WARNING
POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating pr actices can result in serious
operator injury or even death.
HOW TO AVOID THE HAZARD
♦ Keep all shields, guards and safety devices (especially the grass
discharge system) in place and in proper working condit ion.
♦ Stop engine and wait for all moving parts to stop. Remove spark
plug wire(s) or remove key before adjust ing, servicing, or
performing maintenance.
♦ If mower deck becomes clogg ed, stop engine and wait for all
moving parts to stop. Remove spark plug wire(s) or r em ove k ey
before cleaning blockage.
♦ Keep hands, feet, and clothing away from power driven parts .
♦ Keep off mower unless seat platf o r m is pr ovided.
♦ Keep others off mower.
WARNING
POTENTIAL HAZARD
♦ Gasoline is harmful or f at a l if swallowed. Long-term exposure to
vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN
♦ Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD
♦ Avoid prolonged breathing of vapors.
♦ Keep face away from nozzle and gas tank/container opening.
♦ Keep away from eyes and skin.
♦ Never siphon by mouth.
IMPORTANT
When the mower is used or oper ated on any California forest, brush or grass covered land, a working
spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442
Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.
Exmark reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products manufactured previously. Exmark, or its
distributors and dealers, accept no responsibility f or variations which may be evident in the actual
specifications of its product s and t he statements and descriptions contained in this publication.
ii
EXMARK PARTS PLUS
PROGRAM
EFFECTIVE DATE: September 1, 1995
Program
If your Exmark dealer does not have the Exmark part in stock,
Exmark will get the parts to the dealer the next business day or
the part will be FREE* Guaranteed!!
How the Program Works
1. If dealer does not have part in stock for a "down" unit at
the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus
shipment of six (6) line items or less.
2. Distributor ships part(s) to dealer or customer, as
requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus
central time, with an Exmark Parts Plus
order of six (6) line items or less.
order, he contacts Exmark by 3:00 p.m.,
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.
5. The customer pays for the part and freight
if it is shipped under the Exmark Parts Plus
and if it arrives in
accordance to the program.
6. Who pays for the part and freight
if it fails to arrive overnight in accordance to the program?
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
1. The dealer not submitting the Exmark Parts Plus
order to his Exmark distributor by 1:00 p.m., the dealer
pays for the part and freight.
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
Exmark pays for the part and freight.
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
pays for the part.
The following restrictions apply -- The Exmark Parts Plus
Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available
only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental
United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air
charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no
responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus
3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus
orders must be received by Exmark by
Program are:
Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and
5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United
Parcel Service size and weight restrictions.
order
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day
or Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps, and wheel motors. These parts can be
ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
iii
CONGRATULATIONS on the purchase of your Exmark Mower. This product has been
carefully designed and manufactur ed to give you a maximum amount of dependability
and years of trouble-free oper at ion.
OPERATOR'S MANUAL
This manual contains assembly, operating, m aintenance, adjustment, and
safety instructions for your Exmark mower.
BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL
IN ITS ENTIRETY.
By following the operating, maintenance and safety instructions, you will prolong
the life of your mower, mainta in it s m aximum efficiency, and promote safe oper ation.
If additional inform at ion is needed, or should you require trained mechanic
service, contact your authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and distribut or s are kept informed of the latest
methods of servicing and are equipped t o pr ovide prom pt and efficient service in the
field or at their service stations. T hey carr y ample stock of service parts or can secure
them promptly for you from the factory.
All Exmark parts are thoroug hly test ed and inspect ed before leaving the factory,
however, attention is required on your part if you are t o obt ain the fullest measure of
satisfaction and performance.
iv
TABLE OF CONTENTS
1. SAFETY............................................................................................PAGE
1.1 Safety Alert Symbol...................................................................................1
1.2 Training.....................................................................................................1
1.3 Preparation.............................................................................................1-3
1.4 Operation ...............................................................................................4-6
1.5 Maintenance & Storage..........................................................................6-7
1.6 Riding Attachments...................................................................................7
1.7 Safety Signs.........................................................................................7-10
2. SPECIFICATIONS
2.1 Model Number ......................................................................................... 11
2.2 Engine..................................................................................................... 11
2.3 Fuel System ............................................................................................ 11
2.4 Electrical System.....................................................................................11
2.5 Safety Interlock System........................................................................... 11
2.6 Steering/Brake Control............................................................................11
2.7 Transmission...........................................................................................11
2.8 Wheel Drive System................................................................................ 11
2.9 Tires........................................................................................................12
2.10 Deck...................................................................................................... 12
2.11 Dimensions.............................................................................................12
2.12 Torque Requirements............................................................................. 13
3. ASSEMBLY INSTRUCTIONS
3.1 to 3.21 Assembly................................................................................13-17
4. OPERATION INSTRUCTIONS
4.1 Controls..............................................................................................17-19
4.2 Pre-Start.............................................................................................19-21
4.3 Operation Instructions........................................................................21-23
4.4 Transporting............................................................................................23
5. MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance.........................................................................24-32
5.2 Adjustments........................................................................................32-37
6. WASTE DISPOSAL
6.1 Motor Oil Disposal...................................................................................37
7. TROUBLE SHOOTING
7.1 Mower Tacks Left or Right.......................................................................38
7.2 Mower Cuts Unevenly..............................................................................38
7.3 Engine Will Not Start .......................................................................... 38-39
8. WIRING DIAGRAM..................................................................................... 40
9. HYDRAULIC DIAGRAM.............................................................................41
10. WARRANTY............................................................................................42-43
v
1. SAFETY
1.1 SAFETY ALERT SYMBOL
This SAFETY ALERT SYMBOL is used both in this manual and on the machine to
identify important safet y messages which must be followed to avoid accidents. This symbol
means:
The safety alert symbol appears above information, which alerts you to unsafe actions or
situations and will be followed by the word DANGER, WARNING, or CAUTION.
DANGER: Indicates an imminently hazardous situation which, if not avoided, WILL result in
death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.
1.2 TRAINING
1.2.1 Regard the Exmark mower as a piece of power equipm ent and t each this regard to
all who operate this unit.
1.2.2 Read the instructions carefully. Familiarize yourself with the cont r ols and the
proper use of the equipment. If the operator(s) or m echanic(s) can not read
English, it is the owner’s responsibility to explain this mater ial t o t hem .
1.2.3 Do not allow operation of this machine by untrained personnel. Never allow
children, teenagers, or people unfamiliar with these instructions to use the mower.
Local regulations may restrict the age of the operator.
1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind
that the operator or user is responsible for accidents or hazards occurring to other
people or their property.
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
1.3 PREPARATION
1.3.1 Evaluate the terrain to det er mine what accessories and attachments are needed to
properly and safely perform the j ob. O nly use accessories and at t achm ents
approved by Exmark.
1.3.2 The use of per sonal pr ot ective equipment, such as (but not limited to) pr otection
for the eyes, ears, feet and head is r ecom m ended.
CAUTION
POTENTIAL HAZARD
♦ This machine produces sound levels in excess of 85
dBA at the operator’s ear when in operation.
WHAT CAN HAPPEN
♦ Exposure to sound levels of 85 dBA or above for
extended periods of time can cause hearing loss.
HOW TO AVOID THE HAZARD
♦ Wear hearing protection when operating this machine.
1.3.3 While mowing, always wear substantial f oot wear and long t r ousers. Do not
operate equipment when barefoot or when wearing open sandals.
- 1 -
1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all
stones, sticks, wires, bones and other f or eign objects which may damage the
equipment or cause personal injury to the operat or or bystander s.
WARNING
POTENTIAL HAZARD
♦ Engine exhaust contains carbon monoxide, which is
an odorless deadly poison.
WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.
HOW TO AVOID THE HAZARD
♦ Do not run engine indoors or in a small confined area
where dangerous carbon monoxide fumes can collect.
DANGER
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable
and highly explosive.
WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can bur n you, ot hers,
and cause property damage.
HOW TO AVOID THE HAZARD
♦ DO NOT smoke while refueling , and stay away from
an open flame or where gasoline fumes m ay be ignited
by spark.
♦ Refuel only in a well ventilated area, or refuel
outdoors.
♦ Store gasoline in an approved container and keep it
out of the reach of children.
♦ Add fuel before start ing the engine. Never remove the
cap of the fuel tank or add fuel when engine is running
or when the engine is hot.
♦ Never fill the fuel tank so that the gasoline level rises
above a level that is 1/2” below the bottom of the filler
neck to allow for gasoline expansion and prevent fuel
spillage.
♦ If fuel is spilled, DO NOT attempt to start the engine.
Move away from the area of the spill and avoid
creating any source of ignition unt il fuel vapors have
dissipated.
- 2 -
DANGER
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable
and highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite g asoline vapors. A fire or
explosion from gasoline can burn you, others, and
cause property damage.
HOW TO AVOID THE HAZARD
♦ Purchase and store gasoline only in an approved
container.
♦ Always place gasoline containers on the ground away
from your vehicle before f illing.
♦ Do not fill gasoline containers inside a vehicle or on a
truck or trailer bed because inter ior car pets or plastic
truck bed liners may insulate the container and slow
the loss of any static charge.
♦ When practical, r emove gas-powered equipment from
the truck or trailer and refuel the equipment with its
wheels on the ground.
♦ If this is not possible, then refuel such equipment on a
truck or trailer from a portable container, rather than
from a gasoline dispenser nozzle.
♦ If a gasoline dispenser nozzle must be used, keep the
nozzle in contact with the rim of the fuel tank or
container opening at all times until fueling is complete.
WARNING
POTENTIAL HAZARD
♦ Gasoline vapor can collect inside enclosed trailers and
may be ignited by electrical sparks or hot
engine/exhaust components.
WHAT CAN HAPPEN
♦ Explosion and fire may occur, resulting in proper t y
damage, personal injury, and/or death.
HOW TO AVOID THE HAZARD
♦ Provide adequate ventilation of any enclosed trailer to
prevent build up of gasoline vapors, especially at floor
level.
♦ Never refuel equipment inside an enclosed tr ailer .
♦ Be sure all fuel tanks and gasoline st or age containers
have proper caps installed to prevent spillage and
minimize vapor escaping into the trailer.
♦ Do not place any equipment that is leaking gasoline in
an enclosed trailer.
- 3 -
1.4 OPERATION
Although hazard control and accident prevention are parti al l y dependent upon the
design and configuration of the equipment, these factors are also dependent upon
the awareness, concern, prudence and proper training of the personnel i nvol ved in
the operation, transport, maintenance and st orage of t he equi pment . It is essential
that all Operator Safety Mechanisms be connect ed and i n operat ing condition prior
to use for mowing.
POTENTIAL HAZARD
♦ Operating engine parts, especially the m uffler, become
extremely hot.
WHAT CAN HAPPEN
♦ Severe burns can occur on contact.
♦ Debris, such as leaves, grass, brush, etc. can cat ch fire.
HOW TO AVOID THE HAZARD
♦ Allow engine parts, especially the muff ler , to cool before
touching.
♦ Remove accumulated debris from muffler and engine area.
♦ Install and maintain in working order a spar k arrester before
using equipment on forest - covered, grass-covered, or
brush-covered unimproved land.
WARNING
WARNING
POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories can become
entangled in rotating part s.
WHAT CAN HAPPEN
♦ Contact with rotating parts can cause traum at ic am putation
or severe lacerations.
HOW TO AVOID THE HAZARD
♦ Do not operate the machine without guards, shields, and
safety devices in place and working.
♦ Keep hands, feet, hair, je welry, or clot hing away from
rotating parts.
1.4.1 Give complete, undivided attent ion t o the job at hand.
1.4.2 Mow only in daylight or good artificial lig ht, keeping away from holes and hidden
hazards. Do Not operate the mower when children or others are in the area!
1.4.3 When feasible, avoid operating the equipment in wet grass.
- 4 -
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction
and/or control could occur. Mow across slopes with walk behind mowers, never
up and down. Loss of control and/or loss of operator’s footing could result in a fall
with an arm or leg getting under t he m ower or engine deck and sustaining serious
injury. Drive slower on slopes. Progressively greater care is needed as t he slope
increases. DO NOT operate on slopes greater than 20 degrees. Watch for
ditches, holes, rocks, dips, and rises, which can cause errat ic handlebar
movement and loss of footing . Keep away from drop-offs and steep banks. Avoid
sudden starts. Look down and behind you before and while moving backwards.
DO NOT mow slopes when grass is wet - slippery conditions create hazardous
footing, affect steering, and reduce traction and braking. The operat or is
responsible for safe operation on slopes. See inside back cover to determine the
approximate slope angle of the area to be mowed.
1.4.5 Stop the blades when crossing surfaces other than grass, if mower must be tilted
for transportation, and when transpor t ing the mower to and from the area to be
mowed.
1.4.6 Never operate the mower with defective guards, shields, or covers. Always have
safety shields, guards, switches, and other devices in place and in proper working
condition.
1.4.7 Do Not change the engine governor sett ings or over-speed the engine. Operating
an engine at excessive speed may increase the hazard of personal injury.
1.4.8 Place speed control levers in neutral lock position, diseng age PTO, and engage
park brake before starting engine.
1.4.9 Start t he engine carefully with feet well away from blades.
1.4.10 Keep hands, feet, and clothing away from rotating parts while the mower is being
operated.
1.4.11 Stop the engine and wait for all moving parts to stop. Remove plug wire(s) or
remove ignition key:
• Before checking, cleaning , or working on the mower.
• After striking a foreign object (inspect the m ower for damage and make
repairs before restart ing and operating the mower).
1.4.12 Stop the engine and wait for all moving parts to stop:
• Before clearing blockages.
• Whenever you leave the mower.
• Before removing the grass catc her .
• Before refueling.
• Before making heig ht adjustments.
1.4.13 Before stopping the eng ine, r e t ur n the throttle control to the idle posit ion for about
one minute to allow the engine to cool down.
1.4.14 The fuel system is provided with a shut-off valve. The fuel shut-off valve is used to
shut off the fuel when:
• The machine will not be used for a few days.
• During transport to and f r om the job.
• When parking inside a building.
1.4.15 This mower was designed for one operator only. Keep all others away fr om m ower
during operation.
1.4.16 Do Not mow without the grass deflector or entir e grass collection system in place
and in proper working condition.
- 5 -
1.4.17 Be aware of the mower discharge direction and do not point it at anyone.
1.4.18 Do NOT operate the mower under the influence of alcohol or drugs.
1.4.19 Use care when approaching blind corners, shrubs, trees, or ot her objects that may
obscure vision.
1.4.20 If jump starting is required: (Electric start unit s only)
a) connect the positive (+) power cable from the posit ive post on t he booster
battery to the positive terminal post on the star ter solenoid switch (this post
has the positive battery cable attached to it).
b) connect the negative or ground cable (-) from the negative post on the
booster battery to the engine block as far away from the battery as possible.
c) disconnect battery cables in the reverse order after start ing.
1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maintenance, follow the eng ine m anufacture’s recommendations
precisely as stated in the engine manual.
1.5.2 Disconnect the battery from t he negative battery post when the unit will be allowed
to sit for more than 30 days without use.
1.5.3 Allowing batteries to stand for an extended period of time without recharging
them will result in reduced performance and ser vice life. To preserve optimum
battery performance and lif e, recharge batteries in storage when the open circuit
voltage drops to 12.4 volts.
Note: To prevent damage due to freezing, battery should be fully charged before
putting away for winter storage.
1.5.4 Keep engine and engine area free from accumulation of grass, leaves, excessive
grease, or oil and other debris, which can accumulate in these areas. These
materials can become combustible and may result in a fir e.
1.5.5 Store fuel in a container specif ically designed for this purpose in a cool, dry place.
1.5.6 Keep the mower and fuel container in locked storage to prevent children from
playing or tampering with them.
1.5.7 Gasoline powered equipment or fuel containers should not be stored in a
basement or any enclosed area, where open pilot lights or heat appliances are
present.
1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly
maintained and operated correctly.
1.5.9 Check all bolts frequent ly to m aintain proper tightness.
1.5.10 Keep all guards, shields, and all safety devices in place and in safe work ing
condition.
1.5.11 Frequently check for worn or deterior ating components that could create a hazard.
1.5.12 All replacement parts must be the same as or equivalent to the parts supplied as
original equipment.
- 6 -
POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure can penetrat e
skin and cause injury.
WHAT CAN HAPPEN
♦ Fluid accidentally injected into the skin must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangr ene m ay result.
HOW TO AVOID THE HAZARD
♦ Make sure all hydraulic fluid hoses and lines are in
good condition an all hydraulic connections and fittings
are tight before applying pressure to hydraulic system.
♦ Keep body and hands away from pinhole leaks or
nozzles that eject high pressure hydraulic fluid.
♦ Use cardboard or paper and not hands to find
hydraulic leaks.
♦ Safely relieve all pressure in the hydraulic system, by
locking drive levers in neutral and shutting off engine,
before performing any work on t he hydraulic system.
1.6 RIDING ATTACHMENTS
WARNING
1.6.1 Use only Exmark riding attachments. The use of other than Exmark riding
attachments may create a hazardous condition resulting in injury.
1.7 SAFETY SIGNS
1.7.1 Keep all safety signs legible. Remove all gr ease, dir t, and debris from saf et y
signs.
1.7.2 Safety signs must be replaced if they are missing or illegible.
1.7.3 When new components are installed, be sur e that current safety signs are affixed
to the replaced components.
1.7.4 New safety signs may be obtained from your authorized Exmark equipment dealer
or distributor or from Exmar k Mfg. Co. Inc.
1.7.5 Safety signs may be affixed by peeling of f the backing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.
1.7.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They are
critical to the safe operation of your Exmark commercial mower.
PART NO. 1-553049
LOCATION: Front of Mower
Deck Top Surface
- 7 -
PART NO. 1-403143
LOCATION: Right Side of Rear
Surface of Engine
Deck
PART NO. 1-303517
LOCATION: Left Side of Rear
Surface of Engine
17 HP Kawasaki Electric Start Only
PART NO. 1-513747
LOCATION: Battery Cover
Deck
PART NO. 1-413421
LOCATION: Left Rear on Top of Engine Deck
PART NO. 1-603845
LOCATION: Rear Center of Top
Surface of Engine Deck
PART NO. 1-413214
LOCATION: Right Side of Hydro
Control Crank Arm
PART NO. 103-1077
LOCATION: On Top LH Side of Mower Deck.
Standard Pistol
Grip Handles
PART NO. 1-303102
LOCATION: Upper Handle
PART NO. 1-303293
LOCATION: On Top RH Side
of Fuel Tank
PART NO. 1-513746
LOCATION: On Engine Blower
Housing Next to Muffler
and On Center Belt Cover
PART NO. 1-403005
LOCATION: RH & LH Corners
of Mower Deck
PART NO. 1-523522
LOCATION: On Top of
Hydraulic Tank
- 8 -
PART NO. 1-303508
LOCATION: Right Front of Mower
Deck Top Surface
Standard Pistol Grip Handles
15 & 17 HP Kawasaki Manual Start
PART NO. 103-1974
LOCATION: Console
PART NO. 103-1798
LOCATION: RH Side
Console
36” Decks
PART NO. 1-413206
LOCATION: Top of Cutter Deck
Under Center Belt Shield
ECS Handles
17 HP Kawasaki Electric Start
PART NO. 103-1976
LOCATION: Console
PART NO. 103-2103
LOCATION: Park Brake
Lever
- 9 -
ECS Handles
15 & 17 HP Kawasaki Manual Start
PART NO. 103-1977
LOCATION: Console
48” & 52” Decks
PART NO. 1-413327
LOCATION: Top Center of Cutter Deck
Under Center Belt Shield
ECS Handles
PART NO. 103-2242
LOCATION: LH Side of Console
PART NO. 98-5954
LOCATION: Under Mower Deck
Belt Shield(s)
PART NO. 1-323540
LOCATION: Front of Mower Deck
Top Surface
ECS Handles
PART NO. 103-2243
LOCATION: RH Side of Console
- 10 -
2. SPECIFICATIONS
2.1 MODEL NUMBER:
Serial Nos. 320,000 & Higher: TT3615KA; TT4817KA; TT5217KA; TT3615KAC;
TT4817KAC; TT5217KAC; TT4817KAEC; TT5217KAEC
2.2 ENGINE
2.2.1 Engine Specifications: See your Engine Owner's Manual.
2.2.2 3600 RPM (No Load).
2.3 FUEL SYSTEM
2.3.1 Capacity: 5.0 gal. ( 18.9 L.)
2.3.2 Type of Fuel: Regular unleaded g asoline, 87 octane or higher. In countries using
the research method, it should be a 90 octane minimum.
2.3.3 Fuel Filter: Replaceable in- line
2.3.4 Fuel Shut-Off Valve: 1/ 4 turn
2.4 ELECTRICAL SYSTEM (Electric start units only)
2.4.1 Charging System : Flywheel Alternator
2.4.2 Charging Capacit y: 15 am ps
2.4.3 Battery Type: BCI Group U1
2.4.4 Battery Voltage: 12 Volt; Polar it y, negative ground
2.4.5 Fuses: Two 20 amp blade type
2.5 SAFETY INTERLOCK SYSTEM
Operator must have speed control lever in neutral, PTO disengaged, (and OPC
levers depressed for electric start ) to start engine. Release of O PC levers will
cause the engine to stop if speed contr ol lever is not in neutral and/or PTO is
engaged.
2.6 STEERING CONTROL:
Fingertip drive control levers provide independent speed control, braking, and
neutral to each drive wheel for moving forward or r everse, stopping, and power
turning.
2.7 TRANSMISSION:
Twin Hydrostatic Drive
2.7.1 Two Hydro Gear BDP-10L series variable displacement high efficiency pumps
independently coupled to two high efficiency Parker / Ross wheel drive motors .
2.7.2 Hydraulic Filter is replaceable cartridge type.
P/N 513211: 10 microns, 18 psi bypass (Summer use above 32°
P/N 523541: 40 microns, 18 psi bypass (Winter use below 32°
F)
F)
2.7.3 Speed Range: Forward 0 - 6.2 mph (10.0 km/h)
Reverse 0 - 2.2 mph (3.5 km/h)
2.8 WHEEL DRIVE SYSTEM:
Drive wheels are direct coupled to Parker/Ross wheel drive motors with 1.0" (25. 4
mm) tapered shaft.
- 11 -
2.9 TIRES
36” Drive 48” & 52” Drive Front Caster
Pneumatic (Air-Filled) Pneumatic (Air-Filled) Semi-Pneumatic
Size 16 x 6.50-8 16 x 7.50-8 9 x 3.50-4
Quantity 2 2 2
Tread Turf Master Turf Master Smooth
Ply Rating 4 4
Pressure 14 psi (97 kPa) 14 psi (97 kPa)
2.10 DECK
2.10.1 Cutting Width:
Model 36 in. ........................................35.25 in. (89.5 cm)
Model 48 in. ........................................47.25 in. (120.0 cm)
Model 52 in. ........................................52.00 in. (132.1 cm)
2.10.2 Discharge: Right Side
2.10.3 Blade Size:
Model 36 in. ..............18.00 in. (45.7 cm) ..............Qty. 2
Model 48 in. ..............16.25 in. (41.3 cm) ..............Qty. 3
Model 52 in. ..............18.00 in. (45.7 cm) ..............Qty. 3
2.10.4 Type of Drive: Manual engagement of belt with over-center lock . Belt tension is
adjustable via turnbuckle.
2.10.5 Deck Mounting: Full floating deck is attached to out-front suppor t frame,
removable for service.
2.10.6 Cutting Height: Adjusts in 1/ 2” (.63 cm) increments from 1. 5” (3.8 cm) to 4 1/2”
(11.4 cm).
2.11 DIMENSIONS
2.11.1 Overall Width: 36” 48” 52”
Discharge chute down
Discharge chute up
(Transport only)
46.25” 58.25” 62.6”
(117.5 cm) (148.0 cm) (159.0 cm)
36.1” 48.1” 53.0”
(91.7 cm) (122.2 cm) (134.62 cm)
2.11.2 Overall Length: 36” 48” 52”
Standard Pistol Grip
Handles
ECS Handles
77.7” 73.7” 75.9”
(197 cm) (187 cm) (193 cm)
77.0” 73.0” 75.2”
(196 cm) (185 cm) (191 cm)
2.11.3 Curb Weig ht: 36” 48” 52”
Standard Pistol Grip
Handles
ECS Handles
537 lbs. 589 lbs. 617 lbs.
(244 kg) (267 kg) (280 kg)
547 lbs. 599 lbs. 627 lbs.
(248 kg) (272 kg) (284 kg)
∗ Weights will vary slightly depending on engine and electric start options.
2.11.4 Overall Height:
Standard Pistol Grip Handles...... 42” (107 cm) (all models)
ECS Handles............................... 44.1” (112 cm) (all models)
2.11.5 Tread W idt h ( t o outside of tires):
36” Model.........................35.0” (88.9 cm)
48” Model.........................39.4” (100.1 cm)
52” Model.........................39.4” (100.1 cm)
- 12 -
2.12 TORQUE REQUIREMENTS
BOLT LOCATION TORQUE
Blade Mounting Bolt.................................................... 115-120 ft-lbs.
Cutter Housing Spindle Nut.............................................. 75-80 ft-lbs.
Anti-Scalp Roller Bolts......................................................40-45 ft-lbs.
Mower Deck Support/Engine Deck Mount........................ 30-35 ft-lbs.
Engine Mounting Bolts
15 &17
HP Kawasaki ........................................ 15-20 ft-lbs.
3. ASSEMBLY INSTRUCTIONS
3.1 UNCRATE UNIT: Remove upper handle assembly, fuel tank, and linkages from the t o p
of the crate.
3.2 SERVICE BATTERY
WARNING: Battery posts, terminals, and related accessories contain lead compounds, chemicals known
to the State of California to cause cancer and reproductive harm. Wash
The machine is shipped with a filled lead acid battery.
3.2.1 Remove battery cover fr om t he m achine.
: (Electric start units only)
hands after handling.
DANGER
POTENTIAL HAZARD
♦ Charging the battery may produce explosive gasses
WHAT CAN HAPPEN
♦ Battery gasses can explode causing serious injury.
HOW TO AVOID THE HAZARD
♦ Keep sparks, flames, or cigarettes away from battery.
♦ Ventilate when charging or using batter y in an
enclosed space.
♦ Make sure venting path of battery is always open once
battery is filled with acid.
3.2.2 Check t he voltage of the battery with a digital voltmet er . Locate the voltage
reading of the batter y in the t able below and charge the battery for the
recommended time interval to bring t he charge up to a full charge of 12.6 volts or
greater.
IMPORTANT: Make sure the negative battery cables are disconnected and the
battery charger used for charging the battery has an output of 16 volts and 7
amps or less to avoid damaging the batter y (see char t below f or r ecom mended
charger settings).
Voltage
Reading
12.6 or greater 100% 16 volts/7 amps No Charging Required
12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes
12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour
12.0 – 12.2 25 – 50% 14.4 volts/4 amps 2 Hours
11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours
11.7 or less 0% 14.4 volts/2 amps 6 Hours or More
Percent
Charge
Maximum
Charger Settings
- 13 -
Charging Interval
CAUTION
POTENTIAL HAZARD
♦ If the ignition is in the “ ON” position there is potential
for sparks and engag em ent of components.
WHAT CAN HAPPEN
♦ Sparks could cause an explosion or moving parts
could accidentally engage causing personal injury.
HOW TO AVOID THE HAZARD
♦ Be sure ignition switch is in the “OFF” position before
charging the battery.
3.2.3 Connect t he negative battery cables.
NOTE: If the positive cable is also disconnected, connect the positive (red)
cable to the positive terminal on the battery first, then connect the negative
(black) cable to the negative ter m inal on t he battery. Reinstall battery cover.
NOTE: If time does not perm it char ging the battery, or if charging equipment is
not available, connect the negative battery cables and run the vehicle
continuously for 20 to 30 minutes to suf ficiently charge the battery.
3.3 Remove and open the bolt bag .
3.4 Loosen the 5/16" hardware at the two (2) discharge chute hing e points so that the
deflector is snug, but can be moved up and down freely.
3.5 Refer to Parts Manual to help you identify and locate part s and their proper position.
3.6 Apply retaining adhesive “Fel-Pro ProLock Retaining I or Retaining II” or “Loctite RC
609 or 680” on the two threaded studs from t he bolt bag and install into the two left
holes underneath fuel tank. I nstall the fuel tank on top of the fuel tank support with the
studs going through the slot s in the support. Install two 5/16 x 3/4 screws with a 5/16
SAE flat washer and 5/16 lock washer into the threaded holes in the right side of the
fuel tank. Do not over ti ght en. Place a 5/16 SAE flat washer, then a spring, over
each of the studs and fasten with a 5/16 nyloc nut. Tighten 5/16 nyloc nut fully then
back off a 1/2 t ur n. This is to allow for normal fuel t ank expansion and contraction with
changes in temperature and fuel levels. Do not over t ighten.
3.7 Attach the fuel tank hose to the tank fitting and secure with the clam p pr ovided.
3.8 Position the lower end of the handle assembly on the outside of t he upper r ear section
of the fuel tank & handle suppor t. Install four 3/8-16 x 1" bolts ( with four spring disk
washers against the head of each bolt) f r om the outside in. Secure using four 3/8"
whizlock nuts on the inside of each handle support and tighten unt il the spring disk
washers are flat (See Figure 1).
FIGURE 1
UPPER HANDLE MOUNTING
- 14 -
3.9 Route the throttle cable along the right side of the upper handle, under the fuel tank
support, and position the cable on the left side of t he engine.
Attach throttle cable to engine:
a) Position the throttle control lever (located on console) ¼” (6mm) from the upper end
of the slot.
b) Attach inner wire of the throttle cable to the top hole in t he throttle control lever as
shown in Figure 2.
c) Loosen the clamp, place the cable behind it and pull on the cable to move the
throttle linkage to t he full throttle position. T ighten the cable clamp screw.
FIGURE 2
SPEED CONTROL
(THROTTLE CABLE HOOK-UP)
3.10 Connect the blade engagement linkages (See Fig. 3). Loosen jam nut and remove
turnbuckle from lower linkage. Screw turnbuckle onto both upper and lower linkag es
simultaneously. Note that threads on upper linkage are left hand. See 5.2. 2 for
linkage adjustment.
Note: The standard pistol grip handles have the drive lever linkage on the
outside of the blade engagement lever tab and the hairpin on the inside. ECS
handles have the drive lever linkage on the inside of the blade engagement
lever tab and the hairpin on the outside.
FIGURE 3
BLADE ENGAGEMENT LINKAGE
3.11 Install the speed control rod assem bly (linkage with the yoke installed on one end)
into the end of the speed control lever located underneath the center of the console.
Insert the end of the link age (opposite the yoke) into the end of t he speed control
lever from the right hand side and fasten with a hairpin from the bolt bag .
- 15 -
3.12 Connect the lower end of the speed control linkage to the speed control crank
located at the top rear of t he fuel tank support. Secure with clevis pin and hairpin
from the bolt bag.
3.13 Install drive lever linkages.
For Standard Pistol Grip Handles: Refer to figures 4 and 5. Position speed
control lever in neutral. Locate two long clevis pins and two hairpin cotters in bolt
bag and temporarily install throug h dr ive levers and neutr al lock latches, but not
through the drive lever linkages. Posit ion dr ive levers and neutral lock latches in
neutral (See Figure 16). Ident ify swivels installed on hydro control arm weldments.
Thread each drive lever linkage into swivel until hole in upper end of dr ive lever
linkage aligns with clevis pin installed through dr ive lever and neutr al lock latch.
Remove clevis pins and install first through t he dr ive lever linkages, then through the
drive levers from the outside , then t hrough the neutral lock latches. I nstall hairpin.
This will give an approximate setting for dr ive lever link ages; you will need to refer to
Section 5.2.6 step d to complete the dr ive lever linkage adjustment.
NOTE: There should NOT be a washer between the neut ral lock latch and the
hairpin cotter.
FIGURE 4
STANDARD PISTOL GRIP HANDLES
DRIVE LINKAGE SWIVEL
FIGURE 5
STANDARD PISTOL GRIP HANDLES
DRIVE LEVER LINKAGE TO DRIVE LEVER
For ECS handles: Refer to f igure 6. Position speed control lever in neutral.
Position drive levers in neutral and engage the neutral lock latches (See Figure 16).
Drive lever linkages are shipped with upper ball joints installed. Thread a 3/8-24 LH
jam nut, from the bolt bag, onto the lower end of each drive lever linka ge. Identify
the lower ball joints installed on hydro control arm weldments. Thread lower end of
each drive lever linkage into the lower ball joint unt il hole in upper ball joint aligns
with hole in drive lever. Install 3/8-16 x 2 hex cap screws and 3/8-16 nyloc nuts from
the bolt bag and tighten. This will give an approximate setting for drive lever
linkages; you will need to refer to Sect ion 5. 2.6 step d to complete the drive lever
linkage adjustment.
- 16 -
FIGURE 6
ECS HANDLES
DRIVE LEVER LINKAGE INSTALLATION
3.14 Connect wiring harness.
For recoil start models: Route the long unat t ached por tion of the wiring harness up
the left handle and under the console. Connect t he connector on the end of the
shorter lead to the keyswitch. Connect the two f lag terminals that are in the longer
lead to the OPC switch in any order. Continue routing t his lead down the right side
of the handle and connect the connector on the end of it to the park brak e switch.
Fasten the harness to the left hand side of the handle using two large ties from the
bolt bag. Fasten the harness to the r ig ht hand side of the handle using two small
ties from the bolt bag. On ECS models fasten the harness to the t wo small holes in
the channel under the console using two small ties from the bolt bag.
For electric start models: Route the long unat t ached portion of the wiring harness
up the left handle and under the console. Connect t he two flag terminals to the OPC
switch in any order. Connect the connector to the keyswitch. Fasten the har ness t o
the left hand side of the handle using two large ties from the bolt bag. On ECS
models fasten the leads connecting to the OPC switch to the small hole in the
channel under the console using a small tie from t he bolt bag.
3.15 If machine is shipped without muffler installed, install muffler with hardware provided.
3.16 SERVICE ENGINE: Refer to Engine Owner’s Manual.
3.17 SERVICE HYDRAULIC OIL
The machine is shipped with hydraulic oil filled to the top of the baffle in the
reservoir. Run the machine for appr oximat ely 15 minutes t o allow any extra air to
purge out of the hydraulic system. Check hydraulic reservoir and if necessary fill the
reservoir to the appropriate level with Mobil 1 15W - 50 synthetic motor oil. See
Section 5.1.8
3.18 GREASE UNIT: NOTE: UNIT IS NOT GREASED AT THE FACTORY.
Refer to 5.1.14, for locations and grease amounts.
3.19 Follow pre-start instructions as outlined in 4.2.
NOTE: After starting the engine and engaging the hydro drive, if either of the
drive wheels acts sluggish or will not rotate at all, stop engine and refer to
Section 5.1.10 on the Hydraulic System Air Purge procedure.
3.20 Perform any needed adjustm ent s as out lined in the Adjustment Section.
- 17 -
4. OPERATION INSTRUCTIONS
4.1 Controls
4.1.1 Operator Pr esence Control (OPC) Levers: Located on the upperhandle assembly
directly above the handle grips. When these levers are depressed, the OPC
system senses that the operator is in the normal operator's position. When
the levers are released, the OPC system senses that the operator has moved
from the normal operating position and will kill the eng ine if either the speed
control lever is not in the neutral position or t he blade clutch is engaged.
4.1.2 Speed Control Lever: Located in m iddle of control console, it controls the m aximum
forward speed and is infinitely variable from neut ral (0 mph) to 6.2 mph.
4.1.3 Drive Levers: Located on each side of the upper handle assem bly direct ly below
the handle grips (See Figure 7). These levers individually control the speed and
direction of each drive wheel. When the speed control lever is moved out of the
neutral position and the neutral lock lat ches are moved into the drive position, as
shown in Figure 7, and the drive levers are released, the drive wheels are engaged
in the forward direction.
Squeezing the left hand and/or r ight hand lever causes the left hand and/or rig ht
hand drive wheel respectively to slow down, stop, or reverse, depending on how far
each drive lever is "squeezed". Squeezing the drive levers beyond the neutral
position causes the drive wheels to engage in the reverse direction regardless of the
position of the neutral lock latches and the speed control lever.
4.1.4 Neutral Lock Latch: Located directly above the drive levers. T hese lat c hes allow the
operator to lock the drive levers in a "neutr a l" posit ion where neither of the drive
wheels are engaged in either a forward or reverse dir ect ion ( See Figure 7).
STANDARD PISTOL GRIP HANDLES ECS HANDLES
FIGURE 7
DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION
4.1.5 PTO Engagement: Locat ed on the left side of the upper handle. To engage the
blades, push the lever forward, or away from the oper at or , until the linkage locks
over-center. To disengage t he blades, pull the lever to the rear, or towards the
operator.
4.1.6 Choke Control: Choke is used to aid in star ting a cold engine.
The choke control is located on the front left corner of the fuel tank support and is
activated by pulling the control outward.
Once the engine has started move the choke control to the off posit ion and m ove
the throttle to the medium or full throttle position.
- 18 -
4.1.7 Throttle Control: Located on t he cont r ol console’s right side. The throttle is used t o
control engine speed. Moving the throttle contr ol forward will increase engine
speed and moving it to the rear will decrease engine speed.
4.1.8 “Off-Run” Switch (15 & 17 HP Kawasaki Manual Start only):
Located on the console. Turn key to the “ Run” posit ion to allow the engine to be
started. Turn key to t he “ O ff” position to shut engine off.
4.1.9 Ignition Switch (17 HP Kawasaki Electric Start only):
Located on the control console. The ignit ion switch starts and stops the engine.
The switch has three positions “OFF”, “O N”, and “START”. Insert key into switch
and rotate clockwise to the “ON” posit ion. Rotate clockwise to the next position to
engage the starter (key must be held against spring pressure in this position).
When engine st arts, release key.
Operator must have speed control lever in neutral and blade engagement
lever fully disengaged to start engine.
4.1.10 Park Brake Lever: Located on the right side of the unit above the hydraulic tank.
The brake lever engages the par k brake on the drive wheels.
Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the brake.
When parking on a steep slope, the wheels must be chocked or blocked in addit ion
to the brake being engag ed. The unit must be tied down and brake engaged when
transporting.
Park brake must be diseng aged to move speed control out of neutral or engine will
kill.
4.1.11 Fuel Shut-Off Valve: Installed in the f uel line m idway between the tank and t he
engine. The fuel shut-off valve is used to shut off the flow of fuel when parking
inside a building, during transport at ion t o and from the job sites, and when the
machine will not be used for a few days.
Rotate valve 1/4 turn clockwise to shut fuel off. Rotate valve 1/4 turn counterclockwise to turn fuel on.
4.1.12 Drive Wheel Release Valves: Located on the top rear corner of the hydrostatic
pumps. Drive wheel release valves are use to release the hydro-static drive system
to allow the machine to be moved by hand without the engine running. Tur n valves
one-half turn counterclock wise to release t he dr ive system.
Turn clockwise to reset the drive system. Do Not over- t i ghten.
4.1.13 Cold Start Kit: (Manual start units only) Located on the right hand side of engine deck,
below the hydro control shield. The cold start kit is used t o ease t he starting of the
unit in cold weather or when the unit has not been operated for a per iod of time. The
cold start kit moves the idler pulley away from the pump belt releasing the tension on
the belt, which allows the engine to turn over with less resistance. See Section 4.3. 2.
4.1.14 Track ing Adjustment Knob: Located on the right- hand side of the rear of the fuel
tank support. Can be adjusted so t hat m achine will “tr ack” straight ahead with
drive levers released.
4.2 Pre-Start
4.2.1 Fill fuel tank. For best results use only clean fresh regular grade unleaded
gasoline with an octane rating of 87 or higher. Regular grade leaded g asoline m ay
also be used; however, combustion chamber and cylinder head will require more
frequent service. See Engine Owner's Manual.
Do not add oil to gasoline.
Never fill the fuel tank so t hat the fuel level rises above a level that is 1/2” below the
bottom of the f iller neck to allow for fuel expansion and prevent fuel spillage.
- 19 -
DANGER
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flamm able and
highly explosive.
WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can bur n you, ot hers, and
cause property damage.
HOW TO AVOID THE HAZARD
♦ DO NOT smoke while refueling , and st ay away from an open
flame or where gasoline fumes ma y be ignit ed by spark.
♦ Refuel only in a well ventilated area, or refuel outdoor s.
♦ Store gasoline in an approved container and keep it out of the
reach of children.
♦ Add fuel before start ing the engine. Never remove the cap of
the fuel tank or add fuel when engine is running or when the
engine is hot.
♦ Never fill the fuel tank so t hat the gasoline level rises above a
level that is 1/2” below the bottom of t he filler neck to allow for
gasoline expansion and prevent fuel spillage.
♦ If fuel is spilled, DO NOT attempt to start the engine. Move
away from the area of the spill and avoid creating any source
of ignition until fuel vapors have dissipated.
DANGER
POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flamm able and
highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite g asoline vapors. A fire or explosion
from gasoline can burn you, others, and cause pr oper t y
damage.
HOW TO AVOID THE HAZARD
♦ Purchase and store gasoline only in an approved container.
♦ Always place gasoline containers on the ground away from
your vehicle before filling.
♦ Do not fill gasoline containers inside a vehicle or on a truck or
trailer bed because interior carpets or plastic t r uck bed liners
may insulate the container and slow the loss of any static
charge.
♦ When practical, r emove gas-powered equipment from the
truck or trailer and refuel the equipment with its wheels on the
ground.
♦ If this is not possible, then refuel such equipment on a truck or
trailer from a port able cont ainer, rather than from a gasoline
dispenser nozzle.
♦ If a gasoline dispenser nozzle must be used, keep the nozzle
in contact with the rim of the f uel t ank or container opening at
all times until fueling is complete.
- 20 -
4.2.2 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary
inspection and maintenance steps.
4.2.3 Familiarize yourself with the controls and operation of unit . See Controls section
4.1 and Operating Instructions section 4.3.
4.3 OPERATING INSTRUCTIONS
4.3.1 Refer to Engine Owner’s Manual for detailed operat ing instructions regarding the
engine.
4.3.2 Starting Engine: Operat or m ust have PTO di sengaged and speed control lever
in neutral.
Lock drive levers in neutral and engage park brake.
Open fuel shut-off valve.
NOTE: A cold weather starting kit has been added for ease of starting in either
cold weather or when the unit has not been run for a period of time.
To use cold start kit: (Manual start unit s only)
a) Pull split ring straight out the side of t he unit, and hook the ring over the
lower rear hydro control shield bolt.
b) Start engine. Refer to the following guidelines for fur ther starting
suggestions.
To engage pump drive (disengag e cold start kit)
a) Pull chain straight out from the side of the unit until the split ring can be
removed from the bolt.
SLOWLY release tension on chain.
On a cold engine, pull out the choke control.
For a 15 & 17 HP Kawasaki manual start engine, turn key to “Run” position. Pull
recoil rope to start engine.
For a 17HP Kawasaki Electric start engine, O PC levers must be depressed, turn
ignition switch to the “start” position. Release the switch when the engine starts.
After the engine star t s and warms up, gradually push down on the choke control
and place the throttle control in the full throttle position
IMPORTANT: For electric start models, do not crank the engine continuously
for more than ten (10) seconds at a time. If t he engine does not start, allow a
60 second starter cool-down period bet ween starting attempts. Failure to
follow these guideli nes can burn out t he st art er mot or.
On a warm engine, place the throttle cont r ol midway between the “Slow” and
“Fast” positions.
NOTE: Kawasaki engines generally need to be “choked” even when warm.
4.3.3 Stopping Engine: Disengage blade dr ive, position speed control lever in neutral,
lock the drive levers in neutral and engage t he par k brake. Move throttle to the
“Slow” position. Allow engine to idle for one minute t o allow cool down. Turn the
key to the “Off” position.
4.3.4 Drive Lever/Neutral Lock Latch Operation:
For Standard Pistol Grip Handles: To lock the drive levers in neutral, squeeze
the drive levers back to the neutral position (Do Not squeeze the drive levers all
the way back as this will cause the drive wheels to go int o full reverse direction).
Place thumbs on the upper portion of the neutral lock latches and move them to
the rear. Release drive levers (See Figure 7).
- 21 -
CAUTION
POTENTIAL HAZARD
♦ If the neutral lock latches are not completely engaged the drive
levers could unexpectedly slip into the forward drive position.
WHAT CAN HAPPEN
♦ If the drive levers slip into the drive position, the unit could
lurch forward and cause injury or property damag e.
HOW TO AVOID THE HAZARD
♦ Be sure the pins protruding throug h the slots of each neutral
lock latch are completely engaged in t he r ear slot of each latch.
To place the drive levers in the drive position, fir m ly hold the dr ive levers, place
thumbs on the upper portion of the neutral lock latches and move them forward to
release drive levers. Slowly and carefully release the drive levers.
For ECS Handles: To lock the drive levers in neutral, squeeze the drive levers
back to the neutral position (Do Not squeeze the drive levers all the way back as
this will cause the drive wheels to go into fu ll r ever s e dir ection). Place thumbs on
the inner thumb lobe of the neutr al lock latches and push downward, moving them
under the drive levers. Release drive levers (See Figure 7).
CAUTION
POTENTIAL HAZARD
♦ If the neutral lock latches are not completely engaged the drive
levers could unexpectedly slip into the forward drive position.
WHAT CAN HAPPEN
♦ If the drive levers slip into the drive position, the unit could
lurch forward and cause injury or property damag e.
HOW TO AVOID THE HAZARD
♦ Be sure the drive levers are past the roller and securely seated
at the bottom of the neut ral lock latches.
To place the drive levers in the drive position, slightly sq ueeze the dr ive levers
while placing thumbs on the outer thumb lobe of t he neutral lock latches and push
forward moving them out from under the drive levers. Slowly and carefully
release the drive levers.
4.3.5 Drive Wheel Engagement/Turning: With drive levers locked in neut r al, shift speed
control lever to desired forward speed. Slowly squeeze and hold both drive levers
in the neutral position and move both neutral lock lat c hes from the neutral lock
position. Do Not squeeze both drive levers all the way back, this will cause the
drive wheels to be engaged in the reverse direction.
For straight ahead motion, sm oot hly release bot h dr ive levers to engage drive
wheels.
Squeeze the right hand drive lever to turn right and the left hand drive lever to
turn left.
To make a “zero turn”, squeeze either the left hand or the right hand drive lever
back into the reverse position while the opposite drive lever is in a f or ward position
at an equal but opposite speed.
To back up, squeeze both drive levers into the reverse posit ion.
For smooth operation of this m achine, avoid q uick, jerky movements of t he dr ive
levers. Move the drive levers smoothly and deliberately.
- 22 -
4.3.6 To Stop: Squeeze drive levers back to the neut ral position. Move neutral lock
latches into the neutral lock position and r elease drive levers. Move the speed
control lever to the neutral position.
4.3.7 PTO Engagement:
DANGER
POTENTIAL HAZARD
♦ The rotating blades under the mower deck are
dangerous.
WHAT CAN HAPPEN
♦ Blade contact can cause serious injury or kill you.
HOW TO AVOID THE HAZARD
♦ DO NOT put hands or feet under t he mower or mower
deck when the PTO is engaged.
Be sure that all persons are clear of mower deck and discharge area before
engaging the PTO. Set throttle to “midway” position. Push the PTO engagement
arm forward and down to engage blades. Accelerate to full throttle to begin
mowing (See Section 4.1.5).
4.3.8 PTO Disengagement: Pull upward and back completely on the PTO engagement
arm to disengage the blades (See Section 4. 1.5).
4.4 TRANSPORTING
POTENTIAL HAZARD
♦ Loading the mower onto a trailer without strong
enough or properly supported ramps could be
dangerous.
WHAT CAN HAPPEN
♦ The ramps could collapse causing the unit to fall,
which could cause injury.
HOW TO AVOID THE HAZARD
♦ Use proper ramps that are secured to the t ruck or
trailer.
♦ Keep feet and legs out f r om under the unit when
loading and unloading.
♦ If necessary, use assistance when loading.
Use a heavy duty trailer to transport the machine. Eng age neutral lock latches and
park brake, then block wheels. Securely fasten the machine to the trailer with
straps, chains, cables, or ropes. Use a safety chain and be sure that the trailer
has all necessary lighting and marking as required by law.
WARNING
- 23 -
5. MAINTENANCE & ADJUSTMENTS
5.1 PERIODIC MAINTENANCE
WARNING
POTENTIAL HAZARD
♦ If you leave the key in the ignition switch, someone
could start the engine.
WHAT CAN HAPPEN
♦ Accidental starting of the engine could seriously injure
you or other bystanders.
HOW TO AVOID THE HAZARD
♦ Remove the key from the ig nit ion switch and pull the
wire(s) off the spark plug(s) before you do any
maintenance. Also push the wire(s) aside so it does
not accidentally contact the spark plug( s) .
WARNING
POTENTIAL HAZARD
♦ The engine can become very hot.
WHAT CAN HAPPEN
♦ Touching a hot engine can cause severe burns.
HOW TO AVOID THE HAZARD
♦ Allow the engine to cool completely before service or
making repairs around the eng ine area.
5.1.1 Check engine oil level.
Service Interval: See Engine Owner's Manual
a) Make sure mower is on a level surface. Stop engine and wait for all m oving
parts to stop.
b) Check with engine cool.
c) Clean area around dipst ick. Remove dipstick and wipe oil off. Reinsert t he
dipstick (DO NOT screw into place). Remo ve dipstick and check oil level.
d) If the oil level is low, add oil as specified in the Engine Owner’s Manual to
bring the oil level up to the “FULL” mark on the dipstick.
DO NOT OVERFILL.
IMPORTANT: DO NOT operate the engine with oil level below the “LOW” (or
“ADD”) mark or over the “FULL” mark.
5.1.2 Clean engine air cooling system .
Service Interval: See Engine Owner's Manual
a) Stop engine and wait for all moving parts to st op. Remove ignition key or
spark plug wire(s).
b) Clean all debris from engine air intak e scr een and from around engine
shrouding.
- 24 -
5.1.3 Clean grass build-up under deck and check mower blades.
Service Interval: Daily
CAUTION
POTENTIAL HAZARD
♦ Raising the mower deck for service or m aint enance
relying solely on mechanical or hydraulic jacks could
be dangerous.
WHAT CAN HAPPEN
♦ The mechanical or hydraulic jacks may not be enough
support or may misfunction allowing the unit to fall,
which could cause injury.
HOW TO AVOID THE HAZARD
♦ DO NOT rely solely on mechanical or hydraulic jacks
for support. Use adequate jack stands or equivalent
support.
a) Disengage PTO.
b) Stop engine and wait for all moving parts to st op. Remove ignition key or
spark plug wire(s).
c) Raise deck and block up using proper safety precautions.
d) Clean out any grass build-up from underside of deck and in deck discharge
chute.
e) Inspect blades and sharpen or replace as required.
f) If blade removal is necessary, be careful for the sharp cutting edges of the
blades.
g) Re-install the blades (if they were removed) and torque blade bolt s t o 115-
120 ft. lbs. Be sure the spring disc washer cone is installed t oward the bolt
head (See Figure 8).
CAUTION
POTENTIAL HAZARD
♦ Operating a mower deck with loose or weakened
blade bolts can be dangerous.
WHAT CAN HAPPEN
♦ A loose or weakened blade bolt could allow a blade
rotating at a high speed to come out from under the
deck, causing serious injury or property damage.
HOW TO AVOID THE HAZARD
♦ Replace the blade bolt after striking a foreign object.
(Use only Exmark replacement parts PN 103-1026 blade bolt and PN 1-513208 – spring disc washer).
♦ DO NOT lubricate the threads of the bolt or spindle
before assembly.
♦ Torque the blade bolt to 115-120 ft. lbs.
g) Remove jack stands (or equivalent support) and lower deck t o ground.
- 25 -
BLADE BOLT INSTALLATION
5.1.4 Check safet y interlock system.
Service Interval: Daily
a) For your safety, your Exmark mower is equipped with Operator Presence
Controls (OPC). When either the mower blades are engag ed, or the speed
control lever is not in neutral and both hands are removed from the handles,
the mower engine MUST stop.
b) For Electric Start Units Only: Check starting circuit. Starter should crank
with: Operator Presence Control levers depressed, speed control lever in
neutral, and electric blade clutch disengaged.
Try to start the engine with OPC levers disengaged, speed control lever in
neutral and electric blade clutch disengaged - starter MUST NOT crank.
Try to start with, OPC levers depressed, speed control lever in any speed
but neutral and electric blade clutch disengaged - start er M UST NO T
crank.
Try to start with OPC levers depressed, speed control lever in neutral and
electric blade clutch engaged-starter MUST NOT crank.
c) Check O PC cir c uit s . Clear the area. Run engine at one-third throttle, then
with drive levers and neutral lock latches in neutral lock position, move the
speed control lever out of neutral and release OPC levers - engine MUST
stop. Again, run engine at one- t hird throttle, move the speed control lever to
neutral, engage blade clutch and release O PC levers - engine MUST stop.
d) If machine does not pass any of these tests, DO NOT operate. Contact your
authorized EXMARK SERVICE DEALER.
IMPORTANT: It is essential that all Operator Safety Mechanisms, be in
place and in proper operating condition prior to mowing.
5.1.5 Check for loose hardware.
FIGURE 8
Service Interval: Daily
a) Stop engine and wait for all moving parts to st op. Remove ignition key or
spark plug wire(s).
b) Visually inspect machine for any loose hardware or any other possible
problem. Tighten hardware or correct the problem before operating .
5.1.6 Service pre-cleaner element and air cleaner .
Service Interval: See Engine Owner's Manual
- 26 -
5.1.7 Change engine oil.
Service Interval: See Engine Owner's Manual
NOTE: Change oil after first five (5) hours of operat ion. Follow engine
manufacturer’s recommendations for future oil changes.
a) Disengage blade clutch.
b) Stop engine and wait for all moving parts to st op. Remove ignition key or
spark plug wire(s).
c) Drain oil while engine is warm from operation.
d) Oil drain valve is located on left hand side of engine. Place pan under
machine to catch oil and open valve with 10mm wrench. Allow oil to drain
then close valve.
e) Replace the oil filter as per Engine Owner's Manual. Clean around oil filter
and unscrew filter to remove.
Before reinstalling new filt er , apply a thin coating of oil on the surface of the
rubber seal. Turn filt er clockwise until rubber seal contacts the filt er adapt er ,
then tighten filter an addit ional 2/ 3 to 3/4 turn.
f) Clean around oil fill cap and remove cap. Fill to the specified capacity and
replace cap. Use oil as specified in Engine Owners Manual. Do not overfill.
g) Start the engine and check for leaks. Stop engine and recheck oil levels.
5.1.8 Check hydraulic oil level.
Service Interval: 40 hr.
a) Stop engine and wait for all moving parts to st op.
b) Clean area around hydraulic reservoir cap and remove cap. Oil level should
be to the top of the baf fle inside the tank. If not, add oil.
WARNING
POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure can penetrat e
skin and cause injury.
WHAT CAN HAPPEN
♦ Fluid accidentally injected into the skin must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangr ene m ay result.
HOW TO AVOID THE HAZARD
♦ Make sure all hydraulic fluid hoses and lines are in good
condition and all hydraulic connections and fittings are
tight before applying pressure to hydraulic system.
♦ Keep body and hands away from pinhole leaks or
nozzles that eject high pressure hydraulic fluid.
♦ Use cardboard or paper to find hydraulic leaks.
♦ Safely relieve all pressure in the hydraulic system, by
locking drive levers in neutral and shutting off engine,
before performing any work on t he hydraulic system.
- 27 -
5.1.9 Change hydraulic system filter.
Service Interval: After First 250 hrs, then yearly thereafter.
Note: Use only Exmark Part No. 513211 f or Sum m er use above 32°
Part No. 523541 for Winter use below 32°
specifications.
a) Place unit on a level surface, stop engine and wait f or all m oving par t s t o
stop. Remove ignition key or spark plug wire(s).
b) Carefully clean area around filter. It is important that no dirt or contamination
enters the hydraulic system.
c) Unscrew filt er to remove and allow oil to drain from r eservoir.
IMPORTANT: Before re-installing new filter, fill it completely with Mobil 1
15W-50 and apply a thin coat of oil on the surface of t he r ubber seal. Turn
filter clockwise until rubber seal contact s t he filter adapter. Do not tighten yet.
d) Fill reservoir as stated in Section 5.1.8.
e) Loosen filter 1/2 turn and allow a small amount of oil to leak from t he oil filter
(this allows air to be purged from the oil filter and supply hose from the
hydraulic reservoir). Turn filter clockwise until rubber seal contacts the filter
adapter. Then tighten t he filter an additional 2/3 to 3/4 turn.
f) Raise the rear of the machine up onto jack stands high enough to raise the
drive wheels off of the gr ound. Run machine to allow any other air to be
purged from the hydraulic system and r echeck the oil level.
g) If either drive wheel does not rotate, one or both of the charge pumps
(located on the top of the main pump as shown in Figur e 9) m ay have lost
their “prime”. Ref er t o Section 5.1.10.
h) DO NOT change hydraulic system oil (except what can be drained w hen
changing filter) unless it is felt t hat oil has been contaminated. Changing oil
unnecessarily could damage the hydraulic system by introducing
contaminates into the system.
5.1.10 Hydraulic system air purge pr ocedur e.
Air must be purged from t he hydraulic system when any hydraulic components,
including the oil filter, ar e r emoved or any of the hydraulic lines are disconnected.
The critical area for purging air from the hydraulic system is bet ween the oil
reservoir and each charge pump located on the top of each variable displacement
pump (See Figure 9).
Air in other parts of the hydraulic system will be purg ed t hr ough normal operation
once the charge pumps are “primed”.
a) Stop engine and wait for all moving parts to st op. Raise the rear of the
machine up onto jack stands high enoug h t o r aise the drive wheels off the
ground.
b) Check oil level as stated in Section 5.1.8.
c) Start engine and move throttle control ahead to full throttle position. Move the
speed control lever to the middle speed position and place the drive levers in
the “drive” position.
If either drive wheel does not rotate, it is possible t o assist the purging of the
charge pump by carefully rotating the tire in the forward direction.
F (0° C) or
F (0° C). Refer to 2. 7.2 for filter
NOTE: It is necessary to lightly touch the charge pump cap with your
hand to check the pump temperature. If the cap is too hot t o t ouch, turn
off engine. The pumps may be damaged if the pump becomes too hot.
If either drive wheel still does not rotate cont inue with step ( d).
- 28 -
d) Thoroughly clean the area around each of the charge pump housings.
P
2
CHARGE PUMP LOCATION
e) To “prime” charge pump, loosen two hex socket head capscrews (shown in
Figure 11) 1-1/2 turns only. Make sure engine is not runni ng. Lift charge
pump housing upward and wait for a steady flow of oil to flow out from under
housing. Retighten capscrews. Do this for both pumps. Note: Hydraulic
reservoir can be pressurized to up to 5 psi to speed this process.
f) If either drive wheel still does not rotate, stop and repeat Steps (d) through
(e) above for the respective pump. If tires rotate slowly, the system may
prime after additional running. Check oil level as stated in Section 5.1.8.
g) Allow unit to run several minutes after the charge pum ps ar e “primed” with
drive system in the full speed position.
Check oil level as stated in Section 5.1.8.
h) Check hydro drive linkage adjustment as stat ed in Sect ion 5.2.6.
5.1.11 Check tire pressur es.
FIGURE 9
LOOSEN 1-1/
TURNS ONLY
CHARGE PUMP CA
Service Interval: Pneumatic (air-filled) Drive Tires- 40 hrs.
Semi-pneumatic Caster Tires – No maintenance
a) Stop engine and wait for all moving parts t o st op. Remove ignition key or
spark plug wire(s). Check air pr essur e in drive tires; recommended tire
pressure is 12-16 psi.
b) Inflate tires to pressures stated above. Measure circumference of each drive
tire. Adjust tire pressures within the above range to t r y to m ake tire
circumferences match as closely as possible.
5.1.12 Inspect Belt wear.
Service Interval: 40 hrs.
a) Stop engine and wait for all moving parts to st op. Remove ignition key or
spark plug wire(s).
b) Remove deck support belt shield to check mower deck drive belt condit ion.
c) Look under engine deck to check the pump drive and clutching belt condit ion.
d) Check all idler arms to be sure they pivot freely. Disassem ble, clean and
grease pivot bushings if necessary.
5.1.13 Inspect PTO Clutching Belt Tension.
Service Interval: Check every 2 hrs. for first 8 hrs. operation then check every
40 hrs. thereafter.
a) St op engine and wait for all moving parts to st op.
- 29 -
b) Engage PTO lever.
c) Look through the round hole in the left rear corner of t he engine deck to
inspect blade clutching belt tension. Bolt on blade engagement linkage
bellcrank and indicator arm should align within 1/16” (See Figure 12). Refer
to section 5.2.2 for adjust m ent .
5.1.14 Lubrication
Service Interval: Refer to Chart.
a) Stop engine and wait for all moving parts to st op. Remove ignition key or
spark plug wire(s).
b) Lubricate fittings with one to two pumps of NGLI grade #2 multi-purpose gun
grease.
Refer to the following chart for fitting locat ions and lubrication schedule.
GREASE LUBRICATION CHART
FITTING
LOCATIONS
1. Caster Wheel Bearings 12 2 2 2 Daily
2. Caster Pivots 2 2 2 2 Daily
3. PTO Engagement Bellcrank 1 1 1 1 Week ly
4. Idler Pivot (Pump Drive) 2 1 1 1 Weekly
5. Clutch Arm Pivot 1 1 1 1 Weekly
6. Cutter Deck Idler Pivots 2 1 1 1 Weekly
7. Pump Control Bearings 2 2 2 2 Weekly
No. 4 (Idler Pivot)
Located Under Engine Deck
No. 5 (Clutch Arm P ivot)
Located Under Engine Deck
No. 4 & 6 (Idler Arm Pivots)
Disassemble and grease once a month
under a “No Load” Condition.
INITIAL
PUMPS
QUANTITY
36” 48” 52”
SERVICE
INTERVAL
c) Lubricate pivot points with a spray penetrating
lubricant as directed below.
SPRAY LUBRICANT CHART
PIVOT POINT
1. PTO Lever 1 Weekly
5.1.15 Check spark plugs.
Service Interval: 160 hrs.
a) Stop engine and wait for all moving parts to st op.
b) Remove spark plugs, check condition and adjust plug gap or replace with
new plugs. See Engine Owner's Manual.
5.1.16 Remove engine shrouds and clean cooling fins.
Service Interval: See Engine Owner's Manual
- 30 -
NO. OF
PLACES
SERVICE
INTERVAL
a) Stop engine and wait for all moving parts to st op. Remove ignition key or
spark plug wire(s).
b) Remove cooling shrouds from engine and clean cooling fins. Also clean dust,
dirt, and oil from external surfaces of engine, which can cause improper
cooling.
c) Make sure cooling shr ouds ar e properly reinstalled. Operating the eng ine
without cooling shrouds will cause engine damage due to overheating.
5.1.17 Change f uel filter.
Service Interval: As Required
a) A fuel filter is installed in the fuel line between the fuel tank and the eng ine.
Replace when necessary.
5.1.18 Refer to Engine Operators Manual for detailed maintenance regarding t he engine.
5.1.19 Wheel hub - slotted nut torq ue specification.
When tig ht ening the slotted nut on the wheel motor tapered shaft:
a) Torque the slotted nut to 100 ft. lbs.
b) Further tighten the nut until the next set of slots line up with the cross hole in
the shaft.
c) Replace cotter pin.
5.1.20 Thread locking adhesives such as “Loctite 242” or “ Fel-Pro, Pro-Lock Nut-Type”
are used on the following fasteners:
a) Pump drive sheave setscrews.
b) Square head setscrews on Hydro pump control arms.
c) OPC lever setscrews.
d) Sheave retaining bolt in end of engine crankshaft.
e) Lower Sheave retaining bolt on clutch arm.
f) Shoulder bolts in ends of speed control crank.
Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pr o Pr o- Lock Retaining I or
Retaining II” are used on the following:
a) OPC lever hubs and cross-shaft
NOTE: Care must be used not to bond the bearing, next to each OPC hub,
to the cross shaft which coul d cause bi nding of the OPC levers and erratic
operation.
5.1.21 An anti-seize compound is used on the following locations:
a) Between engine crankshaft and pump and blade drive sheaves.
b) On clutch arm assembly between bearings and shaft and between lower
sheave and shaft.
c) Between pump shafts and sheaves.
5.1.22 Dielectric grease is used on all blade type electrical connections to prevent
corrosion and loss of contact.
5.1.23 Check battery charge: (Electric st ar t units only)
Service Interval: Monthly
Allowing batteries to stand for an extended period of time without recharging
them will result in reduced performance and ser vice life. To preserve optimum
battery performance and lif e, recharge batteries in storage when the open circuit
voltage drops to 12.4 volts.
- 31 -
Note: To prevent damage due to freezing, battery should be fully charged before
putting away for winter storage.
a) Check the voltage of the battery with a digital voltm et er. Locate the voltage
reading of the batter y in the t able below and charge the battery for the
recommended time interval to bring the charge up to a full charg e of 12.6 volts
or greater.
IMPORTANT: Make sure the negative battery cables are disconnected and
the battery charger used for char ging the battery has an output of 16 volts and
7 amps or less to avoid damaging the batter y (see char t below for
recommended charger settings).
Voltage
Reading
12.6 or greater 100% 16 volts/7 amps No Charging Required
12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes
12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour
12.0 – 12.2 25 – 50% 14. 4 volts/ 4 am ps 2 Hours
11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours
11.7 or less 0% 14.4 volts/2 amps 6 Hours or More
Percent
Charge
Maximum
Charger Settings
5.2 ADJUSTMENTS
5.2.1 Cutting heig h t and ant i-scalp roller adjustment.
WARNING
POTENTIAL HAZARD
♦ When the two f r ont support rod hairpins are removed
from the mower deck, the weight of the tractor section
may cause the front frame to rise suddenly
WHAT CAN HAPPEN
♦ If the unit rises suddenly, injury may occur.
HOW TO AVOID THE HAZARD
♦ Securely hold down the front of the unit when the f ront
support rod hairpins are removed.
Charging Interval
a) Stop engine and wait for all moving parts t o stop.
b) Install hairpin clips in the holes for the desired cut ting height (See Figure 11).
IMPORTANT: To maintain correct cutting height and rake, check the
following for proper adjustment .
1. The front and rear hair pins are in the same holes with the proper
spacers under the hair pins (See Figure 10).
2. The tire pressures are set as directed in Section 5.1.11.
3. The length of the r ear deck support link assemblies are set t o 6. 89”
(approximately 6 7/8”) from t he cent er of the balljoint to the center of
the furthest hole (See Figure 10).
- 32 -
FIGURE 10
CUTTING HEIGHT ADJUSTMENT
FIGURE 11
ANTI-SCALP ROLLER BOLT INSTALLATION
ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT
c) Adjust anti-scalp rollers For Normal Operat ing Conditions. Place rollers in one
of the positions shown in Figure 11. Rollers will maintain 3/4 in. (19 mm)
clearance to the ground to minimize gouging and roller wear or damage. For
Maximum Deck Flotation, place rollers one hole posit ion lower. Roller s
should maintain 1/4 in. (6.4 mm) minimum clearance to ground. Do Not
adjust rollers to support the deck. Be sure roller bolts and nuts are installed
with the spring disc washer between head of the bolt and mounting bracket.
Torque to 40-45 ft-lbs., or loss of roller may result.
d) When operating in extr em ely rough conditions it may be necessary to
position the anti-scalp rollers one or two holes higher than described in "c" to
prevent damage to the rollers and/or bolt failure (See Figure 11).
NOTE:When anti-scalp rollers are placed in these positions, reduced deck
flotation will result.
5.2.2 PTO Linkage: Located bet ween the PT O lever on t he left handle and the left rear
corner of the engine deck.
a) Stop engine and wait for all moving parts to stop.
b) With PTO eng aged, adjust the linkage length by loosening the locknut on the
turnbuckle and adjusting the tur nbuckle so that the bolt on the bellcrank and
the indicator arm align with each other within 1/16”. See Figure 12. Tighten
locknut against turnbuck le.
- 33 -
Indicator
Align Bolt to
Indicator
within 1/16”
Engine Deck
FIGURE 12
BLADE ENGAGEMENT LINKAGE
5.2.3 PTO Safety Switch: Mounted to a tab on the inside lef t hand side of the fuel tank
support.
a) Stop engine and wait for all moving part s to stop. Remove ignition key or
spark plug wire(s).
b) With PTO disengaged and the bellcrank touching the rear of the slot in the
engine deck, adjust the PT O safety switch (if needed) until the bellcrank arm
is 5/16” from the switch body.
c) Be sure the bellcr ank DOES NOT touch the switch body or damage to the
switch could occur.
d) Retighten PTO switch mounting hardware.
5.2.4 Engine to Cutter Deck Belt:
No adjustment necessary.
5.2.5 Pump Drive Belt Tension Adj ustment:
No adjustment necessary.
5.2.6 Hydro Drive Linkage Adj ust m ent:
a) Adjust Speed Control Linkage and Neutr al Safety Switch
1. Stop engine and wait for all moving parts to st op.
2. Move the speed control lever (located on the console) to t he full forward
position and check the orientation of t he tabs on the ends of the speed
control crank (Figure 14) . These tabs should be pointing straight down at
the 6 o’clock position or slightly f or ward. Adjust the threaded yoke at the
bottom of the speed control linkage (Figure 14) until t he tabs are
positioned correctly.
3. Pull the speed control lever back to neutral. Check that the neut r a l safety
switch actuating tab has depressed the plunger of the switch so that there
is about 5/16” between the tab and the switch (See Figure 13). If
necessary, move the switch fore and aft.
FIGURE 13
NEUTRAL SAFETY SWITCH ADJUSTMENT
b) Adjust Neutral Control Linkag es
- 34 -
1. Raise the rear of the machine up onto jack stands high enough to raise
the drive wheels off of the g r ound.
2. Start the engine and move the throttle ahead to the full throttle position.
Place the neutral lock latches in the drive position as shown in Figure 7 and
move the speed control lever to the “mid-speed” position.
Note: The OPC levers must be held down whenever the speed control
lever is out of the neutral position or t he engine will kill.
3. Squeeze the respective drive lever until an increased resist ance is felt,
this is where neutral should be.
For Standard Pistol Grip Models: Make sure you have not reached the
end of the neutral lock latch slot. If you have, shorten the drive lever
linkage.
If the wheel turns while holding the drive lever in neutral, the neutral
control linkages need to be adjusted. I f wheels stop then go to step 7.
FIGURE 14
HYDRO DRIVE LINKAGE ADJUSTMENT
4. Loosen the nut against the neutral control linkage yoke as shown in
Figure 14.
5. Adjust the neutral control linkag e unt il the respective drive wheel stops
when the lever is pulled against the neutral spring (neut r al position). Turn
the adjusting bolt approximately 1/4 tur n clockwise if the wheel is turning
in reverse or turn the bolt approximately 1/4 tur n counter-clockwise if the
wheel is turning forward. Release the drive lever to the forward drive
position and squeeze back into the neutral position. Check to see if the
wheel stops. If not, repeat the above adjustment procedure.
6. Make this adjustment on bot h sides.
7. After adjustments are made and the wheels stop when the drive levers
are in the neutral position, tight en t he nuts against the yokes.
c) Adjust Hydro Cont rol Linkages:
1. Place the speed control lever in the “neutral” position.
Note: Neutral lock latches should still be “unlocked” and in the drive
position.
This adjustment is again made with rear of machine on jack stands and
engine running at full t h r ottle. OPC levers will have to be held down
whenever speed control lever is moved out of the neutral position.
2. Loosen the fr ont nut on left hydro contr ol linkage as shown in Figure 14.
Turn the rear control link age adjusting nut counter-clockwise until wheel
rotates forward. Turn the rear nut of left cont r ol link clockwise 1/4 of a
turn at a time, stopping to m ove the speed cont r ol forward and back to
- 35 -
neutral, until left wheel stops rotating forward. Turn the r ear nut an
additional 1/2 turn and tighten the front nut making sure not to put a bind
on the linkage. Make sure f lat par t of linkage is perpendicular to pin par t
of swivel. See Figure 15.
FIGURE 15
HYDRO CONTROL LINK/SWIVEL ADJUSTMENT
After adjusting t he left hydro control linkage, m ove the speed cont rol lever
to the mid-speed position and then back to t he neutral position. Recheck
the left drive wheel rotation to see if further adjustment is necessary - be
sure the speed control lever is in the neutral position.
If inconsistent neutral occurs, check to be sure bot h spri ngs are
properly tightened on the speed control lever under the console especially the rear pivot spring.
Repeat above adjustments if necessary.
3. Place the speed control lever in neutral. Adjust the rig ht side linkage by
turning the quick t r ack knob counter-clockwise until the tire begins to
rotate forward. Begin to r et ighten the knob clockwise about 1/4 turn at a
time, stopping to move the speed control forward and back to neutral.
Recheck the drive wheel rotation to see if f ur t her adjustment is necessary.
4. The spring that keeps tension on the k nob should nor mally not need
adjustment. However if adjustment is needed, adjust to where length of
spring is about 1” between the washers. Adjust spring leng t h by tur ning
nut at front of spring.
d) Drive Lever Linkage Adjustment
1. With rear of machine still on jack stands and engine running at full
throttle, move the speed control lever to t he m idway position. Move the
respective drive lever upward until it reaches the neutral position and
engage neutral lock latches. See Figure 16. If the tire rotates in either
direction, the length of the drive lever link will need to be adjusted.
2. For Standard Pistol G r ip Handles: Adjust the linkage length by
releasing the drive lever and removing clevis pin and rotating t he linkage
in the lower swivel. Lengthen the linkage if the tire is turning in reverse
and shorten the linkage if the tire is creeping forward. Rota t e the linkage
several turns if the tire is rotating fairly fast. But as the adjustment gets
closer, adjust the linkage in 1/ 2 turn increments. Release and re-engag e
neutral lock latch checking t hat the tire stops. Continue this process until
the tire is at a dead stop. Replace the hairpin back int o each clevis pin.
For ECS Handles: Adjust the linkage length by loosening the jam nuts at
both ends of the linkage and r o t ating the linkage in the ball joint s .
Lengthen the linkage if the tire is turning in reverse and shorten the
linkage if the tire is cr eeping forward. Tighten the jam nuts at both ends.
Release and re-engage the neutral lock latch checking that the tire st ops.
Continue this process until the tire is at a dead stop.
- 36 -
STANDARD PISTOL GRIP HANDLES ECS HANDLES
FIGURE 16
DRIVE LEVER AND LATCH IN NEUTRAL POSITION
3. Make this adjustment for both sides.
e) Tracking Adjustment
1. Stop engine and wait for all moving parts to st op. Raise the rear of the
machine, remove jack stands and carefully lower the machine to the
ground. (Check the drive tire pressur e and tire circumference. See
5.1.11.)
2. Run the unit and observe the tracking on a level, smooth, hard sur face
such as concrete or asphalt.
3. If the unit tracks to one side or t he other, turn the quick track knob. Turn
the knob right to “st eer” right; turn the knob left to “steer” left.
5.2.7 Hydro Pump Spring Tension Sett ing
a) For medium or heavy duty drive conditions such as operation with a sulky on
steep slopes, a higher spring f or ce may be required on the hydro pump
control arms to prevent the drive system f r om stalling.
b) For a heavier dr ive sett ing, relocate the spring anchor link to either the
“medium” or “heavy duty” positions as shown in Figure 17. The spring
anchor links are attached to the upper rear corner of the hydro drive shields
on the left and right hand sides of the machine.
Note: In the “medium” or “heavy duty” positions, the drive lever forces at
the upper handle will also be increased.
6. WASTE DISPOSAL
6.1 MOTOR OIL DISPOSAL
Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at a
certified recycling center or accor ding to your state and local regulations.
FIGURE 17
HYDRO PUMP SPRING TENSION SETTING
- 37 -
6.2 BATTERY DISPOSAL
DANGER
POTENTIAL HAZARD
♦ Battery electrolyte contains sulfuric acid, which is
poisonous and can cause severe burns
WHAT CAN HAPPEN
♦ Swallowing electrolyte can be fatal or if it t ouches skin
can cause severe burns.
HOW TO AVOID THE HAZARD
♦ Wear safety glasses to shield eyes, and rubber gloves
to protect skin and clothing when handling elect r olyte.
♦ Do not swallow electrolyte.
Federal law states that batteries should not be placed in the garbage. Management and
disposal practices must be within relevant federal, state, or local laws.
If a battery is being replaced or if the unit containing the batt er y is no long er oper ating and is
being scrapped, take the battery to a local certified recycling center. If no local recycling is
available return the battery to any certif ied battery reseller.
7. TROUBLE SHOOTING
7.1 MOWER TRACKS TO LEFT OR RIGHT.
a) Check the drive tire pressure and tire circumference. See 5. 1. 11.
b) Turn knob on the right hydro control linkage in the direction that the m o wer
needs to be adjusted to. Turn the knob in 1/4 turn increments until the
mower tracks correctly.
7.2 MOWER CUTS UNEVENLY.
a) Check the drive tire pressure and tire circumfer ence. See 5.1.11.
A more uniform cutting height may be obtained with higher tire pressure on
rough terrain. A lower tire pressure pr ovides mor e flotation.
b) Check deck support pins. Hairpin clips must be in t he sam e hole posit ion on
each support pin. See Section 5.2.1
c) Check deck support alignment and check mount ing brackets to be sure all
bolts are tight.
d) Check blades tip to tip for straig ht ness. (They should be within 3/16”, or one
blade width from being in line.)
7.3 ENGINE WILL NOT START.
a) Make sure battery has a full charge (Electric start only). ( See sect ion 5. 1.23)
b) Check that choke is in the “ON” posit ion for a cold engine or in the “OFF”
position for a warm engine. See 4.3. 2.
NOTE: Kawasaki engines may need to be choked even when warm.
c) Make sure the key switch is in the “ON” position (15 & 17 HP Kawasaki
Manual start).
d) Make sure the speed control lever is in the “true neutral” position. (See
section 5.2.6)
e) Check that the PTO is diseng aged and the PTO switch is depressed.
f) Make sure the OPC levers are depressed. ( Elect r ic st ar t only)
g) Check that there is fuel in the t ank and that the fuel valve is open.
- 38 -
PROBLEM
Will not start
Hard starting
Stops suddenly
Lacks power
Operates erratically
Knocks or pings
Skips or misfires
Backfires
Overheats
High fuel
consumption
h) Check that the spark plug wire(s) are properly connected.
i) Check for loose or f ault y wiring connections. If it is necessary to disconnect
wire connectors, Do Not pull on the wires while disconnecting.
j) Check for corrosion at all wiring connections. Even minor corrosion may
cause a faulty connection. Clean connector terminals thor oughly with
electrical contact cleaner, apply dielectric grease and r econnect.
IMPORTANT: It is essential that all operator safety mechanisms be
connected and in proper operating condition prior to mower use.
NOTE: After carefully checking the above steps, attempt to start the engine. If
it does not start, contact your authorized Exmark service dealer.
ENGINE TROUBLESHOOTING
When a problem occur s , do not overlook the simple causes. For example, starting
problems could be caused by an empty fuel tank.
The following table lists some of t he common causes of trouble.
Do not attempt to service or replace major items or any items that call for special
timing or adjustment procedures (such as valves, governor, etc.). Have this work
done by your Engine Service Dealer.
ENGINE TROUBLESHOOTING TABLE
NO
FUEL
IMPROPER
FUEL
DIRT IN
FUEL LINE
DIRTY AIR
FILTER
FAULTY
SPARK
PLUG
ENGINE
OVERLOADED
XXXXXX
XX X X X X X
XXX XXXX
XXXX X XXX
XXXX X X X
XXX
XXXX X
XXXX X
XX X XX
XX X X
BLOCKED
FUEL
FILTER
INCORRECT
OIL
LEVEL
DIRTY
AIR
SCREEN
- 39 -
8. WIRING DIAGRAMS
- 40 -
9. HYDRAULIC DIAGRAM
- 41 -
10. WARRANTY
Limited Warranty
Exmark Commercial Turf Equipment
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement
between them, jointly warrant on the terms and conditions herein, that we will repair, replace or
adjust any part manufactured by Exmark and found by us (in the exercise of our reasonable
discretion) to be defective in fact or y mat er ial or work m anship.
This warranty is limited to one year from the date of original retail pur chase ( 90 days for rental use)
for any Exmark mower that is used f or com m ercial or any other income producing purpose. The
blade spindle assemblies will be warranted for three years, one year parts and labor with an
additional two years parts only, from date of or iginal retail purchase against def ect s in m at erials or
workmanship. The frame and hydrost at ic t r act ion dr ive system, excluding hoses, will be warranted
for two full years from date of original retail purchase against defects in materials or work m anship.
We will extend the Peerless 5-speed tr ansm ission manufacturer's warranty from 90 days to one
year. Belts and tires are warranted for 90 days against defects in materials or workmanship.
The engine warranty is covered by its respective engine manufactur er . Please refer to the engine
manufacturers warranty statem ent t hat is included in the literature packet. We are not author ized
to handle warranty adjustments on engines. Engine warranties should be r eferred to the nearest
authorized service outlet of the engine manufacturer.
This warranty extends only to the original retail purchaser of the equipment. This warrant y may
not be assigned or transferred without the prior express written consent of Exmark and Exmark
Warranty Company. The warranty period commences upon the date of the original retail purchase.
The Exmark turf equipment, including any defective part, m ust be returned to an authorized Exmark
service dealer within the warranty period. The warranty shall extend to the expense of repair or
replacement (as determined by us) of t he defective part, including labor. The warrant y shall not
extend to the expense of delivering the mower to the dealer for warranty work nor the expense of
returning it back t o t he owner after repair or replacement. Our responsibility in respect to claims is
limited to making the r equired repairs or replacements, and no claim of breach of warranty shall be
cause for cancellation or rescission of t he cont r act of sale of any Exmark mower. Proof of
purchase may be required by the dealer to substantiate any warranty claim. All warrant y work mu st
be performed by an authorized Exmark service dealer.
This warranty extends only to turf equipment oper ated under normal conditions and properly serviced
and maintained. The warranty expressly does not cover: (i) any damage or deterior ation due to
normal use, wear and tear, or exposure; (ii) normal maintenance services, such as oil change,
cleaning, lubrication; adjustment; (iii) replacement of ser vice items, such as oil, lubricants, spark
plugs, or other items subject t o nor m al ser vice replacem ent ; (iv) damage or defects arising out of or
relating to misuse, neglect, alteration, negligence or accident; (v) repair or replacement arising from
operation of or use of the turf equipment which is not in accordance with operating instructions as
specified in the operator's manual or other operational instructions provided by Exmark; ( vi) r epair or
replacement arising as a result of any operation from turf equipment that has been altered or
modified so as to, in the determ ination of Exmark or Exmark Warranty Company, adversely affect the
operation, performance or dur abilit y of the equipment or that has alter ed, modified or aff ect ed the turf
equipment so as to change the intended use of the product; (vii) repair or replacem ent necessitated
by 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 m anual or other operational
instructions provided by Exmark; (viii) repairs or r eplacem ent s resulting from parts or accessor ies
which have adversely affected the operation, performance or durability of the turf equipment; or (ix)
damage or defects due to or ar ising out of repair of turf equipment by person or persons other than
an authorized Exmark service dealer or the installation of parts other than genuine Exmark or Exmark
recommended parts.
- 42 -
As a condition to this warranty, customer shall have read the operator ' s m anual and shall have
completed and returned to Exmark Warranty Company, within the prescr ibed t im e, the Exmark
warranty registration.
The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be
repair and replacement as set for t h herein. Neither Exmark nor Exmark Warranty Company shall
have any liability for any other cost, loss or damage, including but not limited to, any incidental or
consequential loss or damage. In par ticular, we shall have no liability or responsibility for: (i)
expenses relating to gasoline, oil or lubricants; ( ii) loss, cost or expense relating to transportat ion
or delivery of turf equipment from the location of owner or locat ion where used by owner to or f r om
any authorized Exmark service dealer; (iii) travel time, overt im e, after hours time or other
extraordinary repair charges or charge r elat ing to repairs or replacements outside of normal
business hours at the place of business of t he aut hor ized Exmark service dealer; (iv) rental of like
or similar replacement equipment dur ing the period of any warranty, repair or replacement work; (v)
any telephone or telegram charges or t r avel charg es; (vi) loss or damage to person or propert y
other than that covered by the terms of this warranty; (vii) any claims for lost revenue, lost profit or
additional cost as a result of a claim of breach of warranty; or (viii) attorney's fees.
There are no representations or warranties which have been authorized and provided to the buyer
of the turf equipment, other than as set f or t h in this warranty. Any and all statements or
representations made by any seller of this equipm ent , including those set forth in any sales
literature or made orally by any sales representative, are superseded by the ter m s of this warranty.
Any affirmation of fact or promise made by Exmark , Exmark Warr anty Company or any of their
representatives to the buyer which relates to the goods that ar e t he subject of this warranty shall
not be regarded as part of the basis of the bargain and shall not be deemed to cr eate any express
warranty that such goods shall conform to t he affirmation or promise.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANT IES,
EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED TO ANY REGARDING THE
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), NOT SPECIFIED HEREIN,
RESPECTING THE EQUI PMENT WHICH IS THE SUBJECT OF THIS WARRANTY.
This warranty applies to all Exmark turf equipment sold in the United States and Canada and
intended to be used for commercial purposes.
- 43 -
NOTES
- 44 -
SERVICE RECORD
Date Description of Work Done Service
Done By
- 45 -
ALIGN THIS EDGE WITH A VERTICAL SURFACE
(TREE, BUILDING, FENCE POST, POLE ETC.)
EXAMPLE: COMPARE
SLOPE WITH FOLDED
EDGE.
T
H
I
S
I
S
A
5
°
S
L
O
P
E
T
H
I
S
I
S
A
1
0
°
S
L
O
P
E
T
H
I
S
I
S
A
1
5
°
S
L
O
P
E
E
T
H
I
S
I
S
A
2
0
°
S
L
O
P
FOLD ALONG APPROPRIATE LINE
- 46 -
SEE EXMARK’S COMPLETE
M
LINE OF PRODUCTS FOR TURF CARE
LAZER Z
LAZER Z
TURF TRACER
METRO
VIKING HYDRO ULTRA VAC
®
®
XP TURF RANGER
®
®
LAZER Z® HP
TURF TRACER® HP
METRO® HP
®
™
GRASS CATCHER SELF STEERING SULKY
MICRO-MULCH
™
ACCESSORY
WARNING
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
©1997,1998, 1999, 2000, 2001 PART NO. 103-1773
EXMARK MFG. CO. INC. (402) 223-6300
INDUSTRIAL PARK BOX 808 FAX (402) 223-5489
BEATRICE, NE 68310
FG. CO . INC.
®
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