Exmark TT20KCC, TT23KCC, TT23KAC User Manual

WARNING
POTENTIAL HAZARD This product is a piece of power equipment.
WHAT CAN HAPPEN Failure to follow safe operating pr actices can result in serious
operator injury or even death.
HOW TO AVOID THE HAZARD Keep all shields, guards, and safety devices (especially the grass
Stop engine and wait for all moving parts to stop. Remove spark
plug wire(s) or remove key before adjust ing, servicing, or performing maintenance.
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 o r m is pr ovided. Keep others off mower.
WARNING
POTENTIAL HAZARD Gasoline is harmful or f at a l if swallowed. Long-term exposure to
vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD
Avoid prolonged breathing of vapors. Keep face away from nozzle and gas tank/container opening. Keep away from eyes and skin. Never siphon by mouth.
IMPORTANT
When the mower is used or oper ated on any California forest, brush or grass covered land, a working spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442 Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.
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 for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication
.
EXMARK PARTS PLUS

PROGRAM
EFFECTIVE DATE: September 1, 1995 Program
If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!!
How the Program Works
1. If dealer does not have part in stock for a "down" unit at 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.
2. Distributor ships part(s) to dealer or customer, as requested by dealer, same day, overnight UPS Distributor bills dealer for part and freight charges where applicable.
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus central time, with an Exmark Parts Plus

order of six (6) line items or less.

order, he contacts Exmark by 3:00 p.m.,
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable.
5. The customer pays for the part and freight
if it is shipped under the Exmark Parts Plus

and if it arrives in
accordance to the program.
6. Who pays for the part and freight
if it fails to arrive overnight in accordance to the program? A. Under any circumstance the customer does not pay. B. If the part does not arrive overnight due to:

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.
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus

order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time, Exmark pays for the part and freight.
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark 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 only available in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus must be six (6) line items or less. Exclusions from the Exmark Parts Plus

orders must be received by Exmark by 3:00 p.m., central time. Orders

Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
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CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and 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, m aint enance, adjustment, and safety instructions for your Exmark mower.
BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
By following the operating, maintenance, and safety instructions, you will prolong the lif e of your mower, maintain its maximum ef ficiency, and promote safe operation.
If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and distribut or s are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the f ield or at their service stations. They carry ample stock of ser vice parts or can secur e t hem promptly for you from the factor y.
All Exmark parts are thoroug hly test ed and inspect ed before leaving the factory, however, attention is required on your part if you are t o obt ain the fullest measure of satisfaction and performance.
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TABLE OF CONTENTS
1. SAFETY.............................................................................................PAGE
1.1 Safety Alert Symbol......................................................................................1
1.2 Training ........................................................................................................1
1.3 Preparation..............................................................................................1 - 3
1.4 Operation.................................................................................................4 - 5
1.5 Maintenance & Storage................................................................................6
1.6 Riding Attachments....................................................................................... 7
1.7 Safety Signs ....................................................................................... ......7-8
2. SPECIFICATIONS
2.1 Model Number..............................................................................................9
2.2 Engine..........................................................................................................9
2.3 Fuel System..................................................................................................9
2.4 Electrical System..........................................................................................9
2.5 Steering/Brake Control .................................................................................9
2.6 Transmission................................................................................................9
2.7 Wheel Drive System.....................................................................................9
2.8 Tires .............................................................................................................9
2.9 Deck...........................................................................................................10
2.10 Dimensions................................................................................................10
2.11 Torque Requirements................................................................................10
3. ASSEMBLY INSTRUCTIONS
3.1 to 3.11 Assembly.................................................................................10 - 13
4. OPERATION INSTRUCTIONS
4.1 Controls...............................................................................................14 - 15
4.2 Pre-Start.....................................................................................................15
4.3 Operation Instructions..........................................................................15 - 17
4.4 Transporting ...............................................................................................18
5. MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance .................................................................................18
5.2 Adjustments.........................................................................................27 - 31
6. WASTE DISPOSAL
6.1 Motor Oil Disposal......................................................................................32
6.2 Battery Disposal.......................................................................................... 32
7. TROUBLE SHOOTING
7.1 Mower Tracks Left or Right.........................................................................32
7.2 Mower Cuts Unevenly.................................................................................32
7.3 Engine Will Not Start ...........................................................................32 - 33
8. HYDRAULIC SCHEMATIC...........................................................................34
9. WIRING DIAGRAMS.....................................................................................35
10. WARRANTY..........................................................................................36 - 37
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1.SAFETY
1.1 SAFETY ALERT SYMBOL
This SAFETY ALERT SYMBOL is used both in this manual and on the machine to
identify important safety messages which must be followed to avoid accidents. This
symbol means:
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: Indicates an imminently hazardous situation which, if not avoided, WILL
result in death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury.
CAUTION: 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 equipm ent and t each this regard to all who operate this unit.
1.2.2 Read the instructions carefully. Familiarize 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.
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
1.3 PREPARATION
1.3.1 Evaluate the terrain to determine what accessories and attachments ar e
needed to properly and safely perform the job. Only use accessories and attachments approved by Exmark.
1.3.2 The use of personal protective equipm ent , 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 to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operat or or bystanders.
WARNING
POTENTIAL HAZARD Engine exhaust contains carbon monoxide, which is
an odorless deadly poison.
WHAT CAN HAPPEN Carbon monoxide can kill you.
HOW TO AVOID THE HAZARD Do not run engine indoors or in a small confined area
where dangerous carbon monoxide fumes can collect.
DANGER
POTENTIAL HAZARD In certain conditions gasoline is extremely flammable
and highly explosive.
WHAT CAN HAPPEN A fire or explosion from gasoline can bur n you, ot hers,
and cause property damage.
HOW TO AVOID THE HAZARD DO NOT smoke while refueling , and stay away from
an open flame or where gasoline fumes m ay be ignited by spark.
Refuel only outdoors. Store gasoline in an approved container and keep it
out of the reach of children.
Add fuel before start ing the engine. Never remove the
cap of the fuel tank or add fuel when engine is running or when the engine is hot.
Never fill the fuel tank so that 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.
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DANGER
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 inter ior car pets or plastic truck bed liners may insulate the container and slow the loss of any static charge.
When practical, r emove gas-powered equipment from
the truck or trailer and refuel the equipment with its wheels on the ground.
If this is not possible, then refuel such equipment on a
truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.
If a gasoline dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.
WARNING
POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and
may be ignited by electrical sparks or hot engine/exhaust components.
WHAT CAN HAPPEN Explosion and fire may occur, resulting in proper t y
damage, personal injury, and/or death.
HOW TO AVOID THE HAZARD Provide adequate ventilation of any enclosed trailer to
prevent build up of gasoline vapors, especially at floor level.
Refuel only outdoors, never inside an enclosed trailer. Be sure all fuel tanks and gasoline st or age containers
have proper caps installed to prevent spillage and minimize vapor escaping into the trailer.
Do not place any equipment that is leaking gasoline in
an enclosed trailer.
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1.4 OPERATION
Although hazard control and accident prevention are parti al l y dependent upon the design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence, and proper training of t he personnel 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
WARNING
POTENTIAL HAZARD Hands, feet, hair, clothing, or accessories can become
entangled in rotating part s. WHAT CAN HAPPEN Contact with rotating parts can cause traum at ic am putation
or severe lacerations. HOW TO AVOID THE HAZARD Do not operate the machine without guards, shields, and
safety devices in place and working. Keep hands, feet, hair, je welry, or clot hing away from
rotating parts.
1.4.1 Give complete, undivided attention to the job at hand.
1.4.2 Mow only in daylight or in good artif icial light, keeping away from holes and hidden hazards. DO NOT operate the mower when children or others are in the area.
1.4.3 When f easible, avoid operating the equipment in wet grass.
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tract ion and/or control could occur. Mow across slopes with walk behind mowers, never up and down. Loss of control and/or loss of operator’s footing could result in a fall with an arm or leg gett ing under the mower or engine deck and sustaining serious injury. Drive slower on slopes. Progressively greater care is needed as the slope increases. DO NOT operate on slopes g r eat er than 20 degrees. Watch for ditches, holes, rocks, dips, and rises which can cause erratic handlebar movement and loss of footing. Keep away from drop-offs and st eep banks. Avoid sudden starts. Look down and behind you before and while moving backwards. DO NOT mow slopes when grass is wet - slippery conditions create hazardous footing, affect steering, and reduce traction and braking. The operator is responsible for safe operation on slopes. See inside the back cover to determine the approximate slope angle of the area to be mowed.
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1.4.5 Stop the blades when crossing surfaces other than g r ass, if mower must be tilted for transport at ion, and when transpor t ing the mower to and from the area to be mowed.
1.4.6 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.
1.4.7 Do Not change the engine governor settings or over speed the engine. Operating an engine at excessive speed may increase the hazard of personal injury.
1.4.8 Place speed control lever in neutral, lock drive levers in neutral, disengage PTO, and engage park brake before starting engine.
1.4.9 Start the engine caref ully with feet well away from the blades.
1.4.10 Keep hands, feet, and clothing away from r o t at ing parts while the mower is being operated.
1.4.11 Stop the engine, wait for all moving parts to stop, and remove plug wire(s) or key:
Before checking, cleaning or working on the mower.
After striking a foreign object (inspect the m ower for damage and make
repairs before restart ing and operating the mower).
Before clearing blockages.
Whenever you leave the mower.
1.4.12 Stop the engine and wait fo r all m oving parts to stop:
Before removing grass catcher .
Before refueling.
Before making heig ht adjustments.
1.4.13 Before stopping the engine, place the throttle control midway between the “slow” and “fast” positions. Allow the engine t o r un a minimum of 15 seconds, then stop the engine.
1.4.14 The fuel system is provided with a shut-off valve. The fuel shut-off valve is used to shut off the fuel when:
The machine will not be used for a few days.
During transport to and from the job.
When parking inside a building.
1.4.15 This mower was designed for one operator only. Keep all others away fr om
mower during operation.
1.4.16 Do NOT mow without the discharge chute or entire grass collection system in
place and in proper working condition.
1.4.17 Be aware of the mower discharg e and dir ect dischar ge away from others.
1.4.18 Do NOT operate t he m ower under t he influence of alcohol or drugs.
1.4.19 Use care when approaching blind corners, shr ubs, trees, or other objects that
may obscure vision.
1.4.20 If j u m p st ar 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 (-) from the negative post on the
booster battery to the engine block as far away from the battery as possible.
c) Disconnect bat t ery cables in the reverse order afterstarting.
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1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maintenance, follow the eng ine m anufacture’s recommendations
precisely as stated in the engine manual.
1.5.2 Disconnect the battery from the negative batter y 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 recharg ing
them will result n reduced performance and ser vice life. To preserve optimum battery performance and lif e, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.
Note: To prevent damage due to freezing, 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 storage 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 frequent ly to m aintain 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 det er iorating components that could create a hazard.
1.5.12 All replacement parts must be t he same as or equivalent to the parts supplied
as original equipment.
WARNING
POTENTIAL HAZARD Hydraulic fluid escaping under pressure can penetrat e
skin and cause injury.
WHAT CAN HAPPEN Fluid accidentally injected into the skin must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangr ene m ay result . HOW TO AVOID THE HAZARD Make sure all hydraulic fluid hoses and lines are in
good condition an all hydraulic connections and fittings
are tight before applying pressure to hydraulic system. Keep body and hands away from pinhole leaks or
nozzles that eject high pressure hydraulic fluid. Use cardboard or paper, not your hands, to f ind
hydraulic leaks. Safely relieve all pressure in the hydraulic system by
locking drive levers in neutral and shutting off the
engine before perfor ming any work on the hydraulic
system.
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1.6 RIDING ATTACHMENTS
Use only Exmark riding attachments. The use of ot her t han Exmar k riding attachments may create a hazardous condition resulting in injury.
1.7 SAFETY SIGNS
1.7.1 Keep all safety signs legible. Remove all gr ease, dirt, and debris from safety signs and instructional labels.
1.7.2 Safety signs must be replaced if they are missing or illegible.
1.7.3 When new components are installed, be sur e that current safety signs are affixed to the replaced components.
1.7.4 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or fr om Exmark Mfg. Co. Inc.
1.7.5 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.
1.7.6 Familiarize yourself with the following safety signs and inst r uction labels. They are critical to the safe operat ion of your Exmark commercial mower.
PART NO. 103-1541 LOCATION: Console
PART NO. 1-413214 LOCATION: Right Side of Hydro Control Crank Arm
PART NO. 1-403005 LOCATION: LH & RH Front Top
Surface of Mower Deck
PART NO. 98-5954 LOCATION: Under LH, RH & Center Belt Shields
PART NO. 1-403143 LOCATION: RH Rear Surface of Engine Deck
PART NO. 103-2239 LOCATION: Top of Mower Deck Beneath Center Shield
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PART NO. 1-603845 LOCATION: Left Rear Top Corner
of Engine Deck
p
PART NO. 1-323540 LOCATION: Front of Mower
Deck Top Surface
PART NO. 1-553049 LOCATION: On Top Front LH Surface of
Mower Deck
PART NO. 1-303517 LOCATION: LH Side of Rear Surface
of Engine Deck
PART NO. 103-1077 LOCATION: On Top Front RH Surface of
Mower Deck
PART NO. 103-2432 LOCATION: Parking Brake
Lever
PART NO. 1-513746 LOCATION: Surface of Engine
Deck Next to Muffler
PART NO. 1-303508 LOCATION: On Top RH Surface
of Mower Deck
PART NO. 1-523552 LOCATION: On Top of
Hydraulic Tank
ECS Handles PART NO. 103-2242 LOCATION: LH Side of Console
PART NO. 1-513747 LOCATION: To
Rear of Battery Cover
PART NO. 1-303293 LOCATION: Top Surface of
Fuel Tank
ECS Handles PART NO. 103-2243 LOCATION: RH Side of Console
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2. SPECIFICATIONS
2.1 MODEL NUMBER:
Serial Nos. 320,000 & Higher: TT23KCC; TT23KAC; TT 20KCC
2.2 ENGINE
2.2.1 Engine Specifications: See your Engine Owner's Manual.
2.2.2 3600 RPM (No Load).
2.3 FUEL SYSTEM
2.3.1 Capacity: 5.0 gal. (18.9 L.)
2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or hig her . 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 O° F
2.4.4 Battery Voltage: 12 Volt; Polarity, negative gr ound.
2.4.5 Fuses: blade type, 20 amp to charging circuit; 20 amp to electr ic clut ch.
2.4.6 Safety Interlock System: Operator must have OPC (O per ator Presence Control) levers held in contact with handle grips, speed control lever in neutral, and PTO disengaged to star t engine. Release of OPC levers will cause the engine to stop if speed control lever is not in neutral and/or PTO is engaged.
Park brake must be diseng aged to move speed control out of neutral or engine will kill.
2.5 STEERING CONTROL:
Fingertip drive control levers provide independent speed control, braking and neutral to each drive wheel for moving forward or r everse, stopping, and power turning.
2.6 TRANSMISSION:
Twin Hydrostatic Drive
2.6.1 Two Hydro Gear BDP-10L series variable displacement pumps independently coupled to two high efficiency Parker / Ross wheel drive motors .
2.6.2 Hydraulic Filter is replaceable cartridge type. P/N 513211: 10 microns, 18 psi bypass (Summer use above 32° P/N 523541: 40 microns, 18 psi bypass (Winter use below 32°
2.6.3 Speed Range: Forward 0 - 6.75 mph (10.9 km/h)
Reverse 0 - 2.25 mph (3.6 km/h)
2.7 WHEEL DRIVE SYSTEM:
Drive wheels are direct coupled to Parker/Ross wheel drive motors with 1.0" (25.4 mm) tapered shaft.
2.8 TIRES Drive Front Caster
Size...........................18 x 8.50-8..........................11 x 4.0-5
Quantity.............................2.........................................2
Tread........................ Turf Master ........................... Smooth
Ply Rating..........................4.........................................4
Pressure.................14 psi (97 kPa)..................16 psi (152 kPa)
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