Exmark Navigator NAV20KC, Navigator NAV27KC Operator's Manual

For Serial Nos.

510,000 & Higher

Part No. 103-8573 Rev. B

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 engine Owner’s Manual become
damaged or illegible, replace immediately. Replacements may be ordered through the engine
manufacturer.

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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 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 following restrictions apply

-- The Exmark Parts Plus® Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available
only 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

®

Program are:
Any wholegood or accessory in its 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.

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CONGRATULATIONS on the purchase of your Exmark mower. This product has
been carefully designed and manufactured to give you a maximum amount of
dependability and years of 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, maint enance, and safety instructions, you will prolong
the life of your mower, mainta in it s m aximum efficiency, and promote safe oper ation.

If additional information is needed, or should you require trained mechanic
service, contact your authorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and distribut or s are kept informed of the latest
methods of servicing and are equipped t o pr ovide prom pt and efficient service in the
field or at their service stations. T hey carr y ample stock of service parts or can
secure them promptly for you fr om the factory.

All Exmark parts are thoroug hly test ed and inspect ed 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.

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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 Safety Signs............................................................................................. 8-10

2. SPECIFICATIONS

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

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

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

2.4 Electrical System....................................................................................10-11

2.5 Operator Controls........................................................................................ 11

2.6 Seat............................................................................................................. 11

2.7 Hydrostatic Ground Drive System ...............................................................11

2.8 Tires............................................................................................................12

2.9 Mower Deck ................................................................................................ 12

2.10 Dimensions.................................................................................................. 12

2.11 Torque Requirements..................................................................................12

3. ASSEMBLY INSTRUCTIONS

3.1 Uncrate Mower............................................................................................12

3.2 Service Battery.......................................................................................12-13

3.3 Install Drive Wheels..................................................................................... 13

3.4 Check Tire Pressure....................................................................................13

3.5 Service Engine............................................................................................ 13

3.6 Service Hydraulic Oil................................................................................... 14

4. OPERATION INSTRUCTIONS

4.1 Controls.................................................................................................. 14-16

4.2 Pre-Start...................................................................................................... 16

4.3 Operating Instructions ............................................................................ 16-18

4.4 Transporting........................................................................................... 18-19

5. MAINTENANCE & ADJUSTMENTS

5.1 Periodic Maintenance.............................................................................20-27

5.2 Adjustments ...........................................................................................27-35

6. WASTE DISPOSAL

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

6.2 Mercury Switch Disposal ............................................................................. 36

6.3 Battery Disposal.......................................................................................... 36

7. TROUBLESHOOTING ..................................................................................37-38

8. ELECTRICAL DIAGRAM ................................................................................... 39

9. HYDRAULIC DIAGRAM ....................................................................................40

10. WARRANTY ..................................................................................................... 41

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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. Familiarize yourself with the controls and the
proper use of the equipment. If the operator(s) or mechanic(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 attachments are needed
to properly and safely perform the job. Only use accessories and attachments
approved by Exmark.

1.3.2 The use of per sonal pr ot ective equipment, such as (but not limited to) pr otection
for the eyes, ears, feet , and head is r ecom m ended.

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.

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1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all
stones, sticks, wires, bones, and other foreign objects which may damage the
equipment or cause personal injury to the operat or or bystanders.

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.

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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 pets 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 partially 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.

WARNING

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

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.

♦ Keep hands, feet, hair, je welry, or clothing away from

rotating parts.

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

1.4.2 Mow only in daylight or good artif icial light, keeping away from holes and hidden
hazards. NEVER carry passengers.

DO NOT operate the mower when children or others are in the area.

1.4.3 When feasible, 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.

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DANGER

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

loss of control.

WHAT CAN HAPPEN
♦ Wheels dropping over edges, ditches, steep banks, or

water can cause rollovers, which may result in serious
injury, death or drowning.

HOW TO AVOID THE HAZARD

♦ Do not mow slopes when grass is wet.
♦ Do not mow near drop-offs or near water.
♦ Do not mow slopes greater than 15 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.

• Use a walk behind mower and/or a hand trimmer near drop- offs, ditches, steep

banks or water. This area can be dangerous, see Figure 1.

Figure 1

SAFE ZONE FOR MOWING

• Progressively greater care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. If tir es lose t r action,

disengage the blades and proceed slowly off the slope.

• Avoid sudden stops when mowing downhill. Mower may tip forwards.

• Be aware that loss of traction may occur going uphill. Weight transfer to the

rear wheel 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 attachments. These can change t he stability of the

machine and cause loss of control.

• Follow the manufacturer’s recommendations for wheel weights or

counterweights to improve stability.

1.4.5 Use EXTREME caut ion when backing up. LOOK BEHIND YOU!

1.4.6 Stop the blades when crossing surfaces other than gr ass and when transporting
the mower to and from the area to be m owed.

- 5 -

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

1.4.8 DO NOT change the engine g overnor set tings or overspeed the engine. Operating
an engine at excessive speed may increase the hazard of personal injury.

1.4.9 Disengage PTO befor e 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 r o t at ing parts while the mower is being
operated.

1.4.12 Stop engine, wait for all moving parts to stop, and remove 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.

Stop the engine and wait for all moving part s t o st op:

• Before refueling.

• Before dumping the gr ass cat c her .

1.4.13 Before stopping the engine, place the throt t le 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.

1.4.14 The fuel system is provided with a shut-off valve. Shut off the fuel:

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

• During transport to and from the job.

• When parked inside a building.

1.4.15 This mower was designed for one operator only. Keep all others away fr om
mower during operation.

1.4.16 Do Not mow with the grass catcher door or the grass cat cher r aised, removed or
altered.

1.4.17 Do Not operate mower under the influence of alcohol or dr ugs.

1.4.18 Use extra care when approaching blind corners, shrubs, trees, or other objects
that may obscure vision.

1.4.19 If jump starting is required:

a) connect the positive (+) power cable from the 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 manufacturer’s recommendations
precisely as stated in the engine manual.

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

- 6 -

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 storag e.

1.5.4 Keep engine, engine area, and pump drive belt compartment free from
accumulation of grass, leaves, excessive grease or oil, and ot her debris which
can accumulate in these areas. These materials can become com bustible and
may result in a fire.

1.5.5 Store fuel in a container specifically designed for this purpose in a cool, dry place.

1.5.6 Keep the m ower and fuel container in locked storage to pr event childr en from
playing or tampering with them.

1.5.7 Gasoline powered eq uipm ent or fuel containers should not be stored in a 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 maintained and operated correctly.

1.5.9 Check all bolts frequently to maint ain 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 com ponent s t hat could create a hazard.

1.5.12 All replacement parts must be the same as or equivalent to the par t s 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

placing the motion control levers in neutral and
shutting off t he engine, before perfor m ing any work on
the hydraulic system.

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1.6 SAFETY SIGNS

1.6.1 Keep all saf et y sig ns legible. Remove all grease, dirt and debris from safety
signs and instructional labels.

1.6.2 Saf et y sig ns m ust be replaced if they are missing or illegible.

1.6.3 When new components are installed, be sure that cur r ent safety signs are
affixed to the replaced components.

1.6.4 New safety signs m ay be obtained from Exmark Mfg. Co. I nc.

1.6.5 Saf et y 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.

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

LOCATION: Molded in LH Console

PART NO. 79-0360
LOCATION: On Front of Blower

Discharge Chute

PART NO. 1-643401
LOCATION: On Frame, Next to Mercury Switch

or On Mercury Switch

PART NO. 98-4361
LOCATION: - On Top of Pump Mounting Plate

- On PTO Shield

PART NO. 98-5954
LOCATION: - On Gear Box Cover, Under Rubber Cover

- On Top of Deck, Under Gear Box Cover

- On LH Frame, Under PTO Shield

- On RH Lower Frame, behind fuel tank

PART NO. 103-8451
LOCATION: On RH Console

PART NO. 1-523552
LOCATION: On Top of Oil Reservoir

- 8 -

PART NO. 103-8611
LOCATION: On Pump Plate,

Above Relays

WARNING

HOT

SURFACE

PART NO. 65-2690
LOCATION: - On Frame LH side in Front

- On Frame RH side behind

PART NO. 103-8444
LOCATION: On Hopper Door Hinge, Each Side

PART NO. 103-8495
LOCATION: On Top of Mainframe, Under Hopper

PART NO. 1-513747
LOCATION: On Battery Cover

65-2690

of Exhaust Cutout
Exhaust Cutout

PART NO. 103-8812
LOCATION: On RH Console

LOCATION: Molded into front of hopper

PART NO. 103-8416
LOCATION: On Top of Seat Console, Under Seat

- 9 -

PART NO. 103-9724
LOCATION: On PTO Guard

PART NO. 103-8425
LOCATION: - On front console,

- On driveshaft

Under Seat

PART NO. 103-9032
LOCATION: On Back of Seat

PART NO. 103-9034
LOCATION: On Rear of LH Drive

Wheel Fender

2. SPECIFICATIONS

2.1 MODEL NUMBER: NAV20KC, NAV27KC

2.2 ENGINE:

2.2.1 Engine Specifications: See your Engine Owner’s Manual

2.2.2 RPM: Full Speed: 3600 RPM (No Load) Idle: 1500 RPM

2.3 FUEL SYSTEM

2.3.1 Capacity: 7.5 gal (28 L)

2.3.2 Type of Fuel: Regular unleaded g asoline, 87 oct ane or higher

2.3.3 Fuel Filter: Kohler units: In-line 15 Micron Kohler P/ N 2405002.

2.3.4 Fuel Shut-Off Valve: 1/4 turn “in-line” valve by fuel filter.

2.4 ELECTRICAL SYSTEM

2.4.1 Charging System: Flywheel Alternator

2.4.2 Charging Capacity: 15 amps

2.4.3 Battery Type: BCI Group U1

2.4.4 Battery Voltage: 12 Volt

2.4.5 Polarity: Negative Ground

- 10 -

2.4.6 Saf et y Int er lock System:
PTO must be disengaged, brake engaged, and speed control lever i n neut ral

position to start engine. (It is not necessary for the operat or to be in the seat
to start the engine.)

Operator must be in seat when PTO is engaged, brake is disengaged, or speed

control lever is moved out of neutral or engine will stop.

Engine will stop in the following conditions:

• If the speed control lever is moved from neutral position while brake is engaged.

• If the PTO is engaged while the hopper is tilted up.

2.4.7 Tilt Switch: Shuts off the engine when the unit is t ilt ed more than 60° from horizontal.

2.5 OPERATOR CONTROLS

2.5.1 Steering and Motion Control:
Speed Control lever, located on RH console, sets maximum forward speed.
Steering levers, centered in front of the seat, control t he speed and dir ection of

travel of the respective drive wheels.

Moving speed control lever rearward to the neutral position places the drive

system in neutral.

NOTE: The unit may be moved in reverse while the speed control is in the

neutral position by pulling back on the steering levers.

2.5.2 PTO Engagement Lever

2.5.3 Park ing Brake Lever

: Engages drive to PTO (mower deck) and blower.

: Pull back to engage parking brake.

2.6 SEAT

2.6.1 Type: Standar d seat with high back, foam padded (internal suspension) .

2.6.2 Mounting: Seat is hinged to tilt up for access to hydraulic pumps and ot her
components. The seat is held in the tilted position with a link.

2.6.3 Seat Safety Switch: Incorporated into the Safety Interlock System. Time delay
seat switch eliminates rough ground cut-out s.

2.6.4 Armrest: None

2.7 HYDROSTATIC GROUND DRIVE SYSTEM

2.7.1 Hydrostatic Pumps: Two Hydro Gear PJ 12 cc variable displacement piston pumps.

2.7.2 Wheel Motors: Hydro Gear planetary reduction motors.

2.7.3 Hydraulic Oil T ype: Use Mobil 1 15W-50 Synthetic Motor Oil.

2.7.4 Hydraulic Oil Capacity: 4. 0 qt. (3.8 L.)

2.7.5 Hydraulic Filter: Replaceable cartridge type.
P/N 109-0071: 25 microns, 10 psi bypass (Summer use above 32° F (0°C))

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

2.7.6 Speeds: 0-7.0 mph (11.3 Km/hr) forward
0-5.5.mph (8.6 km/ hr ) r everse

2.7.7 Drive wheel release valves allow machine to be moved when engine is not running.

- 11 -

2.8 TIRES

Pneumatic (Air-Filled) Semi-Pneumatic Semi-Pneumatic
Quantity 2 2 1
Tread Multi Trac C/S Smooth Smooth
Size 18 x 10.50-10 8 x 3.00-4 13 x 8.00-6
Ply Rating 4
Pressure 15 psi (103 kPa)

Drive Front Caster Rear Caster

2.9 MOWER DECK (Sold Separ ately)

2.9.1

Models CD42CD CD48CD

Discharge Center Discharge Center Discharge
Cutting Width 42 in. (106.7 cm) 48 in. (121.9 cm)

2.9.2 Deck Drive: Clutching belt on horizontal engine shaft. Dual “ A” section hexagon
belt with spring tensioned idler to jackshaft and blower. Heavy-duty cast iron,
spiral bevel gearbox is final drive to blades.

2.10 DIMENSIONS

Overall Width 42.6” (108.2 cm) 43.2” (109.7 cm) 49.2” (125.0 cm)
Overall Height 51.2” (130.0 cm) 51.2” (130.0 cm) 51.2” (130.0 cm)
Overall Length 67.3” (170.9 cm) 91.8” (233.2 cm) 94.5” (240.0 cm)
Curb Weight 850 lbs (386 kg) 1145 lbs (519 kg) 1170 lbs (531 kg)

Without deck With 42” Deck With 48” Deck

Tread Width (Center to Center of Drive Wheels)
Wheel Base (Center of Drive Wheel to Center of Rear Caster Wheel)

32.7” (83.1 cm)

44.2” (112.3 cm)

2.11 TORQUE REQUIREMENTS

Bolt Location

Torque

Blade Mounting Bolt.....................................................85-110 f t -lbs. (115-149 N-M)

Engine Mounting Bolts ......................................................30-35 ft-lbs. (41-47 N-M)

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

Wheel Motor Mounting Bolts............................................72-77 ft -lbs. (98-104 N-M)

3. ASSEMBLY INSTRUCTIONS

3.1 UNCRATE MOWER

3.2 SERVICE BATTERY

WARNING: Battery posts, terminals, and related accessories contain lead compounds, chemicals known

to the State of California to cause cancer and reproductive harm. Wash

The machine is shipped with a filled lead acid battery.

hands after handling.

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 batter y in an

enclosed space.

♦ Make sure venting path of battery is always open once

battery is filled with acid.

- 12 -

3.2.1 Check the voltage of the 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 t he following chart for
recommended charger settings).

Voltage

Reading

Percent

Charge

Maximum

Charger Settings

Charging Interval

12.6 or greater 100% 16 volts/7 amps No Charging Required

12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes

12.2 – 12.4 50 – 75% 16 volts/7 amps 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 am ps 3 Hour s

11.7 or less 0% 14.4 volts/2 amps 6 Hours or More

CAUTION

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

for sparks and 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.

3.2.4 Connect the negative battery cables.
NOTE: If the positive cable is also disconnected, connect the positive (red)

cable and the red wire to the positive term inal on t he battery first, then connect
the negative (black) cable and black wire to t he negative terminal on the battery.
Slip insulator boot over the positive terminal.

NOTE: If time does not permit charging t he battery, or if charging equipment is

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

3.3 INSTALL DRIVE WHEELS.

3.3.1 Mount drive wheels with the valve stem to the outside of the unit. Secure using
four (4) ½-20 wheel nuts installed on studs in hubs f or each wheel. T or que to
95 ft-lbs (128 N-m).

3.4 CHECK TIRE PRESSURE.

3.4.1 Check tire pressure in drive tires. Proper inflation pressure for tires is 15 psi
(103 kPa). Adjust if necessar y.

Mower deck casters and rear caster tires are semi-pneum atic and do not need to

be inflated.

3.5 SERVICE ENGINE.

Engine is shipped with oil; check oil level and if necessary and fill to t he appropriate

level with oil as specified in Engine Owner’s Manual.

- 13 -

3.6 SERVICE HYDRAULIC OIL

The machine is shipped with hydraulic oil in the reservoir. Run the machine for

approximately 15 minutes to allow any extra air to purge out of the hydraulic system .
Check hydraulic reservoir and if necessary fill t he r e ser voir t o the appropriate level with
Mobil 1 15W-50 synthetic motor oil. Replace hydraulic reservoir cap and tighten until
snug. Do not overtighten.

NOTE: The baff le is labeled “ HO T” 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 temperat ur e of the oil. For example: If the
oil is about 150° F (65°C). Fill to half way between the “HOT ” and “COLD” levels. If
the oil is at room temperatur e (about 75° F (24°C)), f ill only to the “COLD” level.

4. OPERATION INSTRUCTIONS

4.1 CONTROLS

4.1.1 Familiarize yourself with all controls before operating the mower.

4.1.2 Steering and Motion Control

Speed Control lever, located on RH console, sets maximum forward speed.

Moving speed control lever rearward to the neutral position places the drive
system in neutral.

Pulling back on the steering levers, cent er ed in front of the seat, pr ogressively

slows, then reverses the direction of travel of t he respective drive wheels.

By moving both steering levers an equal amount back, the machine can be

slowed down or travel backward in a straight line.

Steering is controlled by varying the position of the steering levers relative to

each other.

To turn left while moving forward, move the left steering lever back toward

neutral to slow the left drive wheel.

To turn right wile moving forward, move the right steering lever back toward

neutral to slow the right drive wheel.

To turn to the left while backing, move the left lever f o r ward toward neutral. To

turn to the right while backing , m ove the right lever forward toward neutral.

NOTE: The unit may be moved in reverse while the speed control is in t he

neutral position by pulling back on the steering levers.

:

POTENTIAL HAZARD
♦ Machine can spin very rapidly by positioning one lever

too much ahead of the other.
WHAT CAN HAPPEN
♦ Operator may lose control of the machine, which may

cause damage to the machine or injury.
HOW TO AVOID THE HAZARD

♦ Use caution when making turns.
♦ Slow the machine down before making sharp turns.

4.1.3 Tracking Adjustment Knob: Located under the seat on the left pump control
link. Rotating this k nob allows f ine t uning adjustments so that the machine
tracks straight.

CAUTION

- 14 -

Run unit at 3/4 speed for at least 5 minutes to bring hydraulic oil up to operating

temperature. Stop machine and wait for all moving parts to stop. Engage park
brake. Tilt seat forward to gain access to the tracking knob. Rotate the knob
towards the right to steer right and rotate towards the left to steer left. Adjust in
1/8-turn increments until the m achine t racks straight. Check that the machine does
not creep when in neutral with the park brakes disengaged.

IMPORTANT: Do not rotate the knob too far, as this may cause the machine

to creep in neutral. Refer to section 5.2. 9 f or cont rol l inkage adjustment.

4.1.4 PTO Engagement Lever

: Located immediately left of the left console.

Lever must be moved up to the “ROTATE” position to engage the PTO and

blower drives. Lever is moved down to the “STOP” position to stop the drives.

4.1.5 Choke Control

: Located on right hand console.

Choke is used to aid in starting a cold engine. Moving the choke lever forward

will put the choke in the “ON” position and moving the choke lever t o t he rear
will put the choke in the “OFF” position. DO NO T r un a warm engine with choke
in the “ON” position.

4.1.6 Throttle Control

: Located on right hand console.

Throttle is used to control engine speed. Moving throttle lever forward will increase

engine speed and moving throttle lever to the rear will decrease engine speed.

4.1.7 Brake Lever

: Located on left side of unit , between the seat and console. The

brake lever engages a parking 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.
The unit must be tied down and brake engaged when transporting.

4.1.8 Ignition Switch

: Located on the right hand console.

The ignition switch is used to start and stop the engine. The switch has three

positions “OFF”, “ON” and “START”. Insert key into switch and rotate clockwise
to the “ON” position. Rotat e clockwise to the next position to engage the star t er
(key must be held against spring pr essur e in t his position).

Brake must be engaged, speed control lever in neutral and PTO lever

“OFF” to start engine. (It is not necessar y for the operator to be in the seat to

start the engine.)

4.1.9 Hour Meter

: Located on the right hand console. The hour m et er is connected to
a pressure switch installed in the engine block and it recor ds t he num ber of
hours that the engine has run. If the ignition switch is left on without engine
running, hour meter 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 Engine Oil Temperature Light and Buzzer:

Located on the right console. The
engine oil temperature light monitors the temperature of the engine oil. An
illuminated engine oil temperature light and intermittent buzzing sound signals
the engine is overheating.

4.1.11 Fuel Shut-Off Valve

: Located in fuel line by fuel tank and fuel filter (accessible by
raising the hopper). The fuel shut-off valve is used to shut off the fuel when the
machine will not be used for a few days, during transpor t t o and from the job site,
and when parked inside a building.

4.1.12 Drive Wheel Release Valves

: Located on the top left front corner of hydrostatic
pumps. Drive wheel release valves are used to release the hydrostatic drive
system to allow the machine to be pushed without the engine running. Tilt seat
up to gain access to pumps.

- 15 -

With a 7/16 wrench, t ur n both valves one turn counter-clockwise to release drive

system. Turn clockwise to reset system. DO NOT overtighten. DO NOT tow
machine.

4.2 PRE-START

4.2.1 Fill fuel tank. For best r esults use only clean, fresh regular gr ade unleaded
gasoline with an octane rating of 87 or higher. Regular grade leaded g asoline
may also be used; however, combustion chamber and cylinder head will require
more frequent service. See Engine Owner's Manual.

DO NOT add oil t o gasoline.
DO NOT overfill fuel t ank. Never fill the fuel t ank so that the fuel level rises

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

4.2. 2 Make sure you understand the cont r ols, their locations, their functions, and t heir
safety requirements.

4.2.3 Refer to Maintenance, Section 5, and perf orm all the necessary inspection and
maintenance steps.

4.3 OPERATING INSTRUCTIONS

4.3.1 Open fuel shut-off valve:

The fuel shut-of f valve is located on the right side of unit in fuel line next to the fuel

filter. Raise the hopper to access.

4.3.2 Starting Engine

Brake must be engaged, speed control lever in neutral position and PTO

lever “OFF” to start engine. (It is not necessar y for the operator to be in the
seat to start the engine.)

On a cold engine, place the throttle midway between the “SLOW” and “FAST”

positions and push choke lever forward into the “ON” position. Turn ignition switch
to the “start” position. Release the switch as soon as the engine starts.

:

IMPORTANT:

DO NOT crank the engine continuously for more then ten (10)
seconds at a time. If the engine does not start, allow a 60 second cool­down period between starting attempts. Failure to f ol l ow these guidelines
can burn out the starter motor.

After starting a cold engine, gradually return choke to the “OFF” position as the

engine warms up.

On a warm engine, place the throttle midway bet ween the “SLOW” and “FAST ”

positions and leave the choke in the “OFF” position.

4.3.3 Engaging PTO

:

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 blades are engaged.

- 16 -

DANGER

POTENTIAL HAZARD
♦ An uncovered discharge opening will allow objects to

be thrown in an operator’s or bystander’s direction.

Also, contact with the blade could occur.
WHAT CAN HAPPEN
♦ Thrown objects or blade contact can cause serious

injury or death.
HOW TO AVOID THE HAZARD
♦ Always operate the mower with the grass catcher down

and with the grass catcher door securely closed.

The PTO lever engages the PTO and blower. Be sure that the hopper is down,

the hopper door is securely closed, and all persons are clear of the mower deck
and discharge area before engaging PTO.

IMPORTANT

: Operator must be in seat and hopper must be dow n bef ore

the PTO can be engaged.

Set throttle to "midway" position. Pull PTO lever upward until locked over center.

Accelerate to full throttle to begin mowing.

4.3.4 Stopping PTO

: Set throttle to the “ m idway” position. Push PT O lever down to

the “STOP” position stopping t he PTO and blower.

4.3.5 Stopping Engine

: Bring unit to a full stop. Disengage the PTO, move speed

control lever to the neutral position and set t he parki ng brake.

Before stopping the eng ine, place t he throttle control 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.

Rotate ignition switch to “OFF” posit ion. Rem o ve the key to prevent children or

other unauthorized persons from star t ing 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.

4.3.6 Emptying Hopper

:

a) A full hopper is indicated by a buzzer located behind the operator in the

hopper. Empty hopper when buzzer sounds to prevent clogging of t he blower
or deck

b) Disengage PTO, move speed control to neutral, set par k brake and

dismount unit to dump hopper.
c) Make sure unit is on a dry level surface.
d) Dump hopper by firmly grasping one of t he hopper handles on either side of

the unit and lifting the hopper . The rear door opens automatically when

hopper is raised. See Figure 2 instructions on disabling the auto door open

feature.

- 17 -

FIGURE 2

DISABLING HOPPER AUTO DOOR OPEN

4.3.7 Clearing Hopper Screen

:
a) Screen may be removed by firmly lifting screen handles. See Figure 3.
b) Pull screen towards the back to remove. Gently tap debris from the screen

as needed.
c) Excessive build-up on the screen can cause the blower to plug.
NOTE: In conditions where the screen clogs quickly, the front removable

screen panel can be turned and reinstalled under the primar y screen to allow

free air flow from the hopper.

4.4 TRANSPORTING

4.4.1 Transporting a Unit: Use a heavy-duty trailer or truck to transport the m achine. Lock
brake and block wheels. Securely fasten the machine to the trailer or truck with
straps, chains, cable, or ropes. Be sure t hat the trailer or truck has all necessary
lighting and marking as required by law. Secure the trailer with a safet y chain.

FIGURE 3

HOPPER SCREEN REMOVAL

- 18 -

CAUTION

POTENTIAL HAZARD
♦ This unit does not have proper turn signals, lights,

reflective markings, or a slow moving vehicle emblem.
These items are required t o dr ive on a public str eet or

roadway.
WHAT CAN HAPPEN
♦ Driving on a street or roadway without such equipment

is dangerous and can lead to accidents causing

personal injury.
♦ Driving on a street or roadway without such equipment

may also be a violation of State laws and the operator

may be subject to traffic t ick ets and/or fines.
HOW TO AVOID THE HAZARD
♦ Do not drive a unit on a public street or roadway.

WARNING

POTENTIAL HAZARD
♦ Loading a unit on a trailer or truck increases the

possibility of tip-over.
WHAT CAN HAPPEN
♦ Tip-over of the unit could cause serious injury or

death.
HOW TO AVOID THE HAZARD

♦ Use extreme caution when operating a unit on a ramp.
♦ Use only a single, full width ramp; DO NO T use

individual ramps for each side of the unit.
♦ If individual ramps must be used, use enough ram ps t o

create an unbroken ramp surf ace wider than t he unit .
♦ DO NOT exceed a 15° angle between ramp and

ground or between ramp and trailer or truck.
♦ Avoid sudden acceleration while driving unit on a

ramp.

4.4.2 Loading a Unit: Use extreme caution when loading units on t railers or trucks.
One full width ramp is required. If it is not possible to use one f u ll width ram p,
use enough individual ramps to simulate a full width continuous ram p.

Ramp should be long enough so that the angles bet ween the ram p and t he

ground and the ramp and the trailer or t r uck do not exceed 15°. A steeper angle
may cause mower deck components to get caught as the unit moves from ramp
to trailer or truck. Steeper angles may also cause the unit to tip. If loading on or
near a slope, position the trailer or tr uck so it is on the down side of the slope
and the ramp extends up the slope. This will minimize the ramp angle. The
trailer or truck should be as level as possible.

DO NO T att em pt to turn the unit while on the ramp, you may lose control and

drive off the side.

Avoid sudden acceleration when driving on a ramp.

- 19 -

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.

5.1 PERIODIC MAINTENANCE

5.1.1 Check engine oil level:
Service Interval: Daily
a) Stop engine and wait for all moving parts to stop. Make sur e unit is on a

level surface.
b) Check with engine cold.
c) Raise hopper.
d) Clean area ar ound dipst ick. Remove dipstick and wipe oil off. Reinsert the

dipstick and push it all the way down into the tube. Remove the dipstick

and read the oil level.
e) If the oil level is low, wipe off the area around the oil fill cap, remove cap

and fill to the “FULL” mark on the dipstick. Use oil as specified in Engine

Owner’s Manual. DO NOT overfill.

IMPORTANT: DO NOT operate the engine with the oil level below the

“LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

5.1.2 Check batter y charge
Service Interval: Monthly

Allowing batteries to stand for an extended per iod 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, batter y should be fully charged

before putting away for winter storag e.

:

- 20 -

a) Check the voltage of the battery with a digital voltm eter. Locate the voltage

reading of the batter y in the t able below and charge the battery for the

recommended time interval to bring t he charge up to a full charge of 12.6

volts or greater.
IMPORTANT: Make sure the negative batter y cables are disconnect ed

and the battery charger used for char ging 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

recommended charger settings).

Voltage

Reading

Percent

Charge

Maximum

Charger Settings

Charging Interval

12.6 or greater 100% 16 volts/7 amps No Charging Required

12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes

12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour

12.0 – 12.2 25 – 50% 14.4 volts/ 4 am ps 2 Hours

11.7 – 12.0 0 – 25% 14.4 volts/ 4 am ps 3 Hours

11.7 or less 0% 14.4 volts/2 amps 6 Hours or More

5.1.3 Clean engine cooling system:
Service I nt erval : Dai l y or more of ten 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 drive belts can create a fire hazard.
HOW TO AVOID THE HAZARD
♦ Clean all debris from around engine and dr ive belts

daily.

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

b) Clean all debris from rotating engine air intake screen and from around

engine shrouding.
c) Clean all debris from around engine and dr ive belts.
d) For 27HP Kohler units: Swing out the fuel tank and remove debris from

around the oil cooler positioned at right front corner of eng ine.

5.1.4 Check safety interlock system

.

Service Interval: Daily
a) Check starting cir cuit. Starter should crank with, parking brake engaged,

PTO disengaged and speed control lever in the neut ral position. The
operator does not need to be in the seat to star t the engine.

Try to start with operator in seat, parking brake disengaged, PTO

disengaged and speed control lever in the neutral position - starter must
not crank.

Try to start with operator in seat, parking brake engaged, PTO engaged and

speed control lever in the neutral position - star ter must not crank.

Try to start with operator in seat, parking brake engaged, PTO

disengaged, and the speed control lever forward (out of neutral) ,
starter must not crank.

- 21 -

b) Check the kill circuits. Run engine at one-third throttle, disengage parking

brake and raise off of seat ( but do not get off of machine) engine must
stop after approx. 1/2 second has elapsed (seat has t im e delay k ill switch
to prevent cut-outs on rough terr ain) .

Run engine at one-third throttle, engage PTO and raise of f of seat (but do

not get off of machine) engine must stop af t er 1/2 second has elapsed.

NOTE: If machine does not pass any of these tests, do not operate.

Contact your authorized EXMARK SERVICE DEALER.

IMPORTANT: It is essential that operator safety mechanisms be

connected and in proper operating condition prior to use for mowing.

5.1.5 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 .

5.1.6 Service air cleaner

.

Service Interval: 50 hrs.

More often under severe conditions.
See Engine manual for additional information.

a) Stop eng ine, wait for all moving parts to stop, and r e m ove k ey.

b) Tilt hopper up to gain access t o t he air cleaner.
c) Loosen retaining clips and r em ove air cleaner com par tment cover.
d) Remove paper element. Check the condition of the paper element.

Replace if dirty, bent or damag ed.

e) Check the condition of the inner element. Replace whenever it appears dirt 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.
f) DO NOT wash or use pressurized air to clean paper element or inner elem ent .
g) Reinstall elements. Position the cover so that the rubber dust ej ect or is

pointing downward and secure with retaining clips.

5.1.7 Change engine oil

:
Service Interval: 100 hrs.
NOTE: Change oil and filter after firs t five (5) hrs. of operation.
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Tilt hopper up to gain access to t he engine area.
b) Drain oil while engine is warm from operat ion.
c) The oil drain valve is located on left hand side of engine at the back of the

unit.

Place pan under machine t o catch oil and open valve. Allow oil to drain,

then close valve.

d) Replace the oil filter every other oil change. Clean around oil filter and

unscrew filter to remove. Bef ore reinstalling new filter, apply a thin coating of
oil on the surface of the r ubber seal. Turn filter clock wise until rubber seal
contacts the filter adapt er t hen tighten filter an additional 2/3 to 3/4 turn.

e) Clean around oil fill cap and remove cap. Fill to specified capacity and replace

cap. Use oil recommended in engine owner’s manual. DO NO T overfill.
f) Lower hopper.
g) Start the engine and check for leaks.

- 22 -

5.1.8 Check hydraulic oil level:
Service Interval: 40 hr.

a) Stop engine and wait for all moving parts to stop.
b) Tilt hopper up.
c) Clean area around hydraulic reservoir cap and rem ove cap. O il level should

be to the top of the baf fle inside the tank. If not, add oil. Use only Mobil 1

15W-50 synthetic motor oil. Replace hydraulic reservoir cap and tighten

until snug. Do not overtighten.
NOT E: 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 appropriat e level depending upon the temperature

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

between the “HOT” and “COLD” levels. If the oil is at room temperatur e

(about 75° F (24°C)), fill only to the “COLD” level.

5.1.9 Check tire pressures

:
Service Interval: 40 hrs.
a) Stop engine, wait for all moving parts to stop, and remove key.

b) Check tire pressure in drive tires. Inflate drive tires to 15 psi (103 kPa).
c) The rear caster tire is semi-pneumatic and does not need to be inflated.

NOTE: Do not add any type of tire liner or foam fill material to the tires.

Excessive loads created by foam filled tires may cause failures to the hydro drive
system, frame, and other components. Foam filling tires will void the warranty.

5.1.10 Check condition of belts

:
Service Interval: 40 hrs.
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Tilt hopper up and check pump and PT O drive belts.
c) Belts are spring tensioned and no adjustment is necessary unless belts are

replaced. See section 5.2.2 and 5.2.3 f or belt replacement.

5.1.11 Lubricate grease fitting s

:
Service Interval: Refer to chart.
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Lubricate fittings with one to t wo pumps of NGLI grade #2 multi-purpose

gun grease.

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

LUBRICATION CHART

FITTING

LOCATIONS

1. Caster Pivot *0 3 *yearly

2. PTO Idler 1 1 yearly

3. Pump Idler 1 1 yearly

4. Rear Caster Hub *0 1 or 2 *yearly

INITIAL

PUMPS

NO. of

PLACES

SERVICE

INTERVAL

* See Section 5.1.11 c) for special lubr icat ion

instructions on the front and rear caster pivots and
Section 5.1.12 for special lubrication inst r uctions on
the rear caster wheel hub.

- 23 -

c) Lubricate 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 thread plug back in. Place cap back on.

5.1. 12 Lubricate rear caster wheel hub:
Service Interval: Once Yearly
a) Stop engine, wait for all m oving par t s to

stop, and remove key.
b) Remove caster wheel from caster f or ks.
c) Remove seal guards from the wheel hub.
d) Remove one of the spacer nuts f r om t he

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) f r om the

wheel assembly.

CASTER WHEEL ASSEMBLY

FIGURE 5

e) Pry out seals, and inspect bearings for

wear or damage and replace if necessary.
f) Pack the bearings with a NGLI grade #1 multi-purpose grease.
g) Insert (1) bearing , (1) new seal into the wheel.
NOTE: Seals (Exmark PN 103-0063) must be replaced.
h) If the axle assembly has had both spacer nuts rem oved (or br oken 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 t he assem bled nut and axle into the wheel on the side of the wheel

with the new seal and bearing.
j) 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.
k) Insert the second bearing and new seal into the wheel.

nd

l) Apply a thread locking adhesive to the 2

spacer nut and thread onto the axle

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

in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut.
n) 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 torq ue on spacer nut until there is a slight amount of dr ag.

Re-apply threadlocking adhesive.

5.1.13 Lubricate seat switch actuator:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving part s to stop, and remove key.
b) Tilt seat up.
c) Lubricat e switch actuator rod with spray type lubricant or light oil.

- 24 -

5.1.14 Lubricate hopper actuator:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving part s to stop, and remove key.
b) Raise hopper and locate actuator on right hand side of mainframe.
c) Lubricat e switch actuator rod with spray type lubricant or light oil.

5.1.15 Lubricate the pivot bushings (locations shown in Figure 5)

:
Service Interval: 160 hrs.
a) Stop engine, wait for all moving part s to stop, and remove key.
b) Lubricate bronze bushings on brake handle pivot with a spray type lubricant

or light oil.

LEFT SIDE OF UNIT SHOWN

FIGURE 6

BUSHING PIVOT LOCATIONS

5.1.16 Lubricate brake rod bushings

:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and r em ove k ey.
b) Unhook seat lat c h and t ilt seat up.
c) Lubricate bronze bushings on each end of brake rod shaft with a spray type

lubricant or a light oil (bushings ar e locat ed to the inside of the flange bear ings).

5.1.17 Lubricate steering linkag e r od ends

:
Service Interval: 160 hrs.
a) Stop engine, wait for all moving parts to stop, and rem ove k ey.
b) Tilt seat up.
c) Lubricate each end of both steering linkage rods with a spray lubricant or a light

oil.

5.1.18 Remove engine shrouds and clean cooling fins

:

Service I nt erval : 80 hrs.
a) Stop engine, wait for all moving parts to st op, and remove key.

b) Remove cooling shroud clean-out covers from eng ine and clean cooling fins.

Also clean dust, dirt, and oil from exter nal sur faces of engine, which can cause
improper cooling.

c) Make sure cooling shroud clean-out covers are reinstalled. Operating the

engine without cooling shroud clean-out covers will cause engine damage due
to overheating.

- 25 -

5.1.19 Check spark plugs

:

Service Interval: 160 hrs.

a) Remove spark plugs, check condition and reset gaps, or replace with new

plugs. See Engine Owners Manual.

5.1.20 Change fuel filter

:

Service Interval: As Required

a) A fuel filter is installed between the fuel tank and the engine. Replace when

necessary.

Replacement Filters

Kohler P/N 2405002

5.1.21 Change hydraulic system filter:

Service Interval: After First 250 hrs.
Then yearl y t hereaf t er

NOTE: Use only Exmark Part No.109-0071 for summer use above 32° F (0°C)

or Part No. 1-523541 for winter use below 32° F (0°C).
a) Stop engine, wait for all m o ving par t s t o stop, and remove key.
b) Carefully clean area around filter. It is important that no dirt or

contamination enter hydraulic system.
c) Unscrew filter to r emove and allow oil to drain from reservoir.
IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15W-50 and

apply a thin coat of oil on the surface of the rubber seal.
Turn filter clock wise until rubber seal contacts the filter adapter , then

tighten the filter an addit ional 2/ 3 to 3/4 turn.
d) Fill reser voir as st at ed in Section 5.1.8.

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.

e) Raise the drive wheels off of the ground and support with jack stands ( or

equivalent support) just high enough to allow drive wheels to turn freely.
f) Start engine and move thrott le cont rol ahead to full throttle position. Move

the speed control lever to the full speed and run for several minutes. Shut

down machine and recheck oil level.
Do not change hydraulic system oil (except for what can be drained when

changing filter), unless it is felt the oil has been contaminat ed or been

extremely hot.
Changing oil unnecessarily could damage hydraulic system by

introducing contaminates into the system.

- 26 -

5.1.22 Wheel Hub – slotted nut torque specification
Service Interval: 500 hrs
When tig ht ening the slotted nut on the wheel motor tapered shaft:
a) Torque the slotted nut to 125 ft-lbs (169 N-m).
NOTE: Do not use antisieze on wheel hub.

5.1.23 Fuel Tank

– mounting hardware specification

When installing the nuts on the fuel tank studs, fully tig ht en t he nyloc nut and

back off ½ tur n. This allows for normal fuel tank expansion and contr act ion with
changes in temperature and f uel levels.

5.1. 24 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro- Lock Nut Type”

are used on the following fasteners:
a) Pump drive sheave set screws.
b) Square head setscrews on Hydro pump control arms.
c) Sheave retaining bolt in t he end of engine crankshaft , blower shaft and

jackshaft.
d) Caster wheel spacer nuts
e) Fuel tank bulkhead fitting nuts.

5.1.25 Dielectric grease

is used on blade type electrical connections to prevent corrosion

and loss of contact. Do not apply grease to sealed connect ors inside hopper.

5.2 ADJUSTMENTS

IMPO RTANT: Disengage PTO, shut off engine, wait for all moving parts to stop,

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

5.2.1 Pump Drive Belt Tension
Spring Tensioned - No adjustment necessary.

5.2.2 PTO Belt Replacement
a) Stop engine, wait for all moving parts to st op, and remove key.
b) With engine “off”, engage PTO lever, then remove the hairpin and clevis

pin at the bottom of the PTO brake band.
c) Rotate the brake band upwards out of the way of the belts keeping clear of

the belt drive.
d) Disengage PTO lever.
e) Remove current belts.
f) Route new belts onto sheaves as shown in the decal located on the back of

the left drive shield. See Figure 8.

PTO BELT ROUTING
g) Rotate brake band back down into original position.
h) Re-install clevis pin and hairpin to secure brake band.

.

.

FIGURE 8

- 27 -

i) Engage the PTO lever.
j) Loosen the jam nuts and adjust linkage as shown in Figure 9 until the

pointer is aligned with the tension arm as shown.

FIGURE 9
PTO BELT REPLACEMENT
k) Tighten jam nuts and disengage PTO lever. Re-engag e PTO lever and

check pointer alignment.

5.2.3 Pump Drive Belt Replacement

.
a) Stop engine, wait for all moving parts to st op, and remove key.
b) Remove PTO Belt. See section 5.2.4 for r em oval instr uctions.
c) Route new belt onto sheaves as shown in the decal located on the back of

the left drive shield. See Figure 10.

d) Reinstall PTO Belt as stated in section 5.2.4.

FIGURE 10

PTO BELT REPLACEMENT

5.2.4 Belt Guide Adjustment
a) Stop engine, wait for all moving parts to st op, and remove key.
b) Engage PTO lever.
c) Adjust belt guides as shown in Figure 11.

FIGURE 11

BELT GUIDE ADJUSTMENT

- 28 -

5.2.5 Adjust Seat Switch
a) If necessary, adjust the seat actuator rod length to where the machine will

shut off when the operator raises off the seat (with brake disengaged or
PTO engaged) but will continue to run with operator in seat (a slight shift in
weight should not shut machine off ) .

NOTE: To prevent the engine from cutting out when operating over

rough ground, the unit is equipped w ith a time-delayed seat switch.
When the operator rises off the seat w i t h ei t her t he brake di sengaged or
the PTO engaged, the engine should stop after 1/2 second has elapsed.

b) To adjust seat switch actuator rod length, loosen lock nut on bottom of the

actuator rod (5/16 x 5 1/2” bolt) and adjust the nuts to move the actuator
plate/washer up or down on the rod, then retighten.

5.2.6 Brake Adjustment

.
Check to make sure each brake is adjusted properly.
a) Pull the br ake lever up and back to the engaged position.
b) A gap must exist between the bottom of the brake bolt head and the top sur face

of the brake swivel as shown in Figure 12. If a gap does not exist, adjust the
linkage to a maximum gap of 0. 5” ± 0.13” (1.3 cm ± 0.33 cm) as shown.

c) The brak es on bot h sides can be sim ultaneously adjusted by lengthening or

shortening the linkage shown in Figur e 12.

d) If individual adjustm ent is necessar y, loosen t he jam nut on the brake bolt that

is against the clevis connected to the brake arm on the wheel motor. Turn the

brake bolt to achieve proper adjustment .
e) Tighten the jam nut against the clevis.
f) Repeat for other side of unit.
g) Engage and disengage the brakes to check for proper engagement and

disengagement. Readjust if necessary. When t he br akes are disengaged,

there should be free play in the brake linkage with no dragging in the brakes.

5.2.7 Adjust Throttle Lever Tension
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Tension in throttle lever can be adjusted by adjusting t he t ightness of the

lever pivot bolt, which is located under the console. See Figure 13.

FIGURE 12

BRAKE BOLT ADJUSTMENT

.

- 29 -

FIGURE 13

THROTTLE TE NSION

5.2.8 Adj ust Speed Control Lever Tension
a) Stop engine, wait for all moving parts to stop, and remove key.
b) Tension in speed control lever can be adjusted by adjusting the tightness of

the lever pivot bolt, which is located under the seat near the speed control
lever. See Figure 14.

c) Set the tension high enough that the speed control lever position is

maintained during operation and loose enough t o be m oved comfortably by
the operator.

FIGURE 14

THROTTLE TE NSION

5.2.9 Motion control linkage adjustment

WARNING

POTENTIAL HAZARD
♦ Engine must be running and drive wheels must be

turning so motion control adjust m ent can be per formed.
WHAT CAN HAPPEN
♦ Contact with moving parts or hot surfaces may cause

personal injury.
HOW TO AVOID THE HAZARD
♦ Keep fingers, hands, and clothing clear of rotating

components and hot surfaces.

- 30 -

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.

Adjust steering levers:
a) Stop engine and wait for all m oving par ts to stop.
b) Pull the speed control lever completely back to t he neutral position. The

two steering levers should be straight up and down (vertical). If necessary,
adjust steering levers by changing the length of the link between the speed
control lever and the control arm on the end of the steering control shaf t .
See Figure 15.

FIGURE 15

SPEED CONTROL LEVER ADJUSTMENT

Set neutral:
a) Remove the electrical connection fr om the seat safety switch, located directly

in front of the seat switch assembly.

b) The neutral adjustment must be made with the drive wheels turning. Raise the

frame and place on jack stands so t hat dr ive wheels can rotate freely.

Temporarily install a jumper wire across the terminals in t he connector of the

wiring harness.
c) Start the engine.
d) Run the unit at least 5 minutes with the dr ive levers at full forward speed to

bring hydraulic system oil up to operating tem per ature.
e) To obtain the neutral position, adj ust the left and right pump control rod

linkages that connect the steering control to the pump control ar m s unt il t he

wheels stop, or creep slightly in reverse.
f) Adjust the left pump linkage by rotating the tracking adjustment knob.
g) Adjust the right pump linkage by using a wrench to turn the double nuts on

the assembly. See Figure 16.

- 31 -

FIGURE 16

TRACKING ADJUSTMENT

h) Move the steering levers to the reverse position. While applying slight

pressure to the levers, allow the steering levers to return to neutral. The

wheels must stop turning (or slightly creep in r everse) .
i) Stop engine and wait for all moving parts to stop. Remo ve jum per wire

from wire harness connector and plug connector int o seat switch.
j) Lower from jackstands.

Set forward stop bolt:

a) Remove seat deck (with seat attached) to obt ain a clear view of the

steering control shaft to complete this adjustment.
b) Push the speed control lever forward to full forward speed position.
c) If either steering control lever surface does not contact the stop bar at the full

forward speed position, adjust the stop bolt until contact occurs. See Figure

17. Once contact occurs, turn the stop bolt one more full turn to prevent

bottoming of the hydraulic pump int er nal st ops.

FIGURE 17

FORWARD STOP BOLT ADJUSTMENT

5.2.10 Steering Control Lever Response Adjustment

:
a) Stop engine, wait for all m oving parts to stop and remove key.
b) Move the speed control lever to the full for ward position.

- 32 -

c) Lift t he seat and locate the pump control springs. To increase

responsiveness, increase spring tension by hooking the rear spring anchor
directly to the anchor bolt. To decrease responsiveness, hook the rear
spring anchor to the anchor tab.

NOTE: Be sure both springs maintain the same adjustment.

FIGURE 18

STEERING CONTROL LEVER RESPONSE ADJUSTMENT

5.2.11 Tracking Adjustment:

5.2.12 PTO Drive Pulley Alignment

See Section 4.1.3 for adjustm ent.

:

PTO drive pulley alignment is necessary for any of the following conditions:

• The blower has been removed or replaced.

• The engine mounting bolts have been loosened or the engine has been

moved or replaced.

• The jackshaft m ount ing bolts have been loosened or the jackshaft has
been moved or replaced.

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Move the speed control lever to the neutral position.
c) Disengage the PTO lever.
d) Verify that the blower is installed and secured tig ht ly.
e) Loosen the 4 engine mounting bolts.
f) Unhook the pump belt tension spring.
g) Loosen the 4 jackshaft m ounting bolts
h) Remove fuel tank mounting nuts and swing out fuel tank.
i) Measuring from the blower pulley as a baseline, move the engine and

jackshaft until t he r ear surface of all 3 pulleys are aligned within 1/32”-1/16”
(0.8 - 1.6 mm). Use a st r aight edge to align all 3 surf aces. See Figure 19.

FIGURE 19

DRIVE PULLEY ALIGNMENT

- 33 -

j) Tighten the 4 engine mounting bolt s and 4 jackshaft mounting bolt s .

Check alignment aft er tightening.
k) Re-install pump belt tension spring.
l) Swing fuel tank in and re-install tank mounting nuts.
m) Complete Pump Drive Pulley Alignment Section 5.2.13.

5.2.13 Pump Drive Pulley Alignment
Pump drive pulley alignment is necessary for any of the following conditions:

• The engine mounting bolts have been loosened or the engine has been
moved or replaced.

• The pump pulleys have been loosened, moved, or replaced.

• The PTO pulley alignment (Section 5.2.11) has been per formed.

a) Stop engine, wait for all moving parts to stop, and remove key.
b) Loosen set screws on the both pump pulleys.
c) Using a straight edge, align each pump pulley with the engine pulley by

sliding along the pump shaft . See Figure 19.

d) Re-tighten pulley set screws and recheck alignm ent.

5.2.14 Rear caster pivot bearings pre-load adjust m ent
a) Remove dust cap from caster and tighten

nyloc nut until washers are flat. Back the
nyloc off 1/4 of a tur n t o properly set the
pre-load on the bearings.

Note: If disassembled, make sure the

spring washers are reinstalled as shown in
Figure 20

.

Door Closing:
a) Loosen 6 door hinge nuts. See Figure 21.
b) Open door and place a 3/8” rubber strip or 3/8” diameter hose bet ween the

c) Close door and push tight against hopper .
d) T ighten hinge hardware. Open hopper door and remove rubber strip.

5.2.15 Hopper Door Adjustment:

hopper and hopper door. See Figure 20.

HOPPER DOOR ADJUSTMENT

CASTER ADJUSTMENT

FIGURE 21

FIGURE 20

- 34 -

Door Opening:
a) Locate the hopper door cables. Loosen the jam nut next to the yoke at t he

end of the hopper door cable/shaft assembly on each side and rotate the

shaft until the rear door has a clear ance of 1/8”-3/8”. See Figur e 22.
b) Verify the cables are pulled equally tight on each side.
c) Tighten the jam nut s against the yokes on each side.

FIGURE 22

HOPPER DOOR ADJUSTMENT

5.2.18 PTO Brake Spring Adjustment
PTO brake spring adjustment is only necessary if the blower has been removed

or replaced or if the PTO dr ive idler ar m has been disassem b led.
a) Stop engine, wait for all moving parts to st op, and remove key.
b) Locate the brake spring and t hr ead the two jam nuts out to the end of the

brake spring rod. See Figur e 23.

c) Tighten jam nuts t ogether at end of brake spring rod.

:

FIGURE 22

PTO BRAKE SPRING ADJUSTMENT

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 accor ding to your state and local regulations.

- 35 -

6.2 MERCURY SWITCH DISPOSAL

CAUTION

POTENTIAL HAZARD
♦ The mercury contained in the tilt switch is poisonous.

WHAT CAN HAPPEN
♦ Exposure to mercury can cause severe illness.
HOW TO AVOID THE HAZARD

♦ Never attempt to open or repair t he t ilt switch
♦ Avoid contact with the mercury.

The tilt switch (PN 1- 633782) on this unit contains mercury, a hazardous material. Mercury

that is outside a sealed container vaporizes at room temperat ur e. The vapors are harmful.
Mercury can be absorbed through the skin. Do not att empt to open or repair this switch.

A very small amount of mercury is contained in a hermetically sealed body. The steel

switch is then potted in a hard epoxy in a plastic case. It is unlikely that the me r cury will
ever escape from the enclosure. These high performance and reliable inexpensive
switches are recyclable. Mercury is an important and beneficial compound but requires
special care in handling and disposal. When used and managed properly, mercury is not
a threat to people or the environment. This information is presented to users so t hat they
are aware that these switches contain mercury and will apply sound disposal practices
when these devices reach their normal end of life or ar e dam aged.

Several states have passed laws concerning the disposal of devices containing mercury.

In all the remaining states it is advisable to follow similar procedures. The laws state that
these sealed devices contain mercury and should not be placed in the garbage unt il the
mercury is removed and reused, recycled or otherwise managed to insure that it does not
become part of solid waste or waters. Management and disposal practices m ust be within
relevant federal, state, or local laws.

Return t he switch to your Exmar k dealer if it is fault y and is being replaced or if the unit

containing the switch is no longer operating and is being scrapped. If the switch is
damaged or broken open use extreme caution in handling. Call your local waste
management authority or Exmark Cust omer Service for instructions.

6.3 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 bat teries 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.

- 36 -

7. TROUBLE SHOOTING

7.1 MOWER PULLS LEFT OR RIGHT (W/LEVERS FULLY FORWARD).

a) Refer to Tracking Adjustment Section 4.1.3.
b) Check air pressure in drive tires; 15 psi
Semi-pneumatic caster s do not require inflation.

7.2 MOWER CUTS UNEVENLY.

a) Check air pressure in drive tires; 15 psi.
Semi-pneumat ic casters do not require inflation.
A more uniform cutting height m ay be obtained with higher tire pressure on

rough terrain.
A lower tire pressure pr ovides mor e flotation.
b) Check deck support pins are secure and cor r ect spacers are position under

hairpins.
c) Check deck leveling (See Adjustments Section 5.2.2.).
Note: The front of the m ower deck will be approximately 1/4” lower than the

back of the mower deck. T his is t he “rake” of the deck.
d) Check the distance from t he bottom edge of the deck skirt to the tip of each

blade. Measurement should be within 3/16".

7.3 ENGINE WILL NOT START.

a) Make sure the battery has a full charge. See section 5.1.2 for charging

instructions.
b) Be sure the throttle control is midway between the “SLOW ” and “FAST”

positions, and the choke is in the “ON” position for a cold engine or the

“OFF” position for a warm eng ine.
c) Make sure there is fuel in the fuel tank and that t he fuel valve is open.
d) Be sure the seat switch is properly adjusted. See Section 5.2.7.
e) Make sure the parking brake is set and speed control levers in the neut r al

position.
f) Check t hat the PTO is disengaged.
g) Check that the spark plug wires are properly connected.
h) Check for loose or faulty wiring connections.
i) Check for corrosion at all wiring connect ions. Even minor cor r o sion m ay

cause a faulty connection. Clean connector terminals t hor oughly with

electrical contact cleaner, apply dielectric grease and r econnect.

NOTE: When disconnecting electrical connectors DO NOT pull on the

wires to separate the connectors.

NOTE: After carefully checking the above steps, attempt to start the

engine. If it does not start, cont act your authorized Exmark service dealer.

IMPORTANT: It is essential that all operator safety mechanisms be

connected and in proper operating condition prior to mower use.

When a problem occur s , do not overlook the simple causes. For example:

starting problems could be caused by an empty fuel tank.

The following table lists some of t he common causes of trouble. Do not att em pt

to service or replace major items or any item s t hat call for special timing of
adjustments procedures (such as valves, governor, etc. ) . Have this work done
by your Engine Service Dealer.

- 37 -

PROBLEM

Will not start
Hard starting

Stops suddenly

Lacks power

Operates erratically

Knocks or pings

Skips or misfires

Backfires

Overheats

High fuel

consumption

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
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

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

SCREEN

AIR

INSUFFICIENT

BATTERY

CHARGE

X

X
X

X
X

X
X

X
X

- 38 -

8. ELECTRICAL DIAGRAM

- 39 -

9. HYDRAULIC DIAGRAM

- 40 -

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
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.

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

Warranty Period

Items and Conditions Not Covered

Instructions for Obtaining Warranty Service

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

[e-mail]

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.

- 41 -

42

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

EZ RIDER

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.

©2005 PART NO. 103-8573 Rev. B
EXMARK MFG. CO. INC. [phone]
INDUSTRIAL PARK BOX 808 FAX [phone]
BEATRICE, NE 68310
ALL RIGHTS RESERVED PRINTED IN U.S.A.

FG. CO. INC.

®