Exmark TR23KC User Manual

Download

For Turf Ranger

Serial Nos. 510,000 & Higher

and

FMD524 & FMD604

Serial Nos. 510,000 & Higher

Part No. 103-9192

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 condition. ♦ 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 clogg ed, 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 orm is provided. ♦ Keep others off mower.

POTENTIAL HAZARD ♦ Gasoline is harmful or f at al 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.

WARNING

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 t he muffler. If not, the operator is violating state law, Section 4442 Public Resource Code. To acquire a spark arrester for your unit, see your Eng ine Ser vice 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 Regul ation 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.

Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously. Exmark, or its distributors and dealers, accept no responsibility f or variations which may be evident in the actual specifications of its product s and t he statements and descriptions contained in this publication.

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995 Program

If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

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

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

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

5. The customer pays for the part

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

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

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

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

the 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.

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

OPERATOR'S MANUAL

This manual contains assembly, operating, maintenance, adjustment, and safety instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS

ENTIRETY.

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

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

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

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

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

iii

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................................................................................ 7

1.6 Safety Signs.............................................................................................. 8-9

2. SPECIFICATIONS

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

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

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

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

2.5 Operator Controls....................................................................................... 10

2.6 Seat............................................................................................................10

2.7 Hydrostatic Ground Drive System.............................................................. 10

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

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

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

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

3. ASSEMBLY INSTRUCTIONS

3.1 to 3.10 Assembly................................................................................... 12-15

4. CONTROLS

..............................................................................................15-17

5. OPERATION INSTRUCTIONS

5.1 Pre-Start.....................................................................................................17

5.2 Mowing.................................................................................................. 17-18

5.3 Transporting.......................................................................................... 18-19

6. MAINTENANCE & ADJUSTMENTS

6.1 Periodic Maintenance............................................................................19-27

6.2 Adjustments..........................................................................................27-33

7. WASTE DISPOSAL

7.1 Motor Oil Disposal...................................................................................... 34

7.2 Battery Disposal.........................................................................................34

8. TROUBLE SHOOTING

8.1 Mower Cuts Unevenly ................................................................................ 34

8.2 Engine Will Not Start.............................................................................34-35

9. WIRING DIAGRAMS 10

WARRANTY

................................................................................................. 37

..................................................................................... 36

1.SAFETY

1.1 SAFETY ALERT SYMBOL

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

identify important safet y 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 lett er ing / Red background. Indicates an im minently hazardous

situation which, if not avoided, WILL result in deat h or ser ious inj ur y.

WARNING: Black lettering / Orange background. Indicates a potentially hazardous

situation which, if not avoided, COULD result in deat h or ser ious inj ury.

CAUTION: Black lettering / Yellow backgr ound. Indicates a potentially hazardous

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

1.2 TRAINING

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

1.2.2 Read the instructions carefully. Familiar ize yourself with the cont r ols and the proper use of the equipment. If the operator(s) or m echanic(s) can not read English, it is the owner’s responsibility to explain this mater ial t o them.

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow children, teenagers, or people unfamiliar with these instructions to use the mower. Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

1.3 PREPARATION

1.3.1 Evaluate the terrain to determine what accessories and 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) protection for the eyes, ears, feet, and head is recommended.

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 t o be used and r em o ve all stones, sticks, wires, bones, and other foreign objects, which may damage the equipment or cause personal injury to the operat or or bystander s.

1.3.5 Always set the park brak e before starting the engine.

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.

POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable

and highly explosive.

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

and cause property damage.

HOW TO AVOID THE HAZARD ♦ DO NOT smoke while refueling , and st ay away from

an open flame or where gasoline fumes m ay be ignited by spark.

WARNING

DANGER

♦ Refuel only outdoors. ♦ Store gasoline in an approved container and keep it

out of the reach of children.

♦ Add fuel before starting 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 the entire exhaust system in

place and in proper working condition.

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POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable

and highly explosive.

WHAT CAN HAPPEN ♦ A static charge can ignite g asoline vapors. A fire or

explosion from gasoline can burn you, others, and cause property damage.

HOW TO AVOID THE HAZARD ♦ Purchase and store gasoline only in an approved

container.

♦ Always place gasoline containers on the ground away

from your vehicle before f illing.

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

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

♦ When practical, r emove gas-powered equipment from

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

♦ If this is not possible, then refuel such equipment on a

truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

♦ If a gasoline dispenser nozzle must be used, keep the

nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

DANGER

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 deat h.

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.

WARNING

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1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the design and configuration of the equipment, t hese factors are also dependent upon the awareness, concern, prudence, and proper training of t he personnel involved in the operation, transport, mai nt enance, and storage of the equipment. It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing.

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

extremely hot.

WHAT CAN HAPPEN

♦ Severe burns can occur on contact. ♦ Debris, such as leaves, grass, brush, etc. can catc h 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 put ation

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

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

rotating parts.

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

1.4.2 Mow only in daylight or good artificial light, keeping away from holes and hidden hazards. NEVER carry passengers. DO NOT oper at e the mower when children or others are in the area.

1.4.3 When feasible, avoid operat ing 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

♦ Mow up and down slopes. ♦ 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.

G0083

Figure 1

SAFE ZONE FOR MOWING

• Progressively greater care is needed as the slope increases.

• Always avoid sudden starts and turns.

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

the front wheels may cause rear wheel to lift off ground cause loss of 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, et c. from the mowing

area. Tall grass can hide obstacles.

• Use extreme care with grass catchers or attachments. These can change

the stability of the machine and cause loss of control.

1.4.5 Use EXTREME caution when backing up. LOOK BEHIND YOU!

1.4.6 Stop the blades when crossing surfaces other than grass and when transporting the mower to and fr om the area to be mowed.

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

1.4.8 Do Not change the engine governor settings or overspeed the engine. O per ating an engine at excessive speed may increase the hazard of personal injury.

1.4.9 Disengage PTO before starting engine.

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

1.4.11 Keep hands, feet, and clothing away from rotat ing parts while the mower is being operated.

1.4.12 Stop the engine, wait for all moving parts to stop, and remove key:

a) Before checking, cleaning , or working on the mower. b) After striking a foreign object (inspect the m ower for damage and

make repairs before r est ar ting and operating the mower). c) Before clearing blockages. d) Whenever you leave the mower.

1.4.13 Stop the engine and wait for all m oving parts to stop: a) Before refueling. b) Before making height adjustments. c) Before dumping the grass catcher.

1.4.14 Before stopping the engine, place the th r ot t le cont r o l m idway between the

“slow” and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds, then stop the engine.

1.4.15 The fuel system is provided with a shut-off valve. The f uel shut-off valve is

used to shut off the fuel when: a) The machine will not be used for a few days. b) During transport to and f r om t he job. c) When parking inside a building.

1.4.16 This mower was designed for one operator only. Keep all others away from

mower during operation.

1.4.17 Do Not mow with the discharge deflector raised, removed or altered unless

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

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

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

1.4.20 Use care when approaching blind corners, shrubs, trees, other object s that

may obscure vision.

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

booster battery to the positive terminal post on t he starter solenoid switch (this post has the positive battery cable attached to it ) .

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

to any engine deck ground, preferably the engine block as far away from the battery as possible.

c) Disconnect battery cables in the reverse order aft er starting.

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1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maintenance, follow the engine m anufacturer’s recommendations

precisely as stated in the engine manual.

1.5.2 Disconnect the battery cable form t he negative battery post when the unit will

be allowed to sit for more than 30 days without use.

1.5.3 Allowing batteries to stand for an extended period of time without recharging

them will result in reduced performance and ser vice life. To preserve optimum

battery performance and lif e, r echarge batteries in storage when the open

circuit voltage drops to 12.4 volts. NOTE: To prevent damage due to freezing, battery should be fully charged

before putting away for winter storag e.

1.5.4 Keep engine and engine area free from accumulation of grass, leaves,

excessive grease or oil, and other debris, which can accumulate in these

areas. These materials can become combustible and may result in a fire.

1.5.5 Store fuel in a container specif ically desig ned for this purpose in a cool, dry place.

1.5.6 Keep the mower and fuel container in locked stor age to prevent children from

playing or tampering with them.

1.5.7 Gasoline powered equipment 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 maintain proper tightness.

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

condition.

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

hazard.

1.5.12 All replacement parts must be the same as or equivalent to the parts supplied

as original equipment.

POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure can penetrate

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 t o 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

letting the foot pedal return to neutral and shutting off the engine before perf orming any work on the hydraulic system.

WARNING

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1.6 SAFETY SIGNS

1.6.1 Keep all safety signs legible. Remove all gr ease, dir t, and debris from saf et y

signs and instructional labels.

1.6.2 Safety signs must be replaced if they are missing or illegible.

1.6.3 When new components are installed, be sur e t hat current safety signs are

affixed to the replaced components.

1.6.4 New safety signs may be obtained from your authorized Exmark equipment

dealer or distributor or fr om Exmar k Mfg. Co. Inc.

1.6.5 Safety signs may be affixed by peeling of f 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.

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

For FMD524 & FMD604 Units with SN 410,000 – 439,999 PART NO. 103-1077 LOCATION: Front RH Side of Mower Deck

PART NO. 1-543624 LOCATION: Front Right Foot Support

PART NO. 103-2432 LOCATION: Left Side of

PART NO. 1-513746 LOCATION: Surface of Engine Deck Next to Muffler

PART NO. 1-553040 LOCATION: Top Surface of Hydraulic Reservoir

Brake Lever

PART NO. 1-513747 LOCATION: Top Front of Battery Cover

FMD524 & FMD604 units only PART NO. 103-2239 LOCATION: Top of Mower Deck, Beneath Center Shield

- 8 -

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

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

of Mower Deck

PART NO. 98-5954 LOCATION: Under Belt Shields

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

Surface of Mower Deck

PART NO. 1-543620 LOCATION: On Intake Screen Below Fuel Tank

PART NO. 103-2248 LOCATION: Steering Console

Type A Anti-Scalp Rollers Only – See Figure 7 PART NO. 1-323540 LOCATION: Front of Mower Deck, Top Surface

PART NO. 1-543896 LOCATION: Under Engine Deck on

Wood Blocks for Shipping

- 9 -

2. SPECIFICATIONS

2.1 MODEL NUMBER

: TR23KC

2.2 ENGINE

2.2.1 Engine Specifications: See your engine owners manual.

2.2.2 3600 RPM (No Load)

2.3 FUEL SYSTEM

2.3.1 Capacity: 5.0 gal. (18.9 L.)

2.3.2 Type of Fuel: Regular unleaded gasoline 87 octane or higher. In countries

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

2.3.3 Fuel Filter: Replaceable in-line

2.3.4 Fuel Shut-Off Valve: 1/4 turn

2.4 ELECTRICAL SYSTEM

2.4.1 Charging System: Flywheel alternator

2.4.2 Charging Capacity: 15 amp

2.4.3 Battery Type: BCI Group U1, 235 amps at 0° F

2.4.4 Battery Voltage: 12 Volt Polarity: Negative g r ound

2.4.5 Fuses: 20, and 30 amp blade type, 20 amp to charging circuit; 20 amp to

electric clutch; 30 amp to electro-m echanical actuator.

2.4.6 Safety Interlock System: Operator m ust be positioned in the seat with PTO

disengaged and brake engaged to start engine. O perator must be in seat when PTO is engaged or when brake is disengag ed or t he engine will stop.

2.5 OPERATOR CONTROLS

2.5.1 Steering Control: Aircraft-style steering yoke.

2.5.2 Motion Control: Single foot pedal operated by the right foot. Provides forward

and reverse speed control with little effor t. Motion control pedal and linkages are protected by the motion override device when the parking brake is engaged.

2.5.3 Parking Brake Lever: Engages par k brake and locks drive system in neutral.

Neutral lockout system prevents accidental engagement of drive system when park brake is engaged and protects hydro-transaxle from potent ial dam age.

2.6 SEAT

2.6.1 Type: high back, foam padded (internal suspension) with standard ar m rests.

2.6.2 Mounting: Attached to activate a seat switch and attached to a seat spring f or

maximum comfort over rough t er r ain. Adjustable fore and aft .

2.6.3 Armrests: foam padded f lip- up armrests with height adjustment st andar d.

2.6.4 Seat Safety switch: Incorporated into the Safety Interlock System. Time

delay seat switch eliminates rough ground cut-outs.

2.7 HYDROSTATIC GROUND DRIVE SYSTEM

2.7.1 Hydrostatic transmission: Eaton 851 transaxle with 23:1 reduction ratio.

2.7.2 Hydrostatic direction control system is protected by a neutral lockout system.

2.7.3 Hydraulic Oil: Use Mobil 1 15W-50 Synthetic Motor O il.

2.7.4 Hydraulic Oil Capacity: 8.5 qts. (8.0 L.)

2.7.5 Filter: Replaceable cartridge type Exmark P/N 1-513211: 10 micron, 18 psi bypass

2.7.6 Speeds: 0 - 6.4 mph (10.2 km/hr) forward; 0 - 3.2 mph (5.1 km / hr ) reverse

2.7.7 Drive wheel release lever allows machine to be moved when engine is not

running.

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2.8 TIRES

Type Pneumatic Pneumatic Pneumatic

Size 18 x 7.50-8 20 x 10.00-8 11 x 4-5

Quantity 1 2 2

Tread Turfsaver Turfmate Smooth

Ply Rating 4 4 4

Pressure 14 psi (97 kPa) 20 psi (138 kPa) 16 psi (110 kPa)

Rear Drive

Front Caster

(FMD Units)

2.9 MOWER DECK

2.9.1 Model Numbers: FMD604 and FMD 524

2.9.1 Cutting Widt h: 60 in. ( 152. 4 cm .) 52 in. (132.1 cm.)

2.9.2 Discharge: Right Side

2.9.3 Optional Mulch Kit and Bagger available.

2.9.4 Blade Size: 60" - (3 ea.) 20.50 in. (52.1 cm.) 52" - (3 ea.) 18.00 in. (45.72 cm.)

2.9.5 Type of Drive: Electric clutch mounted on engine shaft. Blades driven by two

belts with self tensioning idlers.

2.9.6 Adjustable anti-scalp rollers (6 ea.)

2.9.7 Cutting Height: Adjusts in 1/2” ( 1. 3 cm) increments from 1 1/2” ( 3.8 cm) to 4

1/2” (11.5 cm).

2.9.8 Deck Mounting: Full floating deck is att ached t o out -front support frame.

Removable for servicing. Can be raised by one-touch electr o- mechanical ball screw deck lift system for ser vicing and cleaning or to transfer weight t o dr ive wheels which aides in climbing hills.

2.10 DIMENSIONS

2.10.1 Overall Width:

2.10.2 Overall Length:

Turf Ranger with FMD524 49.9” (126.8 cm) 53.4” (135.6 cm) 64.2” (163.1 cm) Turf Ranger with FMD604 49.9” (126.8 cm) 61.4” (156.0 cm) 72.2” (183.4 cm)

Turf Ranger with FMD524 70.2” (178.3 cm) 112.4” (285.5 cm) Turf Ranger with FMD604 70.2” (178.3 cm) 112.4” (285.5 cm)

without deck deflector up

without deck with deck

deflector down

2.10.3 Curb Weight:

Turf Ranger with FMD524 Turf Ranger with FMD604 972 lbs. (441 kg)

931 lbs. (422 kg)

2.10.4 Overall Height: 44.0” (111.8)

2.10.5 Wheel Base (center of caster tire to cent er of drive tire): 50.5” (128.3 cm)

2.10.6 Tread Width (center to center of drive wheels): 39.75” (101 cm)

2.11 TORQUE REQUIREMENTS

Bolt Location Torque

Cutter Housing Spindle Nut (secured with threadlocker) ...................140-145 ft-lbs. (190-197 N-m)

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

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

Anti-Scalp Roller (See Figure 7)

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

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

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

Engine Mounting Bolts ..............................................................................25-30 ft-lbs. (34-41 N-m)

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

Wheel Hub Slotted Nut ..................................................................... minimum100 ft-lbs. (136 N-m)

Clutch Retaining Bolt (secured with threadlocker) ....................................55-60 ft-lbs. (68-76 N-m)

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3. ASSEMBLY INSTRUCTIONS

3.1 Uncrate tractor and mower deck.

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 hands after handling.

The machine is shipped with a filled lead acid battery.

3.2.1 Remove battery cover from machine.

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.

3.2.2 Check the voltage of the battery with a digital voltm et er. Locate the voltage reading

of the battery in the table below and charge the bat tery for the recommended time

interval to bring the charge up t o a full charge of 12.6 volts or greater. IMPORTANT: Make sure the negative battery cables are disconnected and

the battery charger used for charging the battery has an output of 16 volts and

7 amps or less to avoid damaging the batter y (see char t below f or

recommended charger settings).

Voltage

Reading

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

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

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

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

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

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

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

for sparks and engag em ent of components.

WHAT CAN HAPPEN ♦ Sparks could cause an explosion or moving parts

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

charging the battery.

Percent

Charge

Maximum

Charger Settings

CAUTION

Charging Interval

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

cable to the positive terminal on the bat t e r y first, then connect t he negative

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(black) cable to the negative ter minal on the battery. Reinstall insulator boots. Reinstall battery cover.

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.

PART NO. 1-513747 LOCATION: Battery Cover

3.3 INSTALL SEAT: Remove seat cushion from seat frame. Rem ove seat frame from crate and discar d

mounting hardware. Mount seat to unit using two 5/16-18 x 3/4” bolt s, two 3/8 flat washers and whizlock nuts from bolt bag in front two holes. Install flat washers between seat frame and seat rails. Mount seat to t wo rear bolt s (which have springs on them), by removing the top whizlock nuts, installing seat frame, and replacing nuts. Reinst all cushion to seat frame.

3. 4 INSTALL REAR STEERING WHEEL:

Mount the rear tire and wheel assembly with a 5/8-11 x 10-1/2” bolt and torque nut.

Tighten torque nut j ust enough to create a slight drag on the wheel while the wheel is being rotated. Inf lat e t ir e t o 14 psi (95 kPa).

3.5 INSTALL DRIVE WHEELS: Mount both drive wheels securing them with four (4) wheel nuts each. Torque to 90-95

ft. lbs. (122-129 N-m ) . Inflate tires to 20 psi (138 kPa) .

3.6 INSTALL HANDLE BAR: Install steering handle bar with two 3/8-16 x 1-1/4” bolts and two 3/8 spring disc washers.

3.7 INSTALL CANISTER AIR CLEANER: a) Remove air cleaner (with bracket attached) fr om cr ate. Keep air cleaner and

mounting bracket together. b) Cut plastic tie holding air cleaner cap to engine and install cap to t he air cleaner. c) Remove the top two throttle plate mounting scr ews from the engine. Keep

screws for re-attaching air cleaner. d) Position the air cleaner assembly over the engine, aligning air cleaner bracket

holes with top holes in the throttle plate. Reinstall thr ot tle plate screws through

air cleaner bracket and thrott le plat e. e) Mount lower holes in air cleaner br acket to holes in engine air cleaner brack et

using (2) M6x1.0x16mm Hex flange capscrews, (2) .216 I.D. x 1.0 O.D.

washers, and (2) M6x1.0 nyloc nuts from bolt bag. Be sure to inst all t he head of

the capscrew to the front of t he unit and the washer next to the nyloc nut to the

rear of the unit on the other side of the air cleaner bracket. f) Remove plastic plugs from air intake elbow on engine and air cleaner hose. Adjust

the air cleaner and hose as required and connect intake hose to air cleaner outlet.

Position and tighten the two hose clamps to secure the hose connections.

3.8 INSTALL MOWER DECK TO TRACTOR:

3.8.1 Rotate drive wheel release lever into position shown in Figure 4 to release drive system (Refer to Section 4.11). Roll t r act or to mower deck and mower deck support aligning them so the t r act or is positioned for ease of mount ing the deck support. Remove center belt shield.

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3.8.2 Remove mower deck support frame from mower deck by removing t he t wo hairpins and spacers from the f r ont deck support pins and remove the hairpins and spacers from the rear deck suppor t pins.

3.8.3 Lift up on support frame until it clears t he suppor t pins. Position support frame so the arms are on each side of the tr act or engine deck and secure.

Secure using eight (8) 3/8-16 x 1 1/4” bolts, disc spr ing washers, and whizlock nuts. NOTE: Place spring washer cone side against bolt head (cupped side away from

head) and install to outside of support frame (as shown in Figure 2). Install with whizlock nuts to the inside of engine deck. Tighten until spring washers are flat.

FIGURE 2

HARDWARE AND SUPPORT PIN

LOCATION FOR DECK SUPPORT FRAME

3.8.4 Position tractor, with mower deck support frame in place, over the mower deck . Align support frame above mower deck and posit ion it so the support pins on the deck align with the mounting holes in the support frame. Lower support fram e ont o deck and Reinstall the two hairpins and spacers on the front support pins and the two hairpins and spacers onto the rear support pins (See Figur e 1) .

3.8.5 After the mower deck support frame and the attached mower deck are in place, it is necessary to remove the two wooden blocks under the engine deck pivot stops.

CAUTION

POTENTIAL HAZARD ♦ Removing the two blocks prior to installing t he mower

deck and support for counter balance will allow the engine deck to flip back wards.

WHAT CAN HAPPEN ♦ If the engine flips backwards pinch points are created,

which may cause injury.

HOW TO AVOID THE HAZARD ♦ Keep hands clear from the engine deck when

removing the blocks.

3.8.6 Install mower deck stationary idler. Idler components are located in t he Turf Ranger bolt bag.

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Locate two holes along the back center section of the m ower deck . Install the

stationary idler and related parts in the left hand hole location as shown in Figure

3. See the belt routing decal on deck. Be sur e t he coned end of the disc spring is against the head of the bolt as illust r ated (See Figure 3).

3/8 WHIZLOCK NUT

3/8 HEX CAP

SCREW

FIGURE 3

IDLER PULLEY KIT AND LOCATION

3.8.7 Install mower deck drive belt.

NOTE: Make sure to use proper belt for your deck. The belt ( Part #1-543523)

that is installed on the unit is for 60” decks only. For 52” decks, the belt (Par t #1-

543749) from the bolt bag m ust be used. Refer to belt routing decal on deck. Slip belt between clutch drive sheave and drive wheel release rod (make sure belt is in the sheave groove).

Install the deck drive belt around the clutch. Refer to belt routing decal. Be sur e belt

is in the clutch drive sheave groove. Place the other end of t he belt int o the Vgroove of the stationary idler, m ove the spr ing loaded idler outward and route the belt around the inside of the spring loaded idler. Position the belt into the Vgroove of the mower deck drive sheave. Carefully release the spring loaded idler. Install the center belt shield.

3.8.8 Adjust cutting height of deck and anti-scalp rollers. (See Section 6.2. 1.)

3. 9 POSITION DISCHARGE CHUTE:

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

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

3.10 SERVICE ENGINE: See Engine Operator's Manual.

4. CONTROLS

4. 1 Steering Handle Bar

4. 2 Motion Control Pedal

For reverse motion, place foot heel on the r ear pedal pad and pr ess downward.

Familiarize yourself with all controls before operat ing the mower.

: Located in center of steering console in front of operator ’s seat. During forward operation of the machine, movement of the steer ing handle to the right will cause the machine to turn to the right and vice versa. The st eer ing system is chain connected from the steering shaft sprocket to the yoke sprocket. The chain has two adjustable connectors.

: Located on the right side of st eer ing console. The foot pedal controls the forward and reverse operation with foot m otion. To increase forward speed press front pedal down until desired speed is obtained, to increase reverse speed press back pedal down until desired speed is obtained. Movement of the front pedal down will cause the machine to go forward. T o st op forward travel, remove foot from pedal. The neutral centering device moves the motion pedal back t o t he neut ral position.

Remove foot from pedal to stop reverse motion. The pedal automatically retur ns to neutral. When parking brake is engaged, the motion control pedal can be moved but will not function.

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4. 3 Electro-mechanical deck lift control: Switch is located on left side of control console. Moving the toggle switch lever forward will lower the cutting deck. Moving the lever backward will raise the deck. Normal operation is with the actuat or fully extended. The actuator has an internal clutch to protect it from excessive loads. When raising or lowering the deck and the actuator has reached it ’s lim it , a "ratcheting" sound is heard. When this ratcheting sound is heard, release switch lever, mom entarily reverse switch to move actuator just off the fully extended or retracted position.

4.4 PTO Engagement

: Located on right side of contr ol console. The switch must be pulled out to the “ROTATE” position to engage the blades. T he switch is pushed in to the “STOP” position to stop the blades. Operat or m ust be in the seat when blades are engaged or engine will stop.

4.5 Choke Control

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

4.6 Throttle Control

: Located on the control console right side. Throttle is used to control engine speed. Moving throttle control ahead will increase engine speed and moving it to the rear will decrease engine speed.

4. 7 Park Brake Lever

: Located ahead and near the right side of cont rol console. Park brake lever engages a parking br ake on the drive wheels and also locks the hydrostatic drive system in neutral. Moving the lever rearward will engage the brake. T o disengage brake, lif t finger latch and move brake ahead. Operator must be in the seat when brake is disengaged or engine will stop.

4.8 Ignition Switch

: Located on the control console just ahead of t he steering handle. The ignition switch is used to start and stop the engine. The switch has three positions “OFF”, “ON” and “ST ART”. Insert key into switch and rotat e to the right to the "ON" position. Rotate clockwise to the next position to eng age the starter (key must be held against spring pressure in this position) . Operator must be in seat with brake engaged and PTO disengaged to start engine. When engine star t s, release key. DO NOT leave key in the “ON” position without engine running, this will run down the battery.

4.9 Hour Meter

: Located on the steering console just below the steer ing wheel. The hour meter is connected to a pressure switch installed in the eng ine block and it records the number of hours that the engine has run. If ignition switch is lef t 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. 10 Fuel Shut-Off Valve

: Located in the fuel line near the rig ht rear corner of the engine. The fuel shut-off valve is used to shut off the f low of fuel when parking inside a building, during transport at ion t o and from job sites and when the machine will not be used for a few days. Rotate valve 1/4 turn clockwise to shut fuel off. Rotat e valve 1/4 turn counter-clockwise to turn f uel on.

4. 11 Drive Wheel Release Lever

: Located under the lower left rear corner of the engine deck (See Figure 4). The drive wheel release lever is used to release the hydrostat ic dr ive system to allow machine to be pushed while the engine is not running. Rotat e lever 1/ 8 turn counter-clockwise until caught under spr ing latch to release drive system. Pull spring latch out far enough to allow lever to rotate 1/8 turn clockwise to engage drive system.

NOTE: Do Not tow machine or transmission damage m ay result.

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FIGURE 4

DRIVE WHEEL RELEASE LEVER

5. OPERATION INSTRUCTIONS

5.1 PRE-START

5.1.1 Fill fuel tank. For best results use only clean, fr esh r egular grade unleaded gasoline with an octane rating of 87 or higher. Regular grade leaded gasoline may also be used; however, combustion chamber and cylinder head will require more frequent service. See Engine Owner's Manual.

Note: Fuel tank may appear loose at set-up, however, once fuel is added, tank

will slowly expand to fit tank straps.

Do not add oil to gasoline. Never fill the fuel tank so that t he fuel level rises above a level that is 1/2” below

the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage.

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

5.1.3 Refer to the Maintenance Section, and perform all of the necessary inspection and maintenance steps.

5.2 MOWING

5.2.1 Starting Engine

: Operator must be in the seat with the parking brake engaged

and the PTO disengaged.

Open fuel shut-off value. On a cold engine, place the throttle midway between the "SLOW" and "FAST"

positions and place the choke in the "ON" position. On a warm engine, place the throttle midway between the "SLOW " and " FAST" positions and leave the choke in the "OFF" position.

Turn ignition switch to "START" position. Release t he switch as soon as t he

engine starts.

After starting a cold engine, gradually return choke to the "O FF" posit ion after

engine warms up.

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

seconds at a time. If the eng ine does not start, allow a 60 second starter cooldown period between starting attempts. Failure t o follow these guidelines can burn out the starter motor.

5.2.2 Stopping Engine

: Bring unit to a full st op. Disengage the PTO and engage the

park brake.

Before stopping the engine, place the throttle control midway between the “slow”

and “fast” positions. Allow the engine to r un a m inim um of 15 seconds; then stop the engine.

- 17 -

Rotate ignition switch to “OFF” position. Remove 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 f ew days, when

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

5.2.3 Engaging PTO

POTENTIAL HAZARD ♦ The rotating blades under the mower deck ar e

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 m ower or m ower

deck when the blades are engaged.

POTENTIAL HAZARD ♦ An uncovered discharge opening will allow objects to

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

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

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

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

collection system or mulch kit in place and working

properly.

DANGER

The PTO switch engages the cutting blades. Be sur e t hat all persons are clear

of mower deck and discharge area before engagi ng t he PTO. IMPORTANT: Operator must be in seat before the PTO can be engaged. Set throttle to "midway" position. The switch must be pulled out t o the "ROTATE"

position to engage the blades. Accelerat e t o full throttle to begin m owing.

5.2.4 Stopping PTO

position to stop the blades.

5.3 TRANSPORTING

5.3.1 Transporting a Unit

machine is on the trailer lower the cutting deck and fully extend the actuator.

Never transport machine with mower deck supported by actuator, damage to the

actuator or other components may occur. Engage the park brake and block the

wheels. Securely fasten the machine to the trailer or t r uck with straps, chains,

cables, or ropes. Be sure that the tr ailer or truck has all necessary lighting and

marking as required by law. Secure to trailer with a safety chain.

5.3.2 Loading a Unit

actuator to lift cutt ing deck off of the ground to provide more traction on t he dr ive

tires while loading the unit. One full width ramp t hat is wide enough t o extend

beyond the drive tires is recommended. If it is not possible to use one full width

ramp, multiple ramps may be used, but should be spaced close enoug h together

: Set throttle to “idle” position. Push in on the switch to the “STOP”

: Use a heavy duty trailer to transport the machine. When the

: Use caution when loading units on a trailer or truck. Use

- 18 -

to simulate a full width ramp. Dr ive forward to load and drive backward to unload

from a trailer. Do not dr ive back ward to load or drive forward to unload a trailer. Ramp should be long enough so that the angles between the ramp and the

ground and the ramp and the trailer or truck do not exceed 15°. After unit is

loaded on the trailer lower the cutting deck and fully extend actuator for transpor t .

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

reflective markings, or a slow moving vehicle emblem. These items are required to 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 tickets and/or fines. HOW TO AVOID THE HAZARD ♦ Do not drive a unit on a public street or roadway.

CAUTION

6. MAINTENANCE & ADJUSTMENTS

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.

6.1 PERIODIC MAINTENANCE

6.1.1 Check engine oil level Service Interval a) Stop engine and wait for all moving parts to stop. Make sure machine is on

a level surface.

b) Check with engine cold.

: Daily

WARNING

- 19 -

c) Clean area around dipstick. Rem ove dipstick and wipe oil off. Reinsert the

dipstick. Do not screw into place. Remove dipstick and read the oil level.

d) If the oil level is low, add oil to bring the oil up to the “F ULL” m ark 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.

6.1.2 Clean engine air cooling system Service Interval

: See Engine Owner's Manual

POTENTIAL HAZARD ♦ Excessive debris can cause the engine and hydraulic

system to overheat. WHAT CAN HAPPEN ♦ Excessive debris around the engine and inside the

transmission cooling compartment can cr eat e a fire

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

transmission daily.

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

shrouding.

6.1.3 Clean transmission cooling compartment Service Interval a) Stop engine, wait for all moving parts to stop, and remove key. b) Clean all debris from screens that encompass cooling compartment, and

then remove the compartment screen. c) Clean all debris from t he fan blades and the cooling fins for the transmission. d) Replace the com par t m ent screen.

6.1.4 Clean gr ass build- up under deck Service Interval: Daily

a) Disengage PTO. b) Raise deck using lift actuat or . c) Stop engine, wait for all moving parts t o st op, and remove key. d) Lift the front of unit and support unit using jack stands or equivalent support.

: Daily

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 t o 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.

CAUTION

- 20 -

e) Clean out any grass build-up from underside of deck and in discharge chute.

6.1.5 Check m ower blades

Service Interval: Daily a) Disengage PTO.

b) Raise deck using lift actuat or . c) Stop engine, wait for all moving parts t o st op, and remove key. d) Lift deck and secure in raised position as st at ed in Sect ion 6.1.4. e) Inspect blades and sharpen or replace as required.

For Serial Nos. 510,000 – 539,999:

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

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

CAUTION

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

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

rotating at a high speed to come out from under the

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

(Use only Exmark replacement parts PN 103-0862 –

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

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

DO NOT USE WRENCH HERE.

FOR BLADE INSTALLATION MAINTAIN

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

FIGURE 5 BLADE BOLT INSTALLATION

For Serial Nos. 540,000 and Higher: d) Re-install the blades (if they were removed) in the following order (See

Figure 6):

1) I nstall bushing through blade with bushing flang e on bot t om (grass) side of blade.

2) Install bushing/blade combo into spindle.

- 21 -

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

FIGURE 6

BLADE BOLT INSTALLATION

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

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

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

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

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

spring disc washers, and blade bolts in the correct

positions as shown.

6.1.6 Check safety interlock system: Service Interval a) Check st ar ting circuit. Starter should crank with operat or in seat; parking

brake engaged, and with PTO disengaged. T r y to start with operator out of seat; parking brake engaged, and PTO disengaged; starter must not crank. Try to start with operator in seat, parking brake disengaged and PTO disengaged; starter must not crank. T r y to star t with operator in seat, parking brake engaged and PTO engaged; starter must not crank.

b) Check kill circuits : Run engine at one-third thrott le with PTO and parking

brake disengaged; lift yourself off the seat (but do not get off the machine) engine must stop after 1/ 2 second has elapsed.

c) Run engine at one-third throttle with PTO and parking brake engaged; lift

yourself off the seat ( but do not get off the m achine) engine must stop after 1/2 second has elapsed.

: Daily

CAUTION

NOTE: If machine does not pass any of these tests, Do Not oper ate. Contact

your authorized EXMARK Servicing Dealer.

- 22 -

IMPORTANT: It is essential that all Operator Safety Mechanism be connected

and in proper working condition prior to use for mowing.

6.1.7 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 .

6.1.8 Service air cleaner Service Interval

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

a) Stop engine, wait for all moving parts to stop, and r em ove k e y. b) Loosen retaining clips and remove air cleaner compartment cover. c) Remove paper element. Check the condition of the paper element.

Replace if dirty, bent or damaged.

d) Check the condition of the inner element. Replace whenever it appears

dirty, typically every other time the paper element is replaced. Clean t he base around the inner element before removing, so dirt does not get into

the engine. e) DO NOT wash or use pressurized air to clean paper element or inner element. f) Reinstall elements. Position the cover so that the rubber dust ejector is

pointing downward and secure with retaining clips.

6.1.9 Change engine oil Service Interval

: See Engine Owner’s Manual

NOTE: Change oil after first f ive (5) hour s of operation, then refer to engine

manual for futur e oil change frequencies. a) Stop engine, wait for all moving parts to stop, and remove key. b) Drain oil while engine is warm from operation. c) Oil drain is located on the left side of t he engine. Place pan under machine

to catch oil and open valve with a 10 mm wrench. Allow oil to drain then close valve.

d) Replace the oil filter as per Engine Owner's Manual. Clean around oil filter

and unscrew filter to remove. Bef o r e r einstalling new filter, apply a thin coating of oil on the surface of the rubber seal. Tur n filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2/3 to 3/4 turn.

e) Clean around oil fill cap and remove cap. Fill t o specified capacity and

replace cap. Use oil as directed in Engine Owner's Manual. Do Not overf ill.

f) Star t the engine and check for leaks. Stop engine and recheck oil level.

6.1.10 Check hydraulic oil level Service Interval

: 40 hrs. a) Make sure mower is on a level surface. b) Stop engine, wait for all moving parts to stop. c) Visually inspect the sight gauge on hydraulic tank. Oil level should be

visible to top of sight gauge. If not, clean area around hydraulic reservoir cap, remove cap, and fill the reservoir with Mobil 1 15W-50 synthetic motor oil. Replace cap.

- 23 -

6.1.11 Check tire pressures: Service Interval

: 40 hrs. a) Stop engine, wait for all moving parts to stop, and remove key. b) Inflate tires to pressures specified in Sect ion 2. 8 ( Specifications). c) See Section 8.1 for further informat ion.

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 t o the hydro drive system, frame, and other com ponents. Foam filling tires will void the warranty.

6.1.12 Check battery charge Service Interval

: Monthly Allowing batter ies t o stand for an extended period of time without rechar ging

them will result in reduced performance and ser vice life. To preserve optimum battery perform ance and life, recharge batter ies in storage when the open circuit voltage drops to 12.4 volts.

Note: To prevent damage due to fr eezing, battery should be fully charged

before putting away for winter storag e.

a) Check the voltag e of the battery with a digital voltmeter. Locate the voltage

reading of the batter y in the table below and charg e 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 battery cables are disconnected

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 chart below 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 amps 3 Hours

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

6.1.13 Inspect Belt W ear: Service Interval

: 40 hrs. a) Stop engine, wait for all moving parts to stop, and remove key. b) Remove the three mower deck belt shields to check mower primary and

secondary belt condition. c) Look under engine deck t o check the transmission drive belt condition. d) Check all idler arms to be sure they pivot freely. Note: Be sure to check idler on transmission drive belt. Disassemble, clean and

grease pivot bushing if necessary.

6.1.14 Lubricate grease fittings

. a) Stop engine, wait f o r all m oving parts to stop, and remove key. b) Lubricate fittings with one to two pumps NGLI g r ade #2 m ulti-purpose gun

grease. Refer to the following chart for fitt ing locations and lubrication schedule.

- 24 -

LUBRICATION CHART

FITTING LOCATION S

INITIAL PUMPS

NO of

PLACES

SERVICE

INTERVAL

1. Front Caster Wheel hubs w/o zerk *0 2 Yearly

2. Front Caster Pivots *0 2 Yearly

3. Drive Wheel Bearings 1 2 200 hours

4. Engine Deck Pivots 1 2 40 hours

5. Steering Column 1 1 40 hours

6. Idler Pivots, Mower Deck 1 2 Yearly

7. Rear Steering Wheel Bearings 1 1 200 hours

* See 6.1.14 Section c) for special lubricat ion instructions on the front caster pivots and Section 6.1.15 for special lubrication inst r uct ions on the front caster wheel hubs.

No. 3 (Drive Wheel Bearings) Located Under Engine Deck

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

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

6.1.15 Lubricate caster wheel hubs: Service Interval: Once Yearly a) Stop engine, wait for all moving parts to

stop, and remove key. b) Remove caster wheel from caster forks. c) Remove seal guards from the wheel hub.

CASTER WHEEL ASSEMBLY

FIGURE 7

d) Remove one of the spacer nut s from the axle assembly in the caster wheel.

Note that thread locking adhesive has been applied to lock the spacer nuts

to the axle. Remove the axle (with the other spacer nut still assembled t o

it) from the wheel assembly. 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 g rease. g) Insert (1) bearing, (1) new seal into the wheel. NOTE: Seals (Exmark PN 103- 0063) m ust be replaced. h) If t he axle assembly has had both spacer nut s r em oved (or br oken loose),

apply a thread locking adhesive to (1) spacer nut and thr ead ont o 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.

- 25 -

i) Insert the assembled nut and axle into the wheel on the side of the wheel

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

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

j) Apply a thread locking adhesive to the 2

spacer nut and thread onto the axle

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

in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut. l) Re-install the seal guar ds over t he 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.

6.1.16 Remove engine shrouds and clean cooling fins Service Interval

: See Engine Owner's Manual

a) Stop engine, wait for all moving parts to stop, and remove key. b) Remove cooling shroud cleanout covers from engine 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 cleanout covers are properly reinstalled.

Operating the engine without cooling shr oud cleanout covers will cause

engine damage due to overheating.

6.1.17 Change fuel filter Service Interval

: As Required

a) A fuel filter is installed in the fuel line between the fuel tank and the engine.

Replace with Kohler P/N 2405002 when necessary.

6.1.18 Lubrication of steering yoke pivot Service Interval

: Monthly

a) The steering yoke pivot is per m anent ly sealed and should require no additional

lubrication. If there is evidence of seal leakage, replace the seals or bearings

and fill with NGLI grade #2 multi- pur pose grease or wheel bearing grease.

6.1.19 Check spark plugs Service Interval

: 160 hrs.

a) Remove spark plugs, check condit ion and adj ust plug gap, or replace with

new plugs. See Engine Owners Manual.

6.1.20 Change hydraulic system oil or filter

6.1.20.1 Change hydraulic filter: Service Interval

: After firs t 250 hr s, then yearly thereafter. a) Stop engine, wait for all moving parts to stop, and remove key. b) Carefully clean area around filter. It is import ant that no dirt or

contamination enters the hydraulic system.

c) Unscrew filter and remove.

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.

- 26 -

Turn filter clock wise until rubber seal contacts the filter adapter, and

then tighten the filt er an additional 2/3 to 3/4 turn. Use only Exmark

(Part No. 1-513211) or Eaton (Part No. 103144) filter elements. d) Start engine and run several minutes. g) Check hydraulic oil level as outlined in 6.1.10.

6.1.20.2 Change hydraulic oil: Service Interval

: Yearly a) Stop engine, wait for all moving parts to stop, and rem o ve k ey. b) Carefully clean area around sm all fitting under oil reservoir. Loosen

clamp, remove hose, and allow oil to drain from r eservoir. It is important that no dirt or cont am ination enters the hydraulic system. Reinstall hose and tighten clamp.

c) Clean around reservoir cap and Refill reser voir t o cent er of sight

gauge with Mobil 1 15W-50. d) Start engine and r un several m inut es. e) Recheck hydraulic oil level as outlined in 6.1.10. Do not attempt to

drain all oil in hydraulic system (except what drains out of the filter or

reservoir when changing filter or hydraulic oil) ; unless it is felt that

the oil has been contaminated or becomes extremely hot. Changing

oil unnecessarily, could damage the hydraulic system by

introducing contaminates into the system.

6.1.21 Inspect Electric clutch gap Service Interval

: 250 hrs.

Refer to Section 6.2.12 for inspect ion and adj ust ment procedures.

6.1.22 Refer to the Engine Owner’s Manual for detailed m aintenance required for

servicing the engine.

6.1.23 Wheel hub, slott ed nut torque specification

. a) Tighten the slott ed nut on t he transaxle tapered shaft and torque t o 100 ft. lbs. b) After proper t o r que has been applied, turn the nut until the next set of slots

lines up with the cross hole in the shaft. c) Replace cotter pin. NOTE: Do not use anti-seize compound on the wheel hub.

6.1.24 Thread locking adhesives

such as "Loctite 242" or "Fel-Pro Pro-Lock , Nut-Type"

are used on the following fasteners: a) Bolt which mounts blade dr ive clutch t o engine crankshaft. b) Transaxle drive shaft pillow block bearing setscrews.

c) Bolts which attach transaxle to lower stabilizer bracket.

d) Caster wheel spacer nuts (Ref er ence Sect ion 6. 1.15).

e) Cutter housing spindle nut .

6.1.25 An anti-seize compound

on the following locations:

a) Between the pillow block bearings and the transaxle shafts.

6.1.26 Mobil HTS grease (or food-gr ade ant isieze) is used in t he following locations: a) Between the cutter housing spindle and bearings.

b) Between the cutter housing spindle and sheave.

c) Under top cutter housing bearing guar d.

6.1.27 Dielectric grease

is used on all blade type electrical connections to prevent

corrosion and loss of contact.

- 27 -

6.2 ADJUSTMENTS

6.2.1 Cutting height and anti-scalp roller adjustment

a) Stop engine and wait for all moving parts to stop. b) Install hairpin clips in the holes for the desir ed cutting height (See Figure 10) . IMPORTANT: To maintain correct cutting height and rake, check the

1. The front and rear hairpins are in t he same holes with the proper spacers

2. The tire pressures are set as directed in Section 6.1. 11.

3. The length of the rear deck support link assemblies should average

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

IMPORTANT: Disengage PTO, shut off engine, wait for all moving part s t o st op, and remove key before servicing, cleaning or making any adjustments to the unit.

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

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

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

mower deck is not installed or front support rod

hairpins are removed.

following for proper adjustment .

under the hair pins (See Figure 8).

6.89” (approximately 6 7/8” (17.5 cm)) from the center of the balljoint to the center of the f ar t hest hole (See Figure 8).

Adjustment in the length of the rear deck support assemblies may be necessary. If one side is longer than 6.89” ( 17. 5 cm), than the opposite side must be shorter by the same amount.

LEFT HAND

SIDE SHOWN

CUTTING HEIGHT ADJUSTMENT

CAUTION

FIGURE 8

- 28 -

c) Adj ust anti-scalp rollers for Norm al O perating Conditions. Place rollers in

one of the positions shown in Figure 9. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize goug ing and roller wear or damage.

For Maximum Deck Flotation, place rollers one hole posit ion lower. Rollers

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

Two types of anti-scalp roller assem blies ar e available. See Figure 9 to

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

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

FIGURE 9 ANTI-SCALP ROLLER INSTALLATION AND CUTTING HEIGHT ADJUSTMENT

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

position the anti-scalp rollers one or two holes higher than described in "c" to prevent damage to the r ollers and/or bolt failure (See Fig ur e 9) .

NOTE: When anti-scalp rollers are placed in these positions, reduced

deck flotation will result.

6.2.2 Transmission drive belt tension adjustment

6.2.3 Mower deck drive belt

6.2.4 Blade drive belt tension

6.2.5 Neutral Centering Adjustment

: No adjustment necessary.

. No adjustment necessary.

: No adjustment necessary.

a) The Neutral Centering Device adjustment should be made with the eng ine

running at full throt tle. First raise and securely block up the frame so that the drive wheels can rotate freely without contacting the gr ound.

- 29 -

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

turning so motion control adjustment can be performed.

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.

WARNING

CAUTION

POTENTIAL HAZARD ♦ Raising the tractor f r am e for service or maintenance

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 stands or equivalent support.

b) Remove the electrical connection from the parking brake saf et y switch

located on the right- hand underside at the front of the engine deck. Temporarily install a jumper wire across the ter m inals in the connector of

the wiring harness. c) Release brake lever. d) The Neutral Centering Device is located on t he r ight-hand underside of the

engine deck. Loosen jam nut (d) from the ball joint which connects the

override assembly (f), to the engine deck anchor mounting (See Figure 10) . e) Start engine. O per at or must be in seat to crank engine. O pen to full throttle. f) Adjust neutral centering device length by rotating the neutral cent er ing

device barrel clockwise or counterclockwise until wheels stop turning or no

longer creep. Tighten j am nut . g) Remove jumper and reconnect electrical connect ion t o par king brake

safety switch. h) Check safety interlock system as outlined in Section 6.1.6.

IMPORTANT: Keep clear of wheels and other moving parts when making

these adjustments.

- 30 -

FIGURE 10

NEUTRAL CENTERING DEVICE ADJUSTMENT

6.2.6 Parking Brake Quadrant Adjustment a) Stop engine, wait for all m oving parts to stop, and remove key. b) Loosen the two 5/16 x 18 screws (a), that clamp the brak e quadrant to the

engine deck. c) Pull parking brake lever towards the operator to the brake “ on” position (b). d) Check linkage to ensure that they butt up against the over-center ing stop

bolt (c), and retighten the t wo 5/16-18 scr ews (See Figur e 11) .

FIGURE 11 PARKING BRAKE QUADRANT ADJUSTMENT

6.2.7 Parking Brake Spring Adjustment a) Stop engine, wait for all moving parts to stop, and remove key. b) Check t he pin to pin length and adjust to 11 5/8” as required. c) Check the compression spring length and adjust to 3 1/32” as required

(See Figure 12).

FIGURE 12 BRAKE CONTROL LINK AND SPRING ADJUSTMENT

6.2.8 Parking Brake Neutral Lockout Adj ust m ent

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

- 31 -

b) Remove inlet screen and fan. c) Engage parking brake. Loosen t he jam nuts securing the two 5/16 x 1-1/2”

carriage bolts to the hydro control arm. Be sure the hydro control arm is in

the neutral position as outlined in the previous adjustment (6.2.5) and the

parking brake is adjusted as per pr evious adjust m ent (6.2.6). d) Adjust two 5/16 x 1-1/2” carriag e bolt s in t he hydro cont r ol ar m in or out until the

head contacts the butterfly plate, and t hen tighten jam nuts (See Figure 13) . NOTE: When the bolts are properly adjusted, there will be no rotational

movement of the hydro control arm when brake is engaged. e) Restar t engine and open to full throttle. f) Step down on the forward pedal, then the rear pedal of the motion control

pedal. Listen for a "whine" from the hydro transaxle. If any "whine" is heard

during any of the above conditions, repeat adjustm ent steps “c”, “d” and “e”. g) Replace fan and inlet screen.

FIGURE 13

PARKING BRAKE NEUTRAL LOCKOUT ADJUSTMENT

6.2.9 Parking brake switch adjustment a) Stop engine, wait for all moving parts to stop, and remove key. b) Engage parking brake. Adjust the parking brake switch mounting brack et until

jack-shaft eng agement arm depresses brake saf ety switch by at least 1/4”. c) Check safety interlock system as outlined in 6.1.6.

6.2.10 Motion Contr ol Linkage Adjustment a) Step down on the forward pedal until it touches the footrest. b) Check the gap between the motion override tube and the spacer. This gap

should measure 1/16” (See Figure 14). c) If adjustment is requir ed, remove clevis pin at foot pedal end and turn yoke

in or out as required to obtain the 1/ 16" gap.

- 32 -

FIGURE 14

MOTION CONTROL LINKAGE ADJUSTMENT

6.2.11 Seat Switch Adjustment a) Stop engine, wait for all m oving parts to stop, and remove key. b) W it h oper at or out of seat, adjust the seat switch to pr ovide a 1/16”

clearance between the switch plunger and the seat frame ( See Figure 15). c) To adjust, loosen the top nut securing the seat switch to the seat rail

weldment. Adjust the bottom nut unt il t he 1/ 16” between plunger and seat

frame has been obtained. Tighten the top nut. Recheck the measurem ent

and adjust again if necessary. d) Check safety interlock system as outlined in 6.1.6.

FIGURE 15

SEAT SWITCH ADJUSTMENT

6.2.12 Electric Clutch Adjustment a) Stop engine, wait for all moving parts to stop, and remove key. b) Engage parking brake. c) Place .015-.021 inch feeler gauge thr ough each of the three clutch gap

holes. If gap exceeds this range, t ighten the three adjusting nuts ( c) until

the proper gap is obtained (See Figure 16) . The three clutch gap holes are

located at the “nut side” of t he adj usting bolts. The adjusting bolt s can be

identified by the springs surrounding each bolt.

( c )

FIGURE 16

ELECTRIC CLUTCH ADJUSTMENT

- 33 -

6.2.13 Steering Chain Adjustment a) Stop engine, wait for all moving part s t o st op, and remove key. b) Position the st eer ing handle bar so that it points the unit str aight forward (the

rear steering wheel should be in line with the rider main fr am e channel) . c) Check to see if the chains are loose. d) To take up slack in the chains, loosen the rear jam nut s connect ing the

eyebolts to cross link bars, then equally tig hten each forward jam nut until

slack is taken up. Retight en t he forward jam nuts onto the links. e) If the unit tends to turn lef t when handle bar is positioned for straight forward

travel, adjust by shortening the rig ht hand link (threading jam nuts closer to

“eye” end of the eyebolt) and lengthening t he left hand link (threading j a m

nuts away from the “ eye” end of the eyebolt) an equal amount. Re check

chain tension. f) If the unit tends to turn right when handle bar is positioned f or st raight

forward travel, reverse procedure as stated in paragraph “d” above.

6.2.14 Throttle Control Adjustment a) Stop eng ine, wait for all moving parts to stop, and r emove key. b) Loosen the cable clamp on the engine and position the thrott le control at the

control console within 1/4” (6mm) from the upper end of the slot. Pull on

cable assembly at lower end, where it attached to the engine, until the

throttle control arm contacts the stop screw. Secure cable with cable clamp.

6.2.15 Throttle Cable Tension a) Stop eng ine, wait for all moving parts to stop, and r emove key. b) Tension in thr ottle lever can be adjusted by adjusting the tightness of the

lever pivot bolt, which is located under the console. See Figure 17.

FIGURE 17 THROTTLE TENSION

6.2.16 Seat armrest adjustment

a) Lift armrest on seat. Locate square

tab marked with the numbers 1

through 4. Rotate square tab 1/4

turn to raise or lower the armrest in

approximately 1/4” increments. See

Figure 18.

Armrest Adjust ment Tab Rotate ¼ Turn

FIGURE 18

RMREST ADJUSTMENT

- 34 -

7. WASTE DISPOSAL

7.1 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.

7.2 BATTERY DISPOSAL

POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid, which is

WHAT CAN HAPPEN ♦ Swallowing electrolyte can be fatal or if it t ouches skin

HOW TO AVOID THE HAZARD

♦ Wear safety glasses to shield eyes, and rubber gloves ♦ 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, stat e, 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 batt ery to a local certified recycling center. I f no local recycling is available return the battery to any certified battery reseller.

poisonous and can cause severe burns

can cause severe burns.

to protect skin and clothing when handling elect r olyte.

DANGER

8. TROUBLE SHOOTING

8.1 MOWER CUTS UNEVENLY.

a) Check air pressure in tires. See Section 2.8. A more uniform cutting height m ay be

obtained with higher tire pressure on rough terrain. A lower tire pressure provides

more flotation. b) Check deck support pins. Hairpin clips must be in the same hole on each support pin. c) Check blades tip to tip for straightness. Blades should be within 3/16” or one blade

width from being in line.

8.2 ENGINE WILL NOT START.

a) Make sure battery has a full charge. b) Check that throttle control is midway between “slow” and “fast” positions, and choke

is in “on” position for a cold engine or “ off” position for a warm engine. c) Be sure there is fuel in the tank and that the fuel valve is open. d) Operator must be in the seat. e) Check that parking brake is set. f) Be sur e that the PTO is disengaged. g) Check that the spark plug wires are properly connected. h) Look for loose or faulty wiring connections. i) Check for corrosion at all wiring connect ions. Even minor corrosion may cause a

faulty connection. Clean connector terminals t hor oughly and reconnect. NOTE: When disconnecting elect rical connectors, DO NOT pull on the wires to

separate connectors. j) Check that the seat switch is properly adjusted. See Section 6.2.12. k) Check that the par king brake switch is properly adjusted. See Section 6. 2. 10.

- 35 -

NOTE: After carefully checking the above steps, attempt to st ar t the engine. If it

does not start, contact your authorized Exmark ser vice dealer. IMPORTANT: It is essential that all Operator Safety Mechanisms be connected and

in proper operating conditions prior to t he use of the mower.

ENGINE TROUBLESHOOTING

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 tables list some common causes of t r oubles. Do not attempt to service or

replace major items or any items that call for special timing or adjustment procedures (governor, valves, etc.). Have this work done by your Engine Service Dealer.

ENGINE TROUBLESHOOTING TABLE

PROBLEM

Will not start Hard starting

Stops suddenly

Lacks power

Operates erratically

Knocks or pings

Skips or misfires

Backfires

Overheats

High fuel consumption

IMPROPER

FUEL

X X X

FUEL

X X X X

DIRT IN

FUEL LINE

X X X X X

X X X

DIRTY AIR

FILTER

X X X X 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

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

AIR

SCREEN

- 36 -

9. WIRING DIAGRAMS

Engine Deck Wiring Diagram

Note: All connectors are viewed from the wire input side of the connector.

N.O. = Normally Open

Console Wiring Diagram

Note: All connectors are viewed from the wire input side of the connector.

N.O. = Normally Open

- 37 -

10.

2-Year Limited Warranty

Exmark Turf Equipment

Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part manufactured by Exmark and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of two years.

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

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

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

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

• Any damage or deterioration due to normal use, wear

• Cost of regular maintenance service or parts, such as

• Any product or part which has been altered or misused

• Any repairs necessary due to use of parts, accessories

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

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

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

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice, NE 68310

402-223-6375 or service@exmark.com

Warranty Period

Items and Conditions Not Covered

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

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

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

Instructions for Obtaining Warranty Service

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

Owner’s Responsibilities

The Exmark turf equipment, including any defective part, must be returned to an authorized Exmark service dealer within the warranty period. This warranty extends only to turf equipment operated under normal conditions. You must properly service and maintain your Exmark product as described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

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

General Conditions

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

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.

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NOTES

- 38 -

NOTES

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SERVICE RECORD

Date Description of Work Done Service Done By

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- 40 -

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

Check us out on the Web:

www.exmark.com

WARNING

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects, or

other reproductive harm.

FG. CO. INC.

Exmark TR23KC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual