Exmark TT20KCE, TT23KAE User Manual

TURFTRACER®

ForSerialNos.
790,000&Higher

PartNo.4500-361Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.

Important:Whenthemowerisusedoroperated
onanyCaliforniaforest,brushorgrasscovered
land,aworkingsparkarrestermustbeattached
tothemufer.Ifnot,theoperatorisviolating
statelaw,Section4442PublicResourceCode.To
acquireasparkarresterforyourunit,seeyour
EngineServiceDealer.

ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada

TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.

Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.

©2008—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

Contactusatwww.Exmark.com.

2

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.

Figure1

1.Modelandserialnumberlocation

ModelNo.

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

SerialNo.

3

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.....................10

Specications.......................................................12

ModelNumbers............................................12

Systems.........................................................12

Dimensions...................................................13

TorqueRequirements....................................14

ProductOverview................................................14

Operation.............................................................15

Controls........................................................15

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

OperatingInstructions..................................17

Transporting.................................................21

Maintenance.........................................................22

RecommendedMaintenanceSchedule(s)...........22

PeriodicMaintenance.......................................23

CheckEngineOilLevel.................................23

CheckBatteryCharge....................................23

CheckMowerBlades.....................................23

CheckSafetyInterlockSystem.......................24

CheckforLooseHardware............................25

ServiceAirCleaner........................................25

ChangeEngineOil........................................25

CheckHydraulicOilLevel.............................25

CheckTirePressures.....................................25

CheckConditionOfBelts..............................26

LubricateGreaseFittings...............................26

LubricateCasterWheelHubs........................26

RemoveEngineShroudsandCleanCooling

Fins...........................................................27

CheckSparkPlugs.........................................27

ChangeHydraulicSystemFilter.....................28

ThreadLockingAdhesives.............................29

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................30

Copper-BasedAnti-seize..............................30

DielectricGrease...........................................30

Adjustments.....................................................30

DeckLeveling...............................................30

PumpDriveBeltTension...............................30

DeckBeltTension.........................................30

BladeDriveBeltTension..............................30

BrakeAdjustment..........................................30

SpeedControlLinkageandNeutralSafety

SwitchAdjustment....................................30

NeutralControlLinkagesAdjustment............31

HydroControlLinkageAdjustment...............31

DriveLeverLinkageAdjustment...................32

TrackingAdjustment.....................................32

HydroPumpSpringTensionSetting..............33

ElectricClutchAdjustment............................33

Cleaning...........................................................33

CleanGrassBuild-UpUnderDeck................33

WasteDisposal..............................................33

Troubleshooting...................................................35

Schematics...........................................................37

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.

CAUTION

DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Y ellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

5

Safety

DANGER

Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anygasolinethatspills.

•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.

•DoNotllthefueltankcompletely
full.Addgasolinetothefueltankuntil
thelevelis1/4to1/2inch(6–13mm)
belowthebottomofthellerneck.This
emptyspaceinthetankallowsgasoline
toexpand.

•Neversmokewhenhandlinggasoline,
andstayawayfromanopenameor
wheregasolinefumesmaybeignitedby
spark.

•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.

•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

DANGER

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.

•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas
tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly .DoNotoperateunlessthey
arefunctioningproperly.

6

Safety

Operation

WARNING

Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,
tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer
andenginearea.

•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.

DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.

•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly .

•DoNotchangetheenginegovernorsettingor
overspeedtheengine.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting

andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:

–Beforerefueling.
–Beforedumpingthegrasscatcher.
–Beforemakingheightadjustments.

WARNING

Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.

•DONOToperatethemowerwhenpeople,
especiallychildren,orpetsareinthearea.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.

7

Safety

DANGER

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Lossof
controland/orlossofoperator’sfooting
couldresultinafallwithanarmorleg
gettingunderthemowerorenginedeck
whichmayresultinseriousinjury,deathor
drowning.

•Mowacrossslopes,neverupanddown.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan20
degrees.

•Reducespeedanduseextremecaution
onslopes.

•Avoidsuddenturnsorrapidspeed
changes.

•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.

•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.

•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect

sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.

•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.

•Letenginecoolbeforestoringanddonotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.

•Keephandsandfeetawayfrommovingparts.
Ifpossible,donotmakeadjustmentswiththe
enginerunning.

•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

8

WARNING

Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.

•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.

Safety

•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.

9

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

1-303517

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

1-403143

103–1541

1-413214

1-513747

103–2076

10

Safety

103–2242

103–2243

103-2432

103-4935

116-0404

11

Specications

Specications

ModelNumbers

SerialNos:790,000andHigher

TT20KCE,TT23KAE

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s
Manual

•RPM:FullSpeed:3600(NoLoad)

FuelSystem

•Capacity:5.0gal.(18.9L)

•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher.

•FuelFilter:ReplaceableIn-line

•FuelShut-OffValve:1/4turnincrements

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:BCIGroupU1235amps0°F

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:Twobladetype,20amptochargingcircuit;
20amptoelectricclutch

OperatorControls

SteeringControl:Fingertipdrivecontrollevers
provideindependentspeedcontrol,brakingand
neutraltoeachdrivewheelformovingforwardor
reverse,stopping,andpowerturning.

Transmission

•TwoHydroGearvariabledisplacementpiston
pumpsindependentlycoupledtotwohigh
efciencyParkerwheeldrivemotors.

•HydraulicOil:UseExmarkPremiumHydroOil.

•HydraulicOilCapacity:2.4qt.(2.2L)

•HydraulicFilterisreplaceablecartridgetype.

P/N109–4180:25microns,10psibypass
(Summeruseabove32°F(0°C))

P/N1–523541:40microns,18psibypass(Winter
usebelow32°F(0°C))

•Speeds:

–0-6.75mph(10.9km/hr)forward.

–0-2.25mph(3.6km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.

SafetyInterlockSystem:

•OperatormusthaveOPC(OperatorPresence
Control)leversheldincontactwithhandle
grips,speedcontrolleverinneutral,andPTO
disengagedtostartengine.ReleaseofOPClevers
willcausetheenginetostopifspeedcontrollever
isnotinneutraland/orPTOisengaged.

•Parkbrakemustbeengagedtomovespeed
controloutofneutralorenginewillkill.

WheelDriveSystem

DrivewheelsaredirectcoupledtoParkerwheeldrive
motorswith1inch(25.4mm)taperedshaft.

12

Specications

Tires&Wheels

DriveFrontCaster

Pneumatic
(Air-Filled)

AllSerial
Nos.

Quantity

Tread

Size18x8.50-811x4.00-511x4.00-5

PlyRating

Pressure

222

TurfMasterSmoothSmooth

44

14psi(96
kPa)

Pneumatic
(Air-Filled)

SN599,999
&Lower

16psi(110
kPa)

CuttingDeck

•ModelNumbers:

–FMD524

–FMD604

•CuttingWidth:

•CuttingHeightAdjustment:

Adjustsfrom11/2inches(3.8cm)to41/2
inches(11.4cm)in1/2inch(1.3cm)increments.

Semi­Pneumatic

SN600,000
&Higher

•MulchingKit:Optional

•Bagger:Optional

Dimensions

OverallWidth:

52inchDeck60inchDeck

DeectorUp53.4inches

(135.6cm)

DeectorDown64.8inches

(164.6cm)

OverallLength:

52inchDeck60inchDeck

83.4inches(211.8cm)83.4inches(211.8cm)

61.4inches
(156.0cm)

73.0inches
(185.4cm)

–52inch(132.1cm)

–60inch(152.4cm)

•Discharge:Side

•BladeSize:(3ea.)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

•BladeSpindles:Solidsteelspindleswith13/4
inch(4.45cm)I.D .bearings.

•DeckDrive:

–Electricclutchmountedonengineshaft.

–Bladesdrivenbytwobelts(w/self-tensioning

idlers).

•Deck:

Fulloatingdeckisattachedtoout-frontsupport
frame,removableforservice.Sixanti-scalprollers
providemaximumturfprotection.Deckdesign
allowsforbagging,mulchingorsidedischarge.

•DeckDepth:

–52inchDeck:5.5inches(14.0cm)

OverallHeight:

52inchDeck60inchDeck

45inches(114.3cm)45inches(114.3cm)

TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)

52inchDeck60inchDeck

45.8inches(116.3cm)45.8inches(116.3cm)

WheelBase:(CenterofCasterTireto
CenterofDriveTire)

52inchDeck60inchDeck

43.3inches(110.0cm)43.3inches(110.0cm)

CurbWeight:

52inchDeck60inchDeck

720lb(327kg)760lb(345kg)

–60inchDeck:5.5inches(14.0cm)

13

ProductOverview

TorqueRequirements

BoltLocation

CutterHousingSpindle
Nut

BladeMountingBolt
(lubricatewithanti-seize)

EngineDeck/Mower
DeckSupportMount
Bolts

Type1Hardware
–Anti-ScalpRoller
WhizlockNutSeeFigure9

Type2
Hardware–Anti-Scalp
RollerNylocNutSee
Figure9

Type2&3Hardware
–Anti-ScalpRollerHex
CapscrewSeeFigure9

Type3
Hardware–Anti-Scalp
RollerFlangedNylocNut
SeeFigure9

Torque

140–145ft-lb(190–197
N-m)

55-60ft-lb(75-81N-m)

30-35ft-lb(41-47N-m)

40-45ft-lb(54-61N-m)

30-35ft-lb(41-47N-m)

50-55ft-lb(68-75N-m)

30-35ft-lb(41-47N-m)

ProductOverview

Figure3

1.Controls

2.FuelCap4.Height-of-CutPins

3.ParkBrakeLever

Type4
Hardware–Anti-Scalp
RollerWhizlockNutSee
Figure9

Type4
Hardware–Anti-Scalp
RollerNylocNutSee
Figure9

EngineMountingBolts

WheelLugNuts

WheelHubSlottedNutsminimum100ft-lb(136

ClutchRetainingBolt
(securedwiththreadlocker)

WheelMotorMounting
Bolts

30-35ft-lb(41-47N-m)

30-35ft-lb(41-47N-m)

15-20ft-lb(20-27N-m)

90-95ft-lb(122-129N-m)

N-m)

55-60ft-lb(75-81N-m)

30-35ft-lb(41-47N-m)

14

Operation

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

OperatorPresenceControl(OPC)
Levers

Locatedontheupperhandleassemblydirectlyabove
thehandlegrips.

Whentheseleversaredepressed,theOPCsystem
sensesthattheoperatorisinthenormaloperator’s
position.Whentheleversarereleased,theOPC
systemsensesthattheoperatorhasmovedfromthe
normaloperatingpositionandwillkilltheengineif
eitherthespeedcontrolleverisnotintheneutral
positionorthePTOisengaged.

asshowninFigure4,andthedriveleversarereleased,
thedrivewheelsareengagedintheforwarddirection.

Squeezingthelefthandand/orrighthandlever
causesthelefthandand/orrighthanddrivewheel
respectivelytoslowdown,stop,orreverse,depending
onhowfareachdriveleveris“squeezed”.Squeezing
thedriveleversbeyondtheneutralpositioncauses
thedrivewheelstoengageinthereversedirection
regardlessofthepositionoftheneutrallocklatches
andthespeedcontrollever.

NeutralLockLatches

Locatedontheupperhandleassemblyontheends
ofthehandlegrips.

Theselatchesallowtheoperatortolockthedrive
leversina“neutral”positionwherethedrivewheels
arenotengagedineitheraforwardorreverse
direction.

ChokeControl

1.OPCLever

2.Rotateneutrallocklatch
downwardforneutral
lockposition

DriveLevers

Figure4

3.NeutralLockLatch

4.DriveLeverinneutral
position

Locatedonthecontrolconsolefrontrighthandside.

Chokeisusedtoaidinstartingacoldengine.The
chokecontrolispulledouttobeinthe“ON”position
andpushedintobeinthe“OFF”position.DoNot
runawarmenginewithchokeinthe“ON”position.

ThrottleControl

Locatedonthecontrolconsole’srightside.

Thethrottleisusedtocontrolenginespeed.Moving
thethrottlecontrolforwardwillincreaseengine
speedandmovingittotherearwilldecreaseengine
speed.Movingthethrottleforwardintothedetent
isfullposition.

SpeedControlLever

Locatedinmiddleofcontrolconsole.

Thespeedcontrollevercontrolsthemaximum
forwardspeedandisinnitelyvariablefromneutral
0–6.75mph(10.9km/hr).

Locatedoneachsideoftheupperhandleassembly
aheadofandbelowthehandlegrips.

Theseleversindividuallycontrolthespeedand
directionofeachdrivewheel.Whenthespeedcontrol
leverismovedoutoftheneutralpositionandthe
neutrallocklatchesaremovedintothedriveposition,

Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.

BrakeLever

Locatedontheleftsideoftheunitabovethe
hydraulictank.

15

Operation

Thebrakeleverengagestheparkbrakeonthedrive
wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe
brake.

Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
engaged.Theunitmustbetieddownandbrake
engagedwhentransporting.

Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.

IgnitionSwitch

Locatedontheleftsideofthecontrolconsole.

Theignitionswitchisusedtostartandstopthe
engine.Theignitionswitchhasthreepositions,
“Off”,“On”and“Start”.Insertkeyintoswitch
androtateclockwisetothe“On”position.Rotate
clockwisetothenextpositiontoengagethestarter
(keymustbeheldagainstspringpressureinthis
position).Operatormusthavespeedcontrolleverin
neutral,OPCleversdepressedandPTOdisengaged
tostartengine.Whenenginestarts,releasekey.

HourMeter

Locatedonthefrontlefthandsideofconsolejust
abovethePTOswitch.

DriveWheelReleaseValves

Locatedontheleftrearcornerofthehydrostatic
pumps.

Drivewheelreleasevalvesareusedtoreleasethe
hydro-staticdrivesystemtoallowthemachinetobe
movedbyhandwithouttheenginerunning.

Witha5/8wrench,turnbothvalvesoneturn
counterclockwisetoreleasethedrivesystem.

Turnclockwisetoresetthedrivesystem.DoNot

overtighten.

TrackingAdjustmentKnob

Locatedontheright-handsideoftherearofthefuel
tanksupport.

Theknobcanbeadjustedsothatmachinewill
“track”straightaheadwiththedriveleversreleased.

PTOEngagementSwitch

Switchislocatedonleftsideofcontrolconsole.

Theswitchmustbepulledouttothe“Rotate”
positiontoengagetheblades.Theswitchispushed
intothe“Stop”positiontostoptheblades.Operator
musthaveoperatorpresencecontrolleversdepressed
whenPTOisengagedorenginewillstop.

Thehourmeterisconnectedtoapressureswitch
installedintheengineblockanditrecordsthe
numberofhoursthattheenginehasrun.Ifignition
switchisleftonwithoutenginerunning,hourmeter
willnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot
alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locatedinthefuellinemidwaybetweenthetank
andengine.

Thefuelshut-offvalveisusedtoshutoffthe
owoffuelwhenparkinginsideabuilding,during
transportationtoandfromthejobsites,andwhen
themachinewillnotbeusedforafewdays.

Rotatevalve1/4turnclockwisetoshutfueloff.
Rotatevalve1/4turncounterclockwisetoturnfuel
on.

Pre-Start

Fillfueltanks.Forbestresultsuseonlyclean,fresh
regulargradeunleadedgasolinewithanoctanerating
of87orhigher.Regulargradeleadedgasolinemay
alsobeused;however,combustionchamberand
cylinderheadwillrequiremorefrequentservice.See
EngineOwner’sManual.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

thatthefuellevelrisesabovealevelthatis1/2inch
belowthebottomofthellernecktoallowforfuel
expansionandpreventfuelspillage.

Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.

RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.

16

Operation

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethevalve1/4turncounterclockwisetoturn
fuelon.

StartingtheEngine

1.Onacoldengine,placethethrottlemidway
betweenthe“Slow”and“Fast”positionsand
placethechokeinthe“On”position.Onawarm
engine,placethethrottlelevermidwaybetween
“Slow”and“Fast”positionsandleavethechoke
inthe“Off”position.

2.Turnignitionswitchto“Start”position.Release
theswitchassoonastheenginestarts.

3.Onacoldengine,graduallyreturnchoketothe
“Off”positionafterenginestartsandwarmsup.

Important:Donotcranktheengine
continuouslyformorethantensecondsat
atime.Iftheenginedoesnotstart,allowa
60secondstartercool-downperiodbetween
startingattempts.Failuretofollowthese
guidelinescanburnoutthestartermotor.

DANGER

Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunless
thereisagrasscollectionsystemormulch
kitinplaceandworkingproperly.

ThePTOswitchengagesthecuttingblades.Besure
thatallpersonsareclearofmowerdeckanddischarge
areabeforeengagingthePTO .

1.Setthrottleto“MIDW AY”position.

2.PullthePTOswitchoutwardtothe“ROTATE”
positiontoengagetheblades.

3.Placethethrottleinthe“FAST”positiontobegin
mowing.

DisengagingthePTO

1.Setthrottleto“MIDW AY”position.

Note:Itishelpfultohavetheleftandright
neutrallocklatcheslockedinneutralwhen
startingtheengine.RefertoNeutralLock
LatchessectioninControls.

PTOEngagement

DANGER

Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.

2.Pushinontheswitchtothe“STOP”position
todisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Lockdriveleversinneutral.

3.DisengagethePTO.

4.Movespeedcontrollevertoneutral.

5.Engagetheparkingbrake.

6.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.

7.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.

8.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.

9.Closethefuelshut-offvalvewhenthemachine
willnotbeinuseforafewdays,when
transporting,orwhentheunitisparkedinside
abuilding.

17

Operation

DrivingtheMachine

DriveLever/NeutralLockLatchOperation

Tolockthedriveleversin“neutrallock”,squeezethe
driveleverstothe“neutral”position(DoNotsqueeze
thedriveleversallthewaybackasthiswillcausethe
drivewheelstogointofullreversedirection).See
Figure5position1.Placethumbsontheinnerlobe
oftheneutrallocklatchesandrotatethemunder
thedriveleversintothe“neutrallock”position.See
Figure5position2.Releasethedrivelevers.

CAUTION

Iftheneutrallocklatchesarenotcompletely
engagedthedriveleverscouldunexpectedly
slipintotheforwarddriveposition.Ifthe
driveleversslipintothedrivepositionthe
unitcouldlurchforwardandcauseinjuryor
propertydamage.

Besurethedriveleversarepasttherollerand
securelyseatedatthebottomoftheneutral
locklatches.

Toplacethedriveleversinthe“forward”position,
slightlysqueezethedriveleverswhileplacingthumbs
ontheouterthumblobeoftheneutrallocklatches
(ortheindexngeronthefrontlobe)androtatethem
fromunderthedrivelevers.Slowlyandcarefully
releasethedrivelevers.SeeFigure5position3.

Toplacethedriveleversinthe“reverse”position,
squeezethedriveleverspasttheneutralposition.See
Figure5position4.

Figure5

1.DriveLeverinneutral
position

2.DriveLeverlockedin
neutralposition

3.DriveLeverinforward
position

4.DriveLeverinreverse
position

DrivingForward

1.Releasetheparkingbrake.

2.Withdriveleverslockedin“neutral”,shiftspeed
controllevertodesiredforwardspeed.

3.Slowlysqueezeandholdbothdriveleversin
theneutralpositionandrotatebothneutrallock
latchesfromtheneutrallockpositiontothe
forwardposition.

Note:DoNotsqueezebothdriveleversallthe
wayback.Thiswillcausethedrivewheelsto
engageinthereversedirection.

4.Tomoveforwardinastraightline,smoothly
releasebothdriveleverstoengagedrivewheels.

Toturnleftorright,squeezetherighthanddrive
levertoturnrightandthelefthanddrivelever
toturnleft.

Tomakea“zeroturn”,squeezeeithertheleft
handortherighthanddriveleverbackintothe
reversepositionwhiletheoppositedriveleverisin
aforwardpositionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine,
avoidquick,jerkymovementsofthedrivelevers.
Movethedriveleverssmoothlyanddeliberately.

Tostop,squeezedriveleversbacktothe“neutral”
position.Movetheneutrallocklatchesintothe
“neutrallock”positionandreleasedrivelevers.
Movethespeedcontrollevertotheneutral
position.

18

DrivinginReverse

Tomoverearwardinastraightline,squeezedrive
leversintothereverseposition.

Toturnleftorright,squeezetherighthanddrivelever
toturnleftandthelefthanddrivelevertoturnright.

Tomakea“zeroturn”,squeezeeitherthelefthand
ortherighthanddriveleverbackintothereverse
positionwhiletheoppositedriveleverisinaforward
positionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine,avoid
quick,jerkymovementsofthedrivelevers.Movethe
driveleverssmoothlyanddeliberately.

Tostop,squeezedriveleversbacktothe“neutral”
position.Movetheneutrallocklatchesintothe
“neutrallock”positionandreleasedrivelevers.Move
thespeedcontrollevertotheneutralposition.

AdjustingtheCuttingHeight

WARNING

Whenthetwofrontsupportrodhairpinsare
removedfromthemowerdeck,theweightof
thetractorsectionmaycausethefrontframe
oftheunittorisesuddenly.Iftheunitrises
suddenly,injurymayoccur.

Securelyholddownthefrontoftheunitwhen
thefrontsupportrodhairpinsareremoved.

Operation

Figure6

1.Decksupportpin

B.ThetirepressuresaresetasdirectedinCheck

TirePressuresintheMaintenancesection.

C.Thelengthofthereardecksupportlink

assembliesaverage6.89inches(approximately
67/8inches)(175.01mm)fromthecenterof
theballjointtothecenterofthefarthesthole.
SeeFigure7.

Note:Allfourpinsmustequallysupportthe
weightofthedeck.Adjustmentinthelength
ofthereardecksupportassembliesmaybe
necessary.Ifonesideislongerthan6.89
inches(approximately67/8inches)(175.01
mm),thantheoppositesidemustbeshorter
bythesameamount.

2.CuttingHeight

Thecuttingheightofthemowerdeckisadjusted
from11/2to41/2inches(3.81cmto11.4cm)in
1/2inchincrements.

1.Stopthemachineandmovethedriveleverstothe
neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Installhairpinclipsintheholesforthedesired
cuttingheight.SeeFigure6.

Important:T omaintaincorrectcutting
heightandrake,checkthefollowingfor
properadjustment.

A.Thefrontandrearhairpinsareinthesame

holeswiththeproperspacersunderthehair
pins.SeeFigure6.

19

Operation

Figure8

Forcuttingheightsabove3.5inches(38mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

Figure7

LeftHandSideShown

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller
position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethedriveleversto
theneutrallockposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe
anti-scalprollersbyremovingthespringdisc
washerandbolt(seestep7).

6.Adjustanti-scalprollersforNormalOperating
Conditions.Placerollersinoneofthepositions
showninFigure8.Rollerswillmaintain3/4
inches(19mm)clearancetothegroundto
minimizegougingandrollerwearordamage.

Note:ForMaximumDeckFlotation,place
rollersoneholepositionlower.Rollersshould
maintain1/4inch(6.35mm)clearancetoground.
DoNotadjustrollerstosupportthedeck.Be
surerollerboltsareinstalledwiththespringdisc
washerbetweenheadoftheboltandmounting
bracket.

1.Anti-scalproller
mountingbracket

2.Cuttingheight

7.Fourtypesofanti-scalprollerassembliesare
available.SeeFigure9todeterminewhich
assemblyhasbeeninstalledontheunit.Torque
hardwareasspecied,orlossofrollermayresult.
SeeFigure9.

Figure9

Frontleftanti-scalpbracketshown

1.Type1hardware

2.Type2hardware

3.Type3hardware

4.Type4hardware

5.(Type1)3/8–16x4hexscrew

6.(Type2&3)3/8–24x2hexscrew—T orqueto50–55
ft-lb(68–75N-m)

7.(Type4)3/8whizlocknut—T orqueto30–35ft-lb

(41–47N-m)

8.Springdiscwasher(conetowardsbolthead)

9.(Type1)3/8whizlocknutandheavyatwasher—
Torqueto40–45ft-lb(54–61N-m)

10.(Type2)3/8nylocnutandheavyatwasher—T orque
to30–35ft-lb(41–47N-m)

11.(T ype3)3/8angednylocnutwithoutwasher—T orque
to30–35ft-lb(41–47N-m)

12.(Type4)3/8nylocnut—T orqueto30–35ft-lb

(41–47N-m).

20

Transporting

TransportingaUnit

WARNING

Loadingthemowerontoatrailerwithout
strongenoughorproperlysupportedramps
couldbedangerous.Therampscould
collapsecausingtheunittofall,whichcould
causeinjury.

•Useproperrampsthataresecuredtothe
truckortrailer.

•Keepfeetandlegsoutfromunderthe
unitwhenloadingandunloading.

•Ifnecessary,useassistancewhenloading .

Besurethefuelshut-offvalveisclosed.

Operation

Useaheavydutytrailertotransportthemachine.
Engageneutrallocklatchesandparkbrake,then
blockwheels.

Securelyfastenthemachinetothetrailerwithstraps,
chains,cables,orropes.

DoNotrelysolelyontheparkingbraketoholdthe
machineonthetrailer.

Besurethatthetrailerhasallnecessarylightingand
markingasrequiredbylawanduseasafetychain.

21

Maintenance

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch,
engageparkingbrake,andpullthewire(s)
offthesparkplug(s)beforeyoudoany
maintenance.Alsopushthewire(s)aside
soitdoesnotaccidentallycontactthespark
plug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst250hours

Beforeeachuseordaily

MaintenanceProcedure

•Changetheengineoil.

•Changethehydrauliclter.

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Cleanthegrassbuild-upfromunderthedeck.

WARNING

Theenginecanbecomeveryhot.Touching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

Every40hours

Every50hours

Every80hours

Every100hours

Every160hours

Every500hours

Every600hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethehydrocontrolarmsupportbushings.

•Servicetheaircleaner.(Mayneedmoreoftenundersevereconditions.SeetheEngine
manualforadditionalinformation.)

•Removeengineshroudsandcleancoolingns.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Checkthesparkplugs.

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Replacetheaircleanerelements.(Mayneedmoreoftenundersevereconditions.Seethe
Enginemanualforadditionalinformation.)

Monthly

Yearly

•Checkthebatterycharge.

•Greasethefrontcasterwheelhubs.

•Greasefrontcasterpivots.

•Greasetheidlerpivots(MowerDeck).

•Greasetheidlerpivot(PumpDrive).

•Lubricatethecasterwheelhubs.

22

Maintenance

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstickand
wipeoiloff.Reinsertthedipstickandpushitall
thewaydownintothetube.DoNotscrewinto
place.Removethedipstickandreadtheoillevel.

4.Iftheoillevelislow ,wipeofftheareaaroundthe
oilllcap,removecapandlltothe“FULL”
markonthedipstick.Useoilasspeciedin
EngineOwner’ sManual.DoNotoverll.

Important:DoNotoperatetheenginewiththe
oillevelbelowthe“LOW”(or“ADD”)markon
thedipstick,oroverthe“FULL”mark.

CheckBatteryCharge

ServiceInterval:Monthly

timeintervaltobringthechargeuptoafullcharge
of12.6voltsorgreater.

Important:Makesurethenegativebattery
cablesaredisconnectedandthebatterycharger
usedforchargingthebatteryhasanoutputof
16voltsand7ampsorlesstoavoiddamaging
thebattery(seechartforrecommendedcharger
settings).

Voltage
Reading

12.6or
greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent
Charge

100%

0%

Maximum
Charger
Settings

16volts/7
amps

16volts/7
amps

16volts/7
amps

14.4volts/4
amps

14.4volts/4
amps

14.4volts/2
amps

Charging
Interval

No
Charging
Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor
More

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof
timewithoutrechargingthemwillresultinreduced
performanceandservicelife.Topreserveoptimum
batteryperformanceandlife,rechargebatteriesin
storagewhentheopencircuitvoltagedropsto12.4
volts.

Note:Topreventdamageduetofreezing,battery
shouldbefullychargedbeforeputtingawayfor
winterstorage.

Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebatteryin
thetableandchargethebatteryfortherecommended

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstated
intheCleanGrassBuild-UpUnderDeck
procedure.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstallblades(iftheywereremoved)inthe
followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

23

Maintenance

Figure10

1.Installbushinginbladepriortoinstallingbushingin
spindle.

B.Installbushing/bladecombointospindle.

WARNING

Incorrectinstallationofthebladeor
componentsusedtoretainthebladecan
bedangerous.Failuretousealloriginal
componentsandassembledasshowncould
allowabladeorbladecomponenttobe
thrownoutfromunderthedeckresultingin
seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,
bladebushings,andbladeboltsasshown.

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

1.Checkstartingcircuit.Startershouldcrankwith:
OperatorPresenceControlleversdepressed,
speedcontrolleverinneutral,andPTO
disengaged.

Figure11

1.Usewrenchherefor
bladeinstallation.This
nuthasbeentorquedto
90–110ft-lb(122–149
N-m)

2.Torqueto55-60ft-lb
(75-81N-m)Apply
lubricanttothreads
asneededtoprevent
seizing.Copper-based
anti-seizepreferable.
Greaseacceptable
substitute.

C.Applylubricanttothreadsofbladeboltas

neededtopreventseizing.Copper-based
anti-seizepreferable.Greaseacceptable
substitute.Installbladeboltngertight.Place
wrenchonthetopspindlenutthentorquethe
bladeboltsto55-60ft-lb(75-81N-m).

TrytostarttheenginewithOPClevers
disengaged,speedcontrolleverinneutraland
PTOdisengaged-startermustnotcrank.

Trytostartwith,OPCleversdepressed,speed
controlleverinanyspeedbutneutralandPTO

disengaged-startermustnotcrank.

TrytostartwithOPCleversdepressed,
speedcontrolleverinneutralandPTO
engaged-startermustnotcrank..

2.CheckOPCcircuits.Clearthearea.Runengine
atone-thirdthrottle,then,withdriveleversand
neutrallocklatchesinneutrallockposition,
movethespeedcontrolleveroutofneutraland
releaseOPCleversenginemuststop.Again,
runengineatone-thirdthrottle,movethespeed
controllevertoneutral,engagePTOandrelease
OPClevers-enginemuststop.

Note:Parkbrakemustbedisengagedbeforethe
speedcontrolleverismovedoutofneutralorengine
willkill.

Note:Ifmachinedoesnotpassanyofthesetests,
donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing.

24

Maintenance

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every50hours—Service

theaircleaner.(May
needmoreoftenunder
severeconditions.See
theEnginemanualfor
additionalinformation.)

Every600hours—Replace
theaircleanerelements.
(Mayneedmoreoften
undersevereconditions.
SeetheEnginemanualfor
additionalinformation.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Loosenretainingclipsandremoveaircleaner
compartmentcover.

3.Removepaperelement.Checkthecondition
ofthepaperelement.Replaceifdirty,bentor
damaged.

4.Checktheconditionoftheinnerelement.Replace
wheneveritappearsdirty,typicallyeveryother
timethepaperelementisreplaced.Cleanthebase
aroundtheinnerelementbeforeremoving,so
dirtdoesnotgetintotheengine.

5.DoNotwashorusepressurizedairtoclean
paperelementorinnerelement.

6.Reinstallelements.Positionthecoversothatthe
rubberdustejectorispointingdownwardand
securewithretainingclips.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseislocatedonrighthandside
ofengine.Placepanundermachinetocatchoil.
Removeplugfromendofdrainhose.Allowoil
todrainandreplaceoildrainplug.Torqueplug
to20-24ft-lb.

4.Replacetheoilltereveryotheroilchange.Clean
aroundoillterandunscrewltertoremove.
Beforereinstallingnewlter,applyathincoating
ofoilonthesurfaceoftherubberseal.Turn
lterclockwiseuntilrubbersealcontactsthelter
adapterthentightenlteranadditional1/2to
3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto
speciedcapacityandreplacecap.

6.Useoilrecommendedinengineowner’smanual.
DoNotoverll.Starttheengineandcheckfor
leaks.Stopengineandrecheckoillevel.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.

2.Cleanareaaroundhydraulicreservoircapand
removecap.Oillevelshouldbetothetopofthe
bafeinsidethetank.Ifnot,addoil.UseExmark
PremiumHydrooil.Replacehydraulicreservoir
capandtightenuntilsnug.DoNotovertighten.

Note:Thebafeislabeled“HOT”and
“COLD”.Theoillevelvarieswiththe
temperatureoftheoil.The“HOT”levelshows
thelevelofoilwhenitisat225°F(107°C).The
“COLD”levelshowstheleveloftheoilwhen
itisat75°F(24°C).Filltotheappropriatelevel
dependinguponthetemperatureoftheoil.For
example:Iftheoilisabout150°F(65°C),llto
halfwaybetweenthe“HOT”and“COLD”levels.
Iftheoilisatroomtemperature(about75°F
(24°C)),llonlytothe“COLD”level.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May
needmoreoftenunder
severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto12–14psi(83–97kPa).

25

Maintenance

4.Inatetirestopressuresstatedabove.Measure
thecircumferenceofeachdrivetire.Adjusttire
pressureswithintheaboverangetotrytomake
tirecircumferencesmatchascloselyaspossible.

5.ForSerialNos.599,999andLower:Checkthe
tirepressureinthepneumaticfrontcastertires.
Adjustthetirepressureto16psi(110kPa).

Note:Frontcastertireshavepermanenttire
sealantinstalled.

ForSerialNos.600,000andHigher:

Semi-pneumaticcastertiresdonotneedtobe
inated.

Note:DoNotaddanytypeoftirelinerorfoam
llmaterialtothetires.Excessiveloadscreatedby

foamlledtiresmaycausefailurestothehydrodrive
system,frame,andothercomponents.Foamlling
tireswillvoidthewarranty.

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

LubricationChart

Fitting

Locations

2.Front
Caster
Pivots

3.Idler
Pivots
(Mower
Deck)

4.Idler
Pivot(Pump
Drive)

5.Hydro
Control
Arm
Support
Bushings

Initial

Pumps

*0

12

21

22

Numberof

Places

2

*Seestep3forspeciallubricationinstructionson
thefrontcasterpivotsandtheLubricateCaster
WheelHubssectionforspeciallubrication
instructionsonthefrontcasterswheelhubs.

Service

Interval

*Yearly

Yearly

Yearly

40Hours

2.Removethethreemowerdeckbeltshields
tocheckmowerprimaryandsecondarybelt
condition.

3.Lookunderenginedecktocheckthepumpdrive
beltcondition.

4.Checkallidlerarmstobesuretheypivotfreely.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Lubricatettingswithonetotwopumpsof
NGLIgrade#2multi-purposegungrease.

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

1.Front
Caster
WheelHubs

Initial

Pumps

*0

Numberof

Places

2

Service

Interval

*Yearly

Number4(IdlerPivot(PumpDrive)Located

UnderEngineDeck

3.Lubricatefrontcasterpivotsonceayear.Remove
hexplugandcap.Threadgreasezerkinholeand
pumpwithgreaseuntilitoozesoutaroundtop
bearing.Removegreasezerkandthreadplugback
in.Placecapbackon.

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

26

Figure12

1.Sealguard2.Spacernutwithwrench
ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxle
assemblyinthecasterwheel.Notethatthread
lockingadhesivehasbeenappliedtolockthe
spacernutstotheaxle.Removetheaxle(with
theotherspacernutstillassembledtoit)from
thewheelassembly .

5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1
multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Seals(ExmarkPN103-0063)mustbe
replaced.

8.Iftheaxleassemblyhashadbothspacernuts
removed(orbrokenloose),applyathreadlocking
adhesivetoonespacernutandthreadontothe
axlewiththewrenchatsfacingoutward.Do
Notthreadspacernutallofthewayontotheend
oftheaxle.Leaveapproximately1/8inch(3mm)
fromtheoutersurfaceofthespacernuttothe
endoftheaxleinsidethenut.

9.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.

10.Withtheopenendofthewheelfacingup,ll
theareainsidethewheelaroundtheaxlefullof
NGLIgrade#1multi-purposegrease.

11.Insertthesecondbearingandnewsealintothe
wheel.

12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.

Maintenance

13.T orquethenutto75-80in-lb(8-9N-m),loosen,
thenre-torqueto20-25in-lb(2-3N-m).Make
sureaxledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully .

Important:Topreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthe
castertire.Thetireshouldnotspinfreely
(morethan1or2revolutions)orhaveanyside
play.Ifthewheelspinsfreely,adjusttorqueon
spacernutuntilthereisaslightamountofdrag.
Reapplythreadlockingadhesive.

RemoveEngineShroudsand
CleanCoolingFins

ServiceInterval:Every80hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removecoolingshroudsfromengineandclean
coolingns.Alsocleandust,dirt,andoilfrom
externalsurfacesofenginewhichcancause
impropercooling.

3.Makesurecoolingshroudsareproperly
reinstalled.Operatingtheenginewithout
coolingshroudswillcauseenginedamagedueto
overheating.

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps,
orreplacewithnewplugs.SeeEngineOwners
Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledinthefuellinebetweenthe
fueltankandtheengine.Replacewhennecessary.

ReplacementFilters

Kawasaki

KawasakiP/N
49019–7001

27

Maintenance

ChangeHydraulicSystem
Filter

ServiceInterval:Aftertherst250hours

Every500hours/Yearly
(whichevercomes
rst)thereafter
(Every250hours/Yearlyif
usingMobil115W50)

Note:UseonlyExmarkPartNo.109-4180for

Summeruseabove32°F(0°C)orP/N1-523541for
Winterusebelow32°F(0°C)(RefertoTransmission
sectioninSpecicationsforlterspecications).

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Carefullycleanareaaroundlter.Itisimportant
thatnodirtorcontaminationenterhydraulic
system.

3.Unscrewltertoremoveandallowoiltodrain
fromreservoir.

Important:Beforereinstallingnewlter,ll
itwithExmarkPremiumHydrooilandapply
athincoatofoilonthesurfaceoftherubber
seal.

mainpumpasshowninFigure13)mayhavelost
their“prime”.RefertoHydraulicSystemAir
Purgesection.

Note:DoNotchangehydraulicsystemoil(except
forwhatcanbedrainedwhenchanginglter),unless
itisfelttheoilhasbeencontaminatedorbeen
extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic
systembyintroducingcontaminatesintothesystem.

HydraulicSystemAirPurge

ServiceInterval:Asrequired

Airmustbepurgedfromthehydraulicsystem
whenanyhydrauliccomponents,includingoil
lter,areremovedoranyofthehydrauliclinesare
disconnected.

Thecriticalareaforpurgingairfromthehydraulic
systemisbetweentheoilreservoirandeach
chargepumplocatedonthetopofeachvariable
displacementpump(Figure13).Airinotherpartsof
thehydraulicsystemwillbepurgedthroughnormal
operationoncethechargepumpis“primed”.

Turnlterclockwiseuntilrubbersealcontactsthe
lteradapter,thentightenthelteranadditional
2/3to3/4turn.

4.FillreservoirasstatedinCheckHydraulicOil

Level.

ExmarkPremiumHydroOilisrecommended.
Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro
Oil(Preferred)

Mobil115W50

5.Loosenlter1/2turnandallowasmallamount
ofoiltoleakfromtheoillter(thisallowsairto
bepurgedfromtheoillterandsupplyhosefrom
thehydraulicreservoir).Turnlterclockwise
untilrubbersealcontactsthelteradapter.Then
tightenthelteranadditional2/3to3/4turn.

6.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely.

7.Ifeitherdrivewheeldoesnotrotate,oneorboth
ofthechargepumps(locatedonthetopofthe

ChangeInterval

500Hours

250Hours

28

Figure13

1.Chargepumpcap2.Loosen11/2turnsonly

Maintenance

asteadyowofoiltoowoutfromunderthe
housing.Retightenthecapscrews.Dothisfor
bothpumps.

Note:Hydraulicreservoircanbepressurizedup
to5psitospeedthisprocess.

6.Ifeitherdrivewheelstilldoesnotrotate,stop
andrepeatsteps4and5abovefortherespective
pump.Ifwheelsrotateslowly,thesystemmay
primeafteradditionalrunning.Checkoillevel
asstatedinChecktheHydraulicOilLevel
section.

7.Allowunittorunseveralminutesafterthecharge
pumpsare“primed”withdrivesysteminthefull
speedposition.CheckoillevelasstatedinCheck
theHydraulicOilLevelsection.

8.Checkhydrodrivelinkageadjustmentasstatedin
HydroDriveLinkageAdjustmentsectionin
Adjustments.

FuelTank—Mounting

1.Stopengineandwaitforallmovingpartstostop.
Raisetherearofthemachineupontojackstands
highenoughtoraisethedrivewheelsoffthe
ground.

2.CheckoillevelasstatedinCheckHydraulicOil
Levelsection.

3.Startengineandmovethrottlecontrolaheadto
fullthrottleposition.Movethespeedcontrol
levertothemiddlespeedpositionandplacethe
driveleversinthe“drive”position.

Ifeitherdrivewheeldoesnotrotate,itispossible
toassistthepurgingofthechargepumpby
carefullyrotatingthetireintheforwardposition.

Note:Itisnecessarytolightlytouchthecharge
pumpcapwithyourhandtocheckthepump
temperature.Ifthecapistoohottotouch,turn
offengine.Thepumpsmaybedamagedifthe
pumpbecomestoohot.

Ifeitherdrivewheelstilldoesnotrotatecontinue
withstep4.

4.Thoroughlycleantheareaaroundeachofthe
chargepumphousings.

5.To“prime”chargepump,loosentwohexsocket
headcapscrews(showninFigure13)11/2turns
only.Makesureengineisnotrunning.Lift
thechargepumphousingupwardandwaitfor

HardwareSpecications

ServiceInterval:Asrequired

Wheninstallingthenutsonthefueltankstuds,fully
tightenthenylocnutandbackoff1/2turn.This
allowsfornormalfueltankexpansionandcontraction
withchangesintemperatureandfuellevels.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242”
or“Fel-Pro,Pro-LockNutType”areusedonthe
followingfasteners:

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol
arms.

•Shoulderboltsinendsofspeedcontrolcrank.

•OPCleversetscrews.

•Electricclutchretainingbolt.

•Pumpdriveidlerpivotbolt.

•Thumblatchscrewthreadsonhandles.

•Casterwheelspacernuts.

•Fueltankbulkheadttingnuts.

Adhesivessuchas“LoctiteRC/609orRC/680”or
“Fel-ProPro-LockRetainingIorRetainingII”are
usedonthefollowing:

29

Maintenance

•OPCleverhubsandcross-shaft

Note:Caremustbeusednottobondthe
bearing,nexttoeachOPChub,tothecross-shaft
whichcouldcausebindingoftheOPCleversand
erraticoperation.

•Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or
Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused
inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing
locations:

OnthreadsofBladeBoltsSerialNos.540,000and
Higher.SeeCheckMowerBladessectionfor
instructions.

Adjustments

Note:DisengagePTO,shutoffengine,waitfor
allmovingpartstostop,engageparkingbrake,and
removekeybeforeservicing,cleaning,ormakingany
adjustmentstotheunit.

DeckLeveling

SeeAdjustingtheCuttingHeightsectionin
Operation.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

BladeDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

BrakeAdjustment

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.

1.Shutoffengineandwaitforallmovingpartsto
stop.

2.Disengagetheparkbrake.

3.Removethehairpinintheparkbrakelinkage.
Turnthelinkageintheyokeuntilthereis3/16
inch(4.8mm)to1/4inch(6.4mm)clearance
betweentheparkbraketirebarsandthetireswith
theparkbrakedisengaged.Re-installthehairpin.

SpeedControlLinkage
andNeutralSafetySwitch
Adjustment

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Movespeedcontrollever(locatedonconsole)to
thefullforwardpositionandcheckorientationof
tabsontheendsofthespeedcontrolcrank,see
Figure14.Thesetabsshouldbepointingstraight
downatthe6o’clockpositionorslightlyforward.
Adjustthreadedyokeatthebottomofspeed

30

Maintenance

controllinkageuntiltabsarepositionedcorrectly.
SeeFigure14.

3.Pullspeedcontrolleverbacktoneutral.Check
thattheneutralsafetyswitchactuatingtabhas
depressedtheplungeroftheswitchsothatthere
isabout5/16inch(7.9mm)betweenthetaband
theswitchasshowninFigure14.Ifnecessary,
movetheswitchforeandaft.

Figure14

Viewedfromleftsideofunit

1.NeutralSafetySwitch3.5/16inch(7.9mm)

2.ActuatingT abinneutral
position

5.Adjusttheneutralcontrollinkageuntilthe
respectivedrivewheelstopswhentheleveris
pulledagainsttheneutralspring(neutralposition).
Turntheadjustingboltapproximately1/4turn
clockwiseifthewheelisturninginreverseorturn
theboltapproximately1/4turncounterclockwise
ifthewheelisturningforward.Releasethedrive
levertotheforwarddrivepositionandsqueeze
backintotheneutralposition.Checktoseeifthe
wheelstops.Ifnot,repeattheaboveadjustment
procedure.

6.Makethisadjustmentonbothsides.

7.Afteradjustmentsaremadeandthewheelsstop
whenthedriveleverisintheneutralposition,
tightenthenutagainsttheyokes.

NeutralControlLinkages
Adjustment

1.Raisetherearofthemachineupontojackstands
highenoughtoraisethedrivewheelsoffofthe
ground.

2.Starttheengineandmovethethrottleaheadto
thefullthrottleposition.Placetheneutrallock
latchesinthe“forward”positionasshownin
Figure4andmovethespeedcontrollevertothe
“mid-speed”position.

Note:Theparkbrakemustbedisengagedand
theOPCleversmustbehelddownwheneverthe
speedcontrolleverisoutoftheneutralposition
ortheenginewillkill.

3.Squeezetherespectivedriveleveruntilan
increasedresistanceisfelt;thisiswhereneutral
shouldbe.

Ifthewheelturnswhileholdingthedriveleverin
neutral,theneutralcontrollinkagesneedtobe
adjusted.Ifwheelsstopthengotostep7.

Figure15

1.NeutralControlLinkage

2.HydroControlLinkage

3.DriveLeverLinkage7.Y oke

4.SpeedControlLinkage

5.Adjusthere;rotateat
approximately1/4turn
increments

6.Loosennut

HydroControlLinkage
Adjustment

1.Placethespeedcontrolleverinthe“neutral”
position.Thisadjustmentisagainmadewithrear
ofmachineonjackstandsandenginerunning
atfullthrottle.OPCleverswillhavetobeheld
downwheneverspeedcontrolleverismovedout
ofneutralposition.

4.Loosenthenutagainsttheneutralcontrollinkage
yokeasshowninFigure15

Note:Theneutrallocklatchesshouldstillbe
“unlocked”andinthe“forward”position.

31

Maintenance

2.Loosenthefrontnutonlefthydrocontrollink
asshowninFigure16.Turntherearcontrol
linkageadjustingnutcounterclockwiseuntilwheel
rotatesforward.Turntherearnutofleftcontrol
linkclockwise1/4ofaturnatatime,stopping
tomovethespeedcontrolforwardandbackto
neutral,untilleftwheelstopsrotatingforward.
Turnthenutanadditional1/2turnandtighten
thefrontjamnutmakingsurenottoputabind
onthelinkage.Makesureatpartoflinkageis
perpendiculartopinpartofswivel.SeeFigure16.

Figure16

1.LeftHydroControlLink
(leftsideshown)

2.Frontnut5.Linkageinincorrect

3.Rearnut

4.Linkageisperpendicular
topin(correctposition)

position

6.Endviewofswivel

DriveLeverLinkage
Adjustment

1.Withrearofmachinestillonjackstandsand
enginerunningatfullthrottle,movethespeed
controllevertothemidwayposition.Movethe
respectivedriveleverupwarduntilitreachesthe
neutralpositionandengageneutrallocklatches
seeFigure17.Ifthetirerotatesineitherdirection,
thelengthofthedriveleverlinkagewillneedto
beadjusted.

Figure17

Afteradjustingthelefthydrocontrollinkage,
movethespeedcontrollevertothemid-speed
positionandthenbacktotheneutralposition.
Rechecktheleftdrivewheelrotationtoseeif
furtheradjustmentisnecessary-besurethespeed
controlleverisintheneutralposition.

Important:Ifinconsistentneutraloccurs,
checktobesurebothspringsareproperly
tightenedonthespeedcontrolleverunderthe
console–especiallytherearpivotspring.

3.Placethespeedcontrolleverinneutral.Adjust
therightsidelinkagebyturningthequicktrack
knobcounterclockwiseuntilthetirebeginsto
rotateforward.Begintoretightentheknob
clockwiseabout1/4turnatatime,stoppingto
movethespeedcontrolforwardandbackto
neutral.Recheckthedrivewheelrotationtoseeif
furtheradjustmentisnecessary.

4.Thespringthatkeepstensionontheknobshould
normallynotneedadjustment.However,if
adjustmentisneeded,adjusttowherelengthof
springisabout1inch(2.5cm)betweenwashers.
Adjustspringlengthbyturningnutatfrontof
spring.

2.Adjustthelinkagelengthbylooseningthejam
nutsatbothendsofthelinkageandrotatingthe
linkageintheballjoints.Lengthenthelinkage
ifthetireisturninginreverseandshortenthe
linkageifthetireiscreepingforward.Tightenthe
jamnutsatbothends.Releaseandre-engagethe
neutrallockcheckingthatthetirestops.Continue
thisprocessuntilthetireisatadeadstop.

3.Makethisadjustmentforbothsides.

TrackingAdjustment

1.Stopengineandwaitforallmovingpartstostop.
Raiserearofmachine,removejackstands,and
carefullylowermachinetotheground.

2.Checkthedrivetirepressuresandtire
circumferencesasstatedinChecktheTire
PressuressectioninMaintenance.

3.Runtheunitandobservethetrackingonalevel,
smooth,hardsurfacesuchasconcreteorasphalt.

4.Iftheunittrackstoonesideortheother,turnthe
quicktrackknob.Turntheknobrightto“steer”
right,turntheknobleftto“steer”left.

32

Maintenance

HydroPumpSpringTension
Setting

1.Formediumorheavydutydriveconditionssuch
asoperationwithasulkyonsteepslopes,ahigher
springforcemayberequiredonthehydropump
controlarmstopreventthedrivesystemfrom
stalling.

2.Foraheavierdrivesetting,relocatethespring
anchorlinkasshowninFigure13.Thespring
anchorlinksarelocatedundertheenginedeckon
theleftandrighthandsides.

Note:In“medium”or“heavyduty”positions,
thedriveleverforcesattheupperhandlewillalso
beincreased.

Cleaning

CleanGrassBuild-UpUnder
Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Raisedecktothetransport(maximumcutting
height)position.Liftthefrontofunitandsupport
unitusingjackstandsorequivalentsupport.

CAUTION

Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.

Figure18

1.Heavyduty

2.Mediumduty4.Retainingbolt

3.Standard

ElectricClutchAdjustment

Noadjustmentnecessary.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof
deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto
theenvironment.Disposeofusedoilatacertied
recyclingcenteroraccordingtoyourstateandlocal
regulations.

33

Maintenance

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

Federallawstatesthatbatteriesshouldnotbeplaced
inthegarbage.Managementanddisposalpractices
mustbewithinrelevantfederal,state,orlocallaws.

Ifabatteryisbeingreplacedoriftheunitcontaining
thebatteryisnolongeroperatingandisbeing
scrapped,takethebatterytoalocalcertiedrecycling
center.Ifnolocalrecyclingisavailablereturnthe
batterytoanycertiedbatteryreseller.

34

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused
byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor
itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have
thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank.

Enginewillnotstart,startshard,orfailsto
keeprunning.

1.PTOisengaged.

2.Speedcontrolleverisarenotinneutral
lockposition.

3.OPCleversarereleased.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose
orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Thethrottleandchokearenotinthe
correctposition.

4.Dirtinfuellter.4.Replacethefuellter.

5.Dirt,water,orstalefuelisinthefuel
system.

6.Aircleanerisdirty.

7.Electricalconnectionsarecorroded,loose
orfaulty.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Faultysparkplug.

10.Sparkplugwireisnotconnected.

1.DisengagethePTO.

2.Ensurethespeedcontrolleverisinthe
neutrallockposition.

3.DepressOPClevers.

5.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Besurethethrottlecontrolismidway
betweenthe“SLOW”and“F AST”
positions,andthechokeisinthe“ON”
positionforacoldengineorthe“OFF”
positionforawarmengine.

5.ContactanAuthorizedServiceDealer.

6.Cleanorreplacetheaircleanerelement.

7.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

9.Clean,adjustorreplacesparkplug.

10.Checkthesparkplugwireconnection.

Enginelosespower.

Engineoverheats.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe
engineareplugged.

5.Ventholeinthefuelcapisplugged.

6.Dirtinfuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel
system.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling
nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

2.Addoiltothecrankcase.

35

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Mowerpullsleftorright(withleversfully
forward).

Machinedoesnotdrive.

Unevencuttingheight.

Abnormalvibration.

1.Trackingneedsadjustment.1.Adjustthetrackingbyturningknobonthe

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor
broken.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

7.Tipsofadjacentbladesareatanuneven
cuttingheight.Bladestipsshouldbeeven
within3/16inchwhichisapproximately
onebladethickness.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade
pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

7.Beltisdamaged.7.Installnewbelt.

righthydrocontrollinkageinthedirection
thatthemowerneedstobeadjustedto.
Turntheknobin1/4turnincrements
untilthemowertrackscorrectly.

2.Changethebelt.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

Bladesdonotrotate.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Drivebeltisoffpulley .2.Checkbeltfordamage;replaceif

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler

5.Brokenormissingidlerspring.

necessary.Installdrivebeltandcheck
adjustingshaftsandbeltguidesforcorrect
position.

pulley,idlerarmandspringforcorrect
positionandfunction.

5.Replacethespring.

36

Schematics

G006174

3. START

POSITION

1

. OFF

2. RUN

B + L + S

CIRCUIT "MAKE"

B + L

G + M

IGNITION SWITCH

TERMINAL CONNECTIONS

TERMINAL L PTO, HOUR METER, ENGINE,

SAFETY MODULE

TERMINAL G GROUND (-)

TERMINAL B BATTERY (+)

TERMINAL S STARTER SOLENOID

TERMINAL M ENGINE KILL

SAFETY

INTERLOCK

MODULE

HOUR

METER

OPC

SWITCH

PTO

SWITCH

KEY

SWITCH

TRANSMISSION

NEUTRAL

SWITCH

BRAKE

SWITCH

FUSE

BLOCK

ENGINE

GROUND

B+

STARTER

SOLENOID

ELECTRIC

CLUTCH

(PTO)

PINK

BLACK

BLACK

ORANGE

ORANGE

WHITE/BLACK

WHITE/BLACK

LT. BLUE

ORANGE

ORANGE

B

ROWN

BROWN

GREY

YELL

OW/BLACK

ORANGE

DK. BLUE

BLACK/WHITE

BLACK/WHITE

BLACK/WHITE

BROWN

BROWN

WHITE/BLACK

BLACK

BLACK

ORANGE

ORANGE

YELLOW

YELLOW

YELLOW

YELLOW/BLACK

YELLOW

LT. BLUE

RED

GREY

BLACK

BLACK

BLACK

BLACK

BLACK/WHITE

WHITE/BLACK

PINK

RED

ORANGE

ORANGE

VIOLET

DK. BLUE

WHITE/BLACK

WHITE/BLACK

VIOLET

ORANGE

NOTES:

CONNECTORS SHOWED FROM WIRE END.

GREY

GREY

ORANGE

ORANGE

TERMINAL B

TERMINAL G

TERMINAL L

TERMINAL M

TERMINAL S

SWITCH IS CLOSED WITH

BRAKE ENGAGED

SWITCH IN - BROWN TO YELLOW/BLACK

SWITCH OUT - ORANGE TO GREY

CLOSED WHEN IN NUETRAL

OPEN WHEN IN NEUTRAL

SWITCH IS CLOSED WHEN

OPC LEVERS ENGAGED

Schematics

ElectricalDiagram

37

Schematics

HydraulicDiagram

38

Conditions and Products Covered

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

This warranty applies to Exmark commercial turf equipment
sold in the U.S. or Canada. This warranty may only be
assigned or transferred to a second (or third) owner by an
authorized Exmark dealer. The warranty period commences
upon the date of the original retail purchase.

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine 2 years*

* The Engine warranty is covered by the engine manufacturer.
Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet.

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized 
 Exmark Service Dealer.

• Any damage or deterioration due to normal use, wear and 
 tear, or exposure.

• Cost of regular maintenance service or parts, such as filters, 
 fuel, lubricants, tune-up parts, and adjustments.

• Any product or part which has been altered or misused or 
 required replacement or repair due to normal wear,  
 accidents, or lack of proper maintenance.

• Any repairs necessary due to use of parts, accessories or 
 supplies, including gasoline, oil or lubricants, incompatible 
 with the turf equipment or other than as recommended in 
 the operator's manual or other operational instructions 
 provided by Exmark.

There are no other express warranties except for engine and
special emission system coverage.

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

Instructions for Obtaining Warranty Service

The product must be registered with original proof of purchase
by an Exmark Service Dealer before obtaining any warranty
service.

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

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

 Exmark Customer Service Department
 The Exmark Warranty Company
 2101 Ashland Avenue
 Beatrice, NE 68310
 402-223-6375 or
 [e-mail]

Owner’s Responsibilities

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

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair or replacement of
defective components as set forth herein. Neither Exmark

nor Exmark Warranty Company shall be liable for any
incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other  
 extraordinary repair charges or charges relating to repairs or
 replacements outside of normal business hours at the place 
 of business of the authorized Exmark Service Dealer.

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

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that 
 covered by the terms of this warranty.

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

• Attorney's fees.

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

All implied warranties of merchantability (that the
product is fit for ordinary use) and fitness for use (that the
product is fit for a particular purpose) are limited to the
duration of the express warranty.

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

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

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-425

39

Notes:

40

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

414243

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES A ND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

©2008ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-361Rev .A
[phone]
Fax[phone]
PrintedintheUSA

www.exmark.com