Exmark TT23KAEP User Manual

TURFTRACER®

TT23KAEPMODELONLY

ForSerialNos.
790,000&Higher

PartNo.4500-382Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.

Important:Whenthemowerisusedoroperated
onanyCaliforniaforest,brushorgrasscovered
land,aworkingsparkarrestermustbeattached
tothemufer.Ifnot,theoperatorisviolating
statelaw,Section4442PublicResourceCode.T o
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.................................................20

Maintenance.........................................................21

RecommendedMaintenanceSchedule(s)...........21

PeriodicMaintenance.......................................22

CheckEngineOilLevel.................................22

CheckBatteryCharge....................................22

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

CheckSafetyInterlockSystem.......................23

CheckforLooseHardware............................24

ServiceAirCleaner........................................24

ChangeEngineOil........................................24

CheckHydraulicOilLevel.............................24

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

CheckConditionOfBelts..............................25

LubricateGreaseFittings...............................25

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

RemoveEngineShroudsandCleanCooling

Fins...........................................................26

CheckSparkPlugs.........................................26

ChangeHydraulicSystemFilter.....................27

WheelHub-SlottedNutTorque

Specication..............................................28

ThreadLockingAdhesives.............................28

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................29

Copper-BasedAnti-seize..............................29

DielectricGrease...........................................29

Adjustments.....................................................29

DeckLeveling...............................................29

PumpDriveBeltTension...............................29

DeckBeltTension.........................................29

BladeDriveBeltTension..............................29

BrakeAdjustment..........................................29

SpeedControlLinkageandNeutralSafety

SwitchAdjustment....................................29

NeutralControlLinkagesAdjustment............30

HydroControlLinkageAdjustment...............30

DriveLeverLinkageAdjustment...................31

TrackingAdjustment.....................................31

HydroPumpSpringTensionSetting..............32

ElectricClutchAdjustment............................32

Cleaning...........................................................32

CleanGrassBuild-UpUnderDeck................32

WasteDisposal..............................................32

Troubleshooting...................................................34

Schematics...........................................................36

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/Yellowbackground.
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.

1–303102

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

103-2076

1-303517

103-5354

1-403143

1-413214

1-513747

10

Safety

103-2432

103-4935

116-0404

11

Specications

Specications

ModelNumbers

SerialNos:790,000andHigher

TT23KAEP

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:12V olt

•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)

Quantity

Tread

Size18x8.50-811x4.00-5

PlyRating

Pressure

22

TurfMasterSmooth

4

14psi(96kPa)

CuttingDeck

•ModelNumbers:

–FMD524

–FMD604

•CuttingWidth:

–52inch(132.1cm)

–60inch(152.4cm)

Dimensions

Semi-Pneumatic

OverallWidth:

52inchDeck60inchDeck

DeectorUp53.4inches

(135.6cm)

DeectorDown64.8inches

(164.6cm)

61.4inches
(156.0cm)

73.0inches
(185.4cm)

OverallLength:

52inchDeck60inchDeck

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

OverallHeight:

52inchDeck60inchDeck

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

•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)

–60inchDeck:5.5inches(14.0cm)

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)

•CuttingHeightAdjustment:

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

•MulchingKit:Optional

•Bagger:Optional

13

ProductOverview

TorqueRequirements

BoltLocation

CutterHousingSpindle
Nut

BladeMountingBolt
(lubricatewithanti-seize)

EngineDeck/Mower
DeckSupportMount
Bolts

Type1Hardware
–Anti-ScalpRoller
WhizlockNutSeeFigure8

Type2
Hardware–Anti-Scalp
RollerNylocNutSee
Figure8

Type2&3Hardware
–Anti-ScalpRollerHex
CapscrewSeeFigure8

Type3
Hardware–Anti-Scalp
RollerFlangedNylocNut
SeeFigure8

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
Figure8

Type4
Hardware–Anti-Scalp
RollerNylocNutSee
Figure8

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.

leverismovedoutoftheneutralpositionandthe
neutrallocklatchesaremovedintothedriveposition,
asshowninFigure4,andthedriveleversarereleased,
thedrivewheelsareengagedintheforwarddirection.

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

NeutralLockLatches

Locateddirectlyabovethedrivelevers.

Theselatchesallowtheoperatortolockthedrive
leversina“neutral”positionwherethedrivewheels
arenotengagedineitheraforwardorreverse
direction,seeFigure4.

Figure4

1.Latchisinthedrive
position

2.Rotatebackforneutral
lockposition

3.Neutral7.Reverse-squeezedrive

4.Fullspeedforward

5.Neutral-holdinthis
position

6.Forward-releasedrive
lever

lever

ChokeControl

Locatedonthecontrolconsolerighthandside.

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

ThrottleControl

Locatedonthecontrolconsole’srightside.

Thethrottleisusedtocontrolenginespeed.Moving
thethrottlecontrolforwardwillincreaseenginespeed
andmovingittotherearwilldecreaseenginespeed.

SpeedControlLever

Locatedinmiddleofcontrolconsole.

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

DriveLevers

Locatedoneachsideoftheupperhandleassembly
directlybelowthehandlegrips.

Theseleversindividuallycontrolthespeedand
directionofeachdrivewheel.Whenthespeedcontrol

Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.

BrakeLever

Locatedontheleftsideoftheunitabovethe
hydraulictank.

15

Operation

Thebrakeleverengagestheparkbrakeonthedrive
wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe
brake.

Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
engaged.Theunitmustbetieddownandbrake
engagedwhentransporting.

Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.

IgnitionSwitch

Locatedonthecontrolconsole.

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

HourMeter

Locatedonthelefthandsideofconsolejustabove
thePTOswitch.

DriveWheelReleaseValves

Locatedontheleftrearcornerofthehydrostatic
pumps.

Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
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“MIDWAY”position.

2.PullthePTOswitchoutwardtothe“ROTATE”
positiontoengagetheblades.

3.Placethethrottleinthe“FAST”positiontobegin
mowing.

DisengagingthePTO

1.Setthrottleto“MIDWAY”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”,squeeze
thedriveleverstothe“neutral”position(DoNot
squeezethedriveleversallthewaybackasthis
willcausethedrivewheelstogointofullreverse
direction).SeeFigure4.Placethumbsontheupper
portionoftheneutrallocklatchesandmovethemto
therear.SeeFigure4.Releasethedrivelevers.

CAUTION

Iftheneutrallocklatchesarenotcompletely
engagedthedriveleverscouldunexpectedly
slipintotheforwarddriveposition.Ifthe
driveleversslipintothedrivepositionthe
unitcouldlurchforwardandcauseinjuryor
propertydamage.

Besurethepinsprotrudingthroughtheslots
ofeachneutrallocklatcharecompletely
engagedintherearslotofeachlatch.

reversepositionwhiletheoppositedriveleverisin
aforwardpositionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine,
avoidquick,jerkymovementsofthedrivelevers.
Movethedriveleverssmoothlyanddeliberately.

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

DrivinginReverse

Tomoverearwardinastraightline,squeezedrive
leversintothereverseposition.

Toturnleftorright,squeezetherighthanddrivelever
toturnrightandthelefthanddrivelevertoturnleft.

Tomakea“zeroturn”,squeezeeitherthelefthand
ortherighthanddriveleverbackintothereverse
positionwhiletheoppositedriveleverisinaforward
positionatanequalbutoppositespeed.

AdjustingtheCuttingHeight

Toplacethedriveleversinthe“forward”position,
rmlyholdthedrivelevers,placethumbsonthe
upperportionoftheneutrallocklatchesandmove
themforwardtoreleasethedrivelevers.Slowlyand
smoothlyreleasethedrivelevers.

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

WARNING

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

Securelyholddownthefrontoftheunitwhen
thefrontsupportrodhairpinsareremoved.

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

1.Stopthemachineandmovethedriveleverstothe
neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Installhairpinclipsintheholesforthedesired
cuttingheight.SeeFigure5.

Important:T omaintaincorrectcutting
heightandrake,checkthefollowingfor
properadjustment.

18

A.Thefrontandrearhairpinsareinthesame

holeswiththeproperspacersunderthehair
pins.SeeFigure5.

Figure5

1.Decksupportpin

2.CuttingHeight

Operation

Figure6

LeftHandSideShown

B.ThetirepressuresaresetasdirectedinCheck

TirePressuresintheMaintenancesection.

C.Thelengthofthereardecksupportlink

assembliesaverage6.89inches(approximately
67/8inches)(175.01mm)fromthecenterof
theballjointtothecenterofthefarthesthole.
SeeFigure6.

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

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller
position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethedriveleverstothe
neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

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

6.Adjustanti-scalprollersforNormalOperating
Conditions.Placerollersinoneofthepositions
showninFigure7.Rollerswillmaintain3/4
inches(19mm)clearancetothegroundto
minimizegougingandrollerwearordamage.

Note:ForMaximumDeckFlotation,place
rollersoneholepositionlower.Rollersshould
maintain1/4inch(6.4mm)clearancetoground.
DoNotadjustrollerstosupportthedeck.Be
surerollerboltsareinstalledwiththespringdisc
washerbetweenheadoftheboltandmounting
bracket.

19

Operation

Figure7

Forcuttingheightsabove3.5inches(38mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller
mountingbracket

7.Fourtypesofanti-scalprollerassembliesare
available.SeeFigure8todeterminewhich
assemblyhasbeeninstalledontheunit.Torque
hardwareasspecied,orlossofrollermayresult.
SeeFigure8.

2.Cuttingheight

Transporting

TransportingaUnit

WARNING

Loadingthemowerontoatrailerwithout
strongenoughorproperlysupportedramps
couldbedangerous.Therampscould
collapsecausingtheunittofall,whichcould
causeinjury.

•Useproperrampsthataresecuredtothe
truckortrailer.

•Keepfeetandlegsoutfromunderthe
unitwhenloadingandunloading.

•Ifnecessary,useassistancewhenloading .

Besurethefuelshut-offvalveisclosed.

Useaheavydutytrailertotransportthemachine.
Engageneutrallocklatchesandparkbrake,then
blockwheels.

Figure8

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—Torque
to30–35ft-lb(41–47N-m)

11.(Type3)3/8angednylocnutwithoutwasher—T orque
to30–35ft-lb(41–47N-m)

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

(41–47N-m).

Securelyfastenthemachinetothetrailerwithstraps,
chains,cables,orropes.

DoNotrelysolelyontheparkingbraketoholdthe
machineonthetrailer.

Besurethatthetrailerhasallnecessarylightingand
markingasrequiredbylawanduseasafetychain.

20

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Maintenance

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rst100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorquespecications.

WARNING

Theenginecanbecomeveryhot.Touching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

Aftertherst250hours

Beforeeachuseordaily

Every40hours

Every50hours

Every80hours

Every100hours

Every160hours

Every500hours

Every600hours

•Changethehydrauliclter.

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Cleanthegrassbuild-upfromunderthedeck.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethehydrocontrolarmsupportbushings.

•Servicetheaircleaner.(Mayneedmoreoftenundersevereconditions.SeetheEngine
manualforadditionalinformation.)

•Removeengineshroudsandcleancoolingns.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Checkthesparkplugs.

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Replacetheaircleanerelements.(Mayneedmoreoftenundersevereconditions.Seethe
Enginemanualforadditionalinformation.)

21

Maintenance

MaintenanceService

Interval

Monthly

Yearly

MaintenanceProcedure

•Checkthebatterycharge.

•Greasethefrontcasterwheelhubs.

•Greasefrontcasterpivots.

•Greasetheidlerpivots(MowerDeck).

•Greasetheidlerpivot(PumpDrive).

•Lubricatethecasterwheelhubs.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

4.Iftheoillevelislow ,wipeofftheareaaroundthe
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

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

storagewhentheopencircuitvoltagedropsto12.4
volts.

Note:Topreventdamageduetofreezing,battery
shouldbefullychargedbeforeputtingawayfor
winterstorage.

Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebatteryin
thetableandchargethebatteryfortherecommended
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

Allowingbatteriestostandforanextendedperiodof
timewithoutrechargingthemwillresultinreduced
performanceandservicelife.T opreserveoptimum
batteryperformanceandlife,rechargebatteriesin

22

Maintenance

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstated
intheCleanGrassBuild-UpUnderDeck
procedure.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstallblades(iftheywereremoved)inthe
followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure9

1.Installbushinginbladepriortoinstallingbushingin
spindle.

B.Installbushing/bladecombointospindle.

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

WARNING

Incorrectinstallationofthebladeor
componentsusedtoretainthebladecan
bedangerous.Failuretousealloriginal
componentsandassembledasshowncould
allowabladeorbladecomponenttobe
thrownoutfromunderthedeckresultingin
seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,
bladebushings,andbladeboltsasshown.

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

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

Figure10

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

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

C.Applylubricanttothreadsofbladeboltas

neededtopreventseizing.Copper-based

TrytostarttheenginewithOPClevers
disengaged,speedcontrolleverinneutraland
PTOdisengaged-startermustnotcrank.

Trytostartwith,OPCleversdepressed,speed
controlleverinanyspeedbutneutralandPTO

disengaged-startermustnotcrank.

TrytostartwithOPCleversdepressed,
speedcontrolleverinneutralandPTO
engaged-startermustnotcrank..

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

Note:Parkbrakemustbedisengagedbeforethe
speedcontrolleverismovedoutofneutralorengine
willkill.

23

Maintenance

Note:Ifmachinedoesnotpassanyofthesetests,

donotoperate.ContactyourauthorizedEXMARK
SERVICEDEALER.

Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing.

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.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May
needmoreoftenunder
severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

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.Useonly
ExmarkPremiumHydrooil.Replacehydraulic
reservoircapandtightenuntilsnug.DoNot
overtighten.

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.

24

Maintenance

Iftheoilisatroomtemperature(about75°F
(24°C)),llonlytothe“COLD”level.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

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

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.

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

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

1.Front
Caster
WheelHubs

2.Front
Caster
Pivots

3.Idler
Pivots
(Mower
Deck)

4.Idler
Pivot(Pump
Drive)

5.Hydro
Control
Arm
Support
Bushings

Initial

Pumps

*0

*0

12

21

22

Numberof

Places

2

2

40Hours

*Seestep3forspeciallubricationinstructionson
thefrontcasterpivotsandtheLubricateCaster
WheelHubssectionforspeciallubrication
instructionsonthefrontcasterswheelhubs.

Service

Interval

*Yearly

*Yearly

Yearly

Yearly

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removethethreemowerdeckbeltshields
tocheckmowerprimaryandsecondarybelt
condition.

3.Lookunderenginedecktocheckthepumpdrive
beltcondition.

4.Checkallidlerarmstobesuretheypivotfreely .

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

Number4(IdlerPivot(PumpDrive)Located

UnderEngineDeck

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

25

Maintenance

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

Figure11

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.

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.

26

Maintenance

ReplacementFilters

Kawasaki

KawasakiP/N
49019–7001

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.

6.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely .

7.Ifeitherdrivewheeldoesnotrotate,oneorboth
ofthechargepumps(locatedonthetopofthe
mainpumpasshowninFigure12)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(Figure12).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.

ChangeInterval

500Hours

250Hours

27

Maintenance

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

Note:Hydraulicreservoircanbepressurizedup
to5psitospeedthisprocess.

6.Ifeitherdrivewheelstilldoesnotrotate,stop
andrepeatsteps4and5abovefortherespective
pump.Ifwheelsrotateslowly,thesystemmay
primeafteradditionalrunning.Checkoillevelas
statedinChecktheEngineOilLevelsection.

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

8.Checkhydrodrivelinkageadjustmentasstatedin
HydroDriveLinkageAdjustmentsectionin
Adjustments.

Figure12

1.Chargepumpcap2.Loosen11/2turnsonly

1.Stopengineandwaitforallmovingpartstostop.
Raisetherearofthemachineupontojackstands
highenoughtoraisethedrivewheelsoffthe
ground.

2.CheckoillevelasstatedinCheckEngineOil
Levelsection.

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

Ifeitherdrivewheeldoesnotrotate,itispossible
toassistthepurgingofthechargepumpby
carefullyrotatingthetireintheforwardposition.

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

WheelHub-SlottedNut
TorqueSpecication

ServiceInterval:Aftertherst100hours

Whentighteningtheslottednutonthewheelmotor
taperedshaft:

1.Torquetheslottednutto100ft-lb(136N-m).

2.Furthertightenthenutuntilthenextsetofslots
lineupwiththecrossholeintheshaft.

3.Replacecotterpin.

Note:DoNotuseanti-seizeonwheelhub.

FuelTank—Mounting
HardwareSpecications

ServiceInterval:Asrequired

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

Ifeitherdrivewheelstilldoesnotrotatecontinue
withstep4.

4.Thoroughlycleantheareaaroundeachofthe
chargepumphousings.

5.To“prime”chargepump,loosentwohexsocket
headcapscrews(showninFigure12)11/2turns
only.Makesureengineisnotrunning.Lift
thechargepumphousingupwardandwaitfor

ThreadLockingAdhesives

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

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol
arms.

28

Maintenance

•Shoulderboltsinendsofspeedcontrolcrank.

•OPCleversetscrews.

•Electricclutchretainingbolt.

•Pumpdriveidlerpivotbolt.

•Thumblatchscrewthreadsonhandles.

•Casterwheelspacernuts.

•Fueltankbulkheadttingnuts.

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

•OPCleverhubsandcross-shaft

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

•Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or
Food-GradeAnti-seize)

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.

MobilHTSgrease(orfood-gradeanti-seize)isused
inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing
locations:

OnthreadsofBladeBoltsSerialNos.540,000and
Higher.SeeCheckMowerBladessectionfor
instructions.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.

BrakeAdjustment

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
Figure13.Thesetabsshouldbepointingstraight
downatthe6o’clockpositionorslightlyforward.
Adjustthreadedyokeatthebottomofspeed

29

Maintenance

controllinkageuntiltabsarepositionedcorrectly.
SeeFigure13.

3.Pullspeedcontrolleverbacktoneutral.Check
thattheneutralsafetyswitchactuatingtabhas
depressedtheplungeroftheswitchsothatthere
isabout5/16inch(7.9mm)betweenthetaband
theswitchasshowninFigure13.Ifnecessary,
movetheswitchforeandaft.

Figure13

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.

Figure14

1.NeutralControlLinkage

2.HydroControlLinkage

3.DriveLeverLinkage7.Yoke

4.SpeedControlLinkage

5.Adjusthere;rotateat
approximately1/4turn
increments

6.Loosennut

HydroControlLinkage
Adjustment

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

4.Loosenthenutagainsttheneutralcontrollinkage
yokeasshowninFigure14.

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

30

Maintenance

2.Loosenthefrontnutonlefthydrocontrollink
asshowninFigure15.Turntherearcontrol
linkageadjustingnutcounterclockwiseuntilwheel
rotatesforward.Turntherearnutofleftcontrol
linkclockwise1/4ofaturnatatime,stopping
tomovethespeedcontrolforwardandbackto
neutral,untilleftwheelstopsrotatingforward.
Turnthenutanadditional1/2turnandtighten
thefrontjamnutmakingsurenottoputabind
onthelinkage.Makesureatpartoflinkageis
perpendiculartopinpartofswivel.SeeFigure15.

Figure15

1.LeftHydroControlLink
(leftsideshown)

2.Frontnut5.Linkageinincorrect

3.Rearnut

4.Linkageisperpendicular
topin(correctposition)

position

6.Endviewofswivel

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.

DriveLeverLinkage
Adjustment

1.Withrearofmachinestillonjackstandsand
enginerunningatfullthrottle,movethespeed
controllevertothemidwayposition.Movethe
respectivedriveleverupwarduntilitreachesthe
neutralpositionandengageneutrallocklatches
seeFigure16.Ifthetirerotatesineitherdirection,
thelengthofthedriveleverlinkagewillneedto
beadjusted.

Figure16

2.Adjustthelinkagelengthbyreleasingthedrive
leverandremovingclevispinandrotatingthe
linkageinthelowerswivel.Lengthenthelinkage
ifthetireisturninginreverseandshortenthe
linkageifthetireiscreepingforward.Rotatethe
linkageseveralturnsifthetireisrotatingfairly
fast.Butastheadjustmentgetscloser,adjust
thelinkagein1/2turnincrements.Releaseand
re-engageneutrallocklatchcheckingthatthetire
stops.Continuetheseprocessuntilthetireisata
deadstop.

Replacethehairpinbackintoeachclevispin.

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.

31

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.

Figure17

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.

32

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.

Maintenance

33

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.

34

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.

35

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

36

HydraulicDiagram

Schematics

37

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

38

Notes:

39

Notes:

40

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

414243

MI D-MOUN T RIDI NG ACCES SORIES AND O PTIONS

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-FRONT RI DING ACC ESSORI ES AND OPTIO NS

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.4500-382Rev .A
[phone]
Fax[phone]
PrintedintheUSA

www.exmark.com