidental or consequential loss or damage.
Such damages include but are not limited to:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other
extraordinary repair charges or charges 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.
All implied warranties of merchantability (that the
product is fit for ordinary use) and fitness for use (that the
product is fit for a particular purpose) are limited to the
duration of the express 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.
Exmark Commercial Turf Equipment
2 Year Limited Warranty
G4500-589_C
45
46
Figure23
Thispagemaybecopiedforpersonaluse.
1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopeindicatortodeterminethe
degreeofslopeofhillsbeforeoperating.DoNotoperatethismachineonaslopegreaterthan20degrees.Fold
alongtheappropriatelinetomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge.
47
MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
MICRO-MULCH SYSTEM
TURF STRIPER
STANDON
CUSTOM RIDE SEAT SUSPENSION SYSTEM
FULL SUSPENSION SEAT
DECK LIFT ASSIST KIT
HITCH KIT
LIGHT KIT
12
V POWER PORT
MICRO-MULCH SYSTEM
OPERATOR CONTROLLED DISCHARGE
ROLL OVER PROTECTION SYSTEM (ROPS)
SUN SHADE
TRASH CONTAINER
TURF STRIPER
ULTRA VAC COLLECTION SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
OU T-F RONT R IDING AC CESSORIES A ND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
DUAL-TAIL WHEEL
FLOOR PAN EXTENDER
HITCH KIT
LIGHT KIT
MICRO-MULCH SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
SNOW BLADE
SNOWBLOWER
SUN SHADE
TRASH CONTAINER
ULTRA VAC COLLECTION SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
WEATHER CAB
PlaceModelNo.andSerialNo.
LabelHere(IncludedintheLiterature
Pack)orFillinBelow
ModelNo. EngineSerialNo.(E/No)
SerialNo.
©2010ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved
DatePurchased
EngineModelNo.andSpec.No.
PartNo.4500-714Rev.A
(402)223-6300
Fax(402)223-5489
PrintedintheUSA
www.exmark.com