Exmark TTS481KA363, TTS481KA483CA, TTS481KA363CA, TTS481KA483, TTS541KA523 Operator's Manual

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Page 1

TURFTRACER®

S-SERIES

ForSerialNos. 312,000,000&Higher

PartNo.4500-955Rev.A

Page 2

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Theengineinthisproductisnot equippedwithasparkarrestermufer.Itisa violationofCaliforniaPublicResourceCode (CPRC)Section4442touseoroperatethis engineonanyforest-covered,brush-covered, orgrass-coveredlandasdenedinCPRC4126. Otherstatesorfederalareasmayhavesimilar laws.

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

Thissparkignitionsystemcomplieswiththe CanadianstandardICES-002.Cesystèmed’allumage parètincelledevèhiculeestconformeàlanorme NMB-002duCanada.

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

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

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

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Page 3

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

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

Ifadditionalinformationisneeded,orshould yourequiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor. Exmarkpartsmanualsareavailableonlineat http://www.exmark.com/manuals.htm

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

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Page 4

Contents

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

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

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

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

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

Specications........................................................14

ModelNumbers.............................................14

Systems..........................................................14

Dimensions....................................................15

TorqueRequirements.....................................16

ProductOverview.................................................16

Operation..............................................................17

Controls.........................................................17

Pre-Start.........................................................19

OperatingInstructions...................................19

Transporting..................................................23

Maintenance..........................................................24

RecommendedMaintenanceSchedule(s)............24

PeriodicMaintenance........................................25

CheckEngineOilLevel..................................25

CheckBatteryCharge(ElectricStartUnits

Only)..........................................................25

CheckMowerBlades......................................27

CheckSafetyInterlockSystem........................28

CheckforLooseHardware.............................29

ServiceAirCleaner.........................................29

ChangeEngineOil.........................................29

CheckHydraulicOilLevel..............................29

CheckTirePressures......................................30

CheckConditionOfBelts...............................30

LubricateGreaseFittings................................30

CheckSparkPlugs..........................................31

ChangeHydraulicSystemFilter......................31

ReplaceEmissionsAirIntakeFilter.................32

WheelHub-SlottedNutTorque

Specication...............................................32

InspectPTOClutchingBeltTension...............33

ThreadLockingAdhesives..............................33

MobilHTSGrease(OrFood-Grade

Anti-seize)..................................................33

Copper-BasedAnti-seize................................33

DielectricGrease............................................33

Adjustments......................................................34

DeckLeveling................................................34

PumpDriveBeltTension................................34

PTOClutchingBeltTension...........................34

DeckBeltTension..........................................34

ParkBrakeAdjustment...................................34

HydroDriveLinkageAdjustment...................34

TrackingAdjustment......................................36

HydroPumpSpringTensionSetting...............36

PTOSafetySwitch.........................................37

Cleaning............................................................37

CleanEngineandExhaustSystem

Area...........................................................37

RemoveEngineShroudsandClean

CoolingFins...............................................37

CleanDebrisFromMachine...........................38

CleanGrassBuild-UpUnderDeck.................38

WasteDisposal...............................................38

Troubleshooting....................................................39

Schematics............................................................41

Page 5

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4 specicationsoftheAmericanNationalStandards Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer reasonablysafeservice;however,failuretocomply withthefollowinginstructionsmayresultinpersonal injury.

ThisSafetyAlertSymbol(

Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

SafetyAlertSymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.

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

CAUTION:Blacklettering/Yellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

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

CAUTION

Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

Page 6

Safety

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

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Fillthefueltanktothebottomoftheller neck.Theemptyspaceinthetankallows gasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengine oremissionsystem.

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

DANGER

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

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

Page 7

Safety

Operation

WARNING

Operatingengineparts,especiallythemufer, becomeextremelyhot.Severeburnscanoccur oncontactanddebris,suchasleaves,grass, brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to coolbeforetouching.

•Removeaccumulateddebrisfrommuferand enginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

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

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly.

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait forallmovingpartstostop,removekeyand engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

–Beforemakingheightadjustments.

WARNING

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

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesinplace andworkingproperly.

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

•DONOToperatethemowerwhenpeople, especiallychildren,orpetsareinthearea.

•Bealert,slowdownandusecautionwhen makingturns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecaution whencrossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

Page 8

Safety

DANGER

Operatingonwetgrassorsteepslopescan causeslidingandlossofcontrol.Lossofcontrol and/orlossofoperator'sfootingcouldresultina fallwithanarmorleggettingunderthemower orenginedeckwhichmayresultinseriousinjury, deathordrowning.

•Mowacrossslopes,neverupanddown.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan20degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.

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

•Letenginecoolbeforestoringanddonotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

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

•Keephandsandfeetawayfrommovingparts. Ifpossible,donotmakeadjustmentswiththe enginerunning.

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

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

•Ventilatewhenchargingorusingbattery inanenclosedspace.

•Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.

•Alwaysshieldeyesandfacefrombattery.

Page 9

Safety

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagementof components.Sparkscouldcauseanexplosion ormovingpartscouldaccidentallyengage causingpersonalinjury.

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipmentparts, orusingnon-Exmarkreplacementpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryordeath.

Replaceallpartsincluding,butnotlimitedto, tires,belts,andbladeswithoriginalExmark parts.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjuryorgangrenemay result.

•Ifequipped,makesureallhydraulicuid hosesandlinesareingoodconditionandall hydraulicconnectionsandttingsaretight beforeapplyingpressuretohydraulicsystem.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands,to ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrollevers inneutralandshuttingofftheenginebefore performinganyworkonthehydraulicsystem.

Page 10

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

1-303508

1-303517

1-403005

1-403143

1-413206

36inchDecksOnly

1-413214

Page 11

Safety

1-413327

48inchand52inchDecksOnly

1-413421

1-553049

98-5954

103-1798

103-1976

ElectricStart

Page 12

Safety

103-1977

ManualStart

103–2076

103-2103

103–2242

103–2243

103-4935

Page 13

Safety

109-3148

116-0404

117–2718

Page 14

Specications

ModelNumbers

SerialNos:312,000,000andHigher

ManualStartModels:TTS481KA363;TTS481KA363CA;TTS481KA483;TTS481KA483CA;TTS541KA523

ElectricStartModels:TTS600KAE483;TTS600KAE523

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’ s Manual

•EngineOilType:Exmark4–CyclePremium EngineOil

•RPM:FullSpeed:3600(NoLoad)

Idle:1550RPM

FuelSystem

•Capacity:5.0gal.(18.9L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher;containingnomorethan10% methanolorethanol.

•FuelFilter:ReplaceableIn-line

•FuelShut-OffValve:1/4turnincrements

ElectricalSystem(ElectricStart)

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:Two20ampbladetype

SafetyInterlockSystem:

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

•Parkbrakemustbedisengagedtomovespeed controloutofneutralorenginewillkill.

OperatorControls

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

Transmission

TwinHydrostaticDrive

•TwoHydroGearvariabledisplacementhigh efciencypumpsindependentlycoupledtotwo highefciencyParker/Rosswheeldrivemotors.

•HydraulicOil:UseExmarkPremiumHydroOil.

•HydraulicOilCapacity:2.4qt.(2.2L)

•HydraulicFilterisreplaceablecartridgetype.

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

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

•Speeds:

–0-6.2mph(10.0km/hr)forward.

–0-2.2mph(3.5km/hr)reverse.

•Drivewheelsreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

WheelDriveSystem

DrivewheelsaredirectcoupledtoParkerwheeldrive motorswith1inch(25.4mm)taperedshaft.

Page 15

Specications

Tires&Wheels

DriveFrontCaster

Pneumatic (Air-Filled)

SemiPneumatic

Quantity

Tread

TurfMasterSmooth

Size16x6.50–89x3.50-4

PlyRating

Pressure

14psi (97kPa)

CuttingDeck

•CuttingWidth:

–36inchDeck:35.25inches(89.5cm)

–48inchDeck:47.25inches(120.0cm)

–52inchDeck:52.00inches(132.1cm)

•Discharge:Side

•BladeSize:

–36inchDeck:18.00inches(45.7cm)—

Quantity:2

–48inchDeck:16.25inches(41.3cm)—

Quantity:3

–52inchDeck:18.00inches(45.7cm)—

Quantity:3

•DeckDrive:Manualengagementofbeltwith over-centerlock.Bladebelttensionisadjustable viaturnbuckle.

•DeckMounting:Fulloatingdeckisattachedto out-frontsupportframe,removableforservice.

•DeckDepth:

–36inchDeck:5.0inches(12.7cm)

–48inchDeck:5.0inches(12.7cm)

–52inchDeck:5.0inches(12.7cm)

•CuttingHeightAdjustment:

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

•MulchingKit:Optional

•Bagger:Optional

Dimensions

OverallWidth:

36inch Deck

48inch Deck

52inch Deck

Deector Up

36.1inches (91.7cm)

48.1inches (122.2cm)

53.0inches (134.6cm)

Deector Down

45.9inches (116.6cm)

57.9inches (147.1cm)

62.8inches (159.5cm)

OverallLength:

36inchDeck48inchDeck52inchDeck

77.7inches (197.4cm)

73.7inches (187.2cm)

75.9inches (192.8cm)

OverallHeight:

36inchDeck48inchDeck52inchDeck

42inches (106.7cm)

TreadWidth:(OutsidetoOutsideof Tires,Widthwise)

36inchDeck48inchDeck52inchDeck

35.0inches (88.9cm)

39.4inches (100.1cm)

CurbWeight:

36inchDeck48inchDeck52inchDeck

634lb(285kg)775lb(349kg)774lb(348kg)

Note:Weightswillvaryslightlydependingonengine andelectricstartoptions.

Page 16

ProductOverview

TorqueRequirements

BoltLocation

Torque

CutterHousingSpindle Nut

140-145ft-lb (190-197N-m)

BladeMountingBolt (lubricatewithanti-seize)

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

EngineDeck/MowerDeck SupportMountBolts

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

Anti-ScalpRollerNyloc NutSee

Figure9

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

Anti-ScalpRollerWhizlock NutSeeFigure9

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

EngineMountingBolts

17-23ft-lb(23-31N-m)

WheelLugNuts

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

WheelHubSlottedNuts140-155ft-lb

(190-210N-m)

WheelMotorMounting Bolts

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

MuferGuardMounting Bolts

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

ProductOverview

Figure3

1.ParkBrakeLever

3.FuelCap

2.Controls4.Height-of-CutPins

Page 17

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

OperatorPresenceControl(OPC) Levers

Locatedontheupperhandleassemblydirectlyabove thehandlegrips.

Whentheseleversaredepressed,theOPCsystem sensesthattheoperatorisinthenormaloperator's position.Whentheleversarereleased,theOPC systemsensesthattheoperatorhasmovedfromthe normaloperatingpositionandwillkilltheengineif eitherthespeedcontrolleverisnotintheneutral positionorthePTOisengaged(see

Figure4).

Figure4

1.OPCLever

3.NeutralLockLatch

2.Rotateneutrallocklatch downwardforneutral lockposition

4.DriveLeverinneutral position

DriveLevers

Locatedoneachsideoftheupperhandleassembly aheadofandbelowthehandlegrips.

Theseleversindividuallycontrolthespeedand directionofeachdrivewheel.Whenthespeedcontrol leverismovedoutoftheneutralpositionandthe neutrallocklatchesaremovedintothedriveposition,

asshowninFigure4,andthedriveleversarereleased, thedrivewheelsareengagedintheforwarddirection.

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

NeutralLockLatches

Locatedontheupperhandleassemblyontheends ofthehandlegrips.

Theselatchesallowtheoperatortolockthedrive leversina“neutral”positionwherethedrivewheels arenotengagedineitheraforwardorreverse direction.

ChokeControl

Locatedonthefrontleftcornerofthefueltank support.

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

ThrottleControl

Locatedonthecontrolconsole’srightside.

Thethrottleisusedtocontrolenginespeed.Moving thethrottlecontrolforwardwillincreaseenginespeed andmovingittotherearwilldecreaseenginespeed. Movingthethrottleforwardintothedetentisfull position.

SpeedControlLever

Locatedinmiddleofcontrolconsole.

Thespeedcontrollevercontrolsthemaximum forwardspeedandisinnitelyvariablefromneutral 0–6.2mph(10.0km/hr).

Parkbrakemustbedisengagedtomovespeedcontrol outofneutralorenginewillkill.

Page 18

Operation

ParkBrakeLever

Locatedontheleftsideoftheunitabovethe hydraulictank.

Thebrakeleverengagestheparkbrakeonthedrive wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe brake.

Whenparkingonasteepslope,thewheelsmustbe chockedorblockedinadditiontothebrakebeing engaged.Theunitmustbetieddownandbrake engagedwhentransporting.

Theparkbrakemustbedisengagedtomovespeed controloutofneutralorenginewillkill.

Formanualstartengines:Theparkbrakemustbe disengagedbeforethePTOisengagedortheengine willkill.

“Off-Run”Switch(ManualStartOnly)

Locatedontheconsole.

Turnkeytothe“Run”positiontoallowtheengine tobestarted.Turnkeytothe“Off”positiontoshut engineoff.

Operatormusthavespeedcontrolleverinneutral andthePTOdisengagedtostartengine.

IgnitionSwitch(ElectricStartOnly)

Locatedonthecontrolconsole.

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

FuelShut-OffValve

Locatedinthefuellinemidwaybetweenthetank andengine.

Thefuelshut-offvalveisusedtoshutoffthe owoffuelwhenparkinginsideabuilding,during

transportationtoandfromthejobsites,andwhen themachinewillnotbeusedforafewdays.

Rotatevalve1/4turnclockwisetoshutfueloff. Rotatevalve1/4turncounterclockwisetoturnfuel on.

DriveWheelReleaseValves

Locatedontheleftrearcornerofthehydrostatic pumps.

Drivewheelreleasevalvesareusedtoreleasethe hydrostaticdrivesystemtoallowthemachinetobe movedbyhandwithouttheenginerunning.

Witha5/8wrench,turnbothvalvesoneturn counterclockwisetoreleasethedrivesystem.

Turnclockwisetoresetthedrivesystem.DoNot

overtighten.

TrackingAdjustmentKnob

Locatedontheright-handsideoftherearofthefuel tanksupport.

Theknobcanbeadjustedsothatmachinewill“track” straightaheadwiththedriveleversreleased.

PTOEngagement

Locatedontheleftsideoftheupperhandle.

Toengagetheblades,pushtheleverforward,oraway fromtheoperator,untilthelinkagelocksover-center. Todisengagetheblades,pullthelevertotherear, ortowardstheoperator.

Formanualstartengines:Theparkbrakemustbe disengagedbeforethePTOisengagedortheengine willkill.

ColdStartKit(ManualStartOnly)

Locatedbelowthehydrocontrolshield.

Thecoldstartkitisusedtoeasethestartingofthe unitincoldweatherorwhentheunithasnotbeen operatedforaperiodoftime.Thecoldstartkit movestheidlerpulleyawayfromthepumpbelt, releasingthetensiononthebeltwhichallowsthe enginetoturnoverwithlessresistance(seeStarting theEngine(ManualStart)sectioninOperation).

Page 19

Operation

Pre-Start

Fillfueltankonlevelground.Forbestresultsuse onlyclean,freshregulargradeunleadedgasolinewith anoctaneratingof87orhigher.

Important:Neverusemethanol,gasoline containingmethanol,gasoholcontainingmore than10%ethanol,premiumgasoline,orwhite gasbecausethefuelsystemcouldbedamaged.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe tankallowsgasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineoremission system(ifequipped).

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

Note:Afterstartingtheengineandengagingthe hydrodrive,ifeitherofthedrivewheelsactssluggish orwillnotrotateatall,stopengineandreferto theHydraulicSystemAirPurgeProcedurein Maintenance.

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethevalve1/4turncounterclockwisetoturn fuelon.

StartingtheEngine(ManualStart)

Note:OperatormusthavePTOdisengagedand

speedcontrolleverinneutralpositionwhenstarting theengine.

1.Lockdriveleversinneutralandengageparkbrake.

Note:Acoldweatherstartingkithasbeenadded foreaseofstartingineithercoldweatherorwhen theunithasnotbeenrunforaperiodoftime.

•Tousecoldstartkit:

A.Pullsplitringstraightoutthesideofthe

unit,andhooktheringoverthelowerrear hydrocontrolshieldbolt.

B.Startengine.Refertothefollowing

guidelinesforfurtherstartingsuggestions.

•Toengagepumpdrive(disengagecoldstart kit):

A.Pullchainstraightoutfromthesideofthe

unituntilthesplitringcanberemoved fromthebolt.

B.Slowlyreleasetensiononchain.

2.Pulloutthechokecontrol.Placethethrottle controlmidwaybetweenthe“Slow”and“Fast” positions.

3.Turnthekeyswitchtothe“Run”position.

4.Pullrecoilropetostartengine.

5.Afterenginewarmsup,graduallypushinthe chokecontrol.DoNotrunwarmenginewiththe chokeinthe“ON”position.

Note:Kawasakienginesgenerallyneedtobe “choked”evenwhenwarm.

StartingtheEngine(ElectricStart)

Note:OperatormusthavePTOdisengaged,speed

controlleverinneutralposition,andOPClevers depressedwhenstartingtheengine.

1.Lockdriveleversinneutralandengageparkbrake.

2.Pulloutthechokecontrol.Placethethrottle controlmidwaybetweenthe“Slow”and“Fast” positions.

3.Turntheignitionswitchtothe“Start”position. Releasetheswitchassoonastheenginestarts.

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

4.Afterenginewarmsup,graduallypushinthe chokecontrol.DoNotrunwarmenginewiththe chokeinthe“ON”position.

Note:Kawasakienginesgenerallyneedtobe “choked”evenwhenwarm.

Page 20

Operation

PTOEngagement

DANGER

Therotatingbladesunderthemowerdeckare dangerous.Bladecontactcancauseserious injuryorkillyou.

DoNotputhandsorfeetunderthemoweror mowerdeckwhenthebladesareengaged.

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunlessthere isagrasscollectionsystemormulchkitinplace andworkingproperly.

ThePTOswitchengagesthecuttingblades.Besure thatallpersonsareclearofmowerdeckanddischarge areabeforeengagingthePTO .

1.Setthrottleto“MIDW AY”position.

2.PushthePTOengagementarmforwardand downtoengageblades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

Formanualstartengines:Theparkbrakemust bedisengagedbeforethePTOisengagedorthe enginewillkill.

DisengagingthePTO

1.Setthrottleto“MIDW AY”position.

2.PullupwardandbackcompletelyonthePTO engagementarmtodisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Lockdriveleversinneutral.

3.DisengagethePTO.

4.Movespeedcontrollevertoneutral.

5.Engagetheparkingbrake.

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

7.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

8.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

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

DrivingtheMachine

DriveLever/NeutralLockLatchOperation

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

CAUTION

Iftheneutrallocklatchesarenotcompletely engagedthedriveleverscouldunexpectedlyslip intotheforwarddriveposition.Ifthedrivelevers slipintothedrivepositiontheunitcouldlurch forwardandcauseinjuryorpropertydamage.

Besurethedriveleversarepasttherollerand securelyseatedatthebottomoftheneutrallock latches.

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

Toplacethedriveleversinthe“reverse”position, squeezethedriveleverspasttheneutralposition.See Figure5position4.

Page 21

Operation

Figure5

1.DriveLeverinneutral position

3.DriveLeverinforward position

2.DriveLeverlockedin neutralposition

4.DriveLeverinreverse position

DrivingForward

1.Releasetheparkingbrake.

2.Withdriveleverslockedin“neutral”,shiftspeed controllevertodesiredforwardspeed.

3.Slowlysqueezeandholdbothdriveleversin theneutralpositionandrotatebothneutrallock latchesfromtheneutrallockpositiontothe forwardposition.

Note:DoNotsqueezebothdriveleversallthe wayback.Thiswillcausethedrivewheelsto engageinthereversedirection.

4.Tomoveforwardinastraightline,smoothly releasebothdriveleverstoengagedrivewheels.

Toturnleftorright,squeezetherighthanddrive levertoturnrightandthelefthanddrivelever toturnleft.

Tomakea“zeroturn”,squeezeeithertheleft handortherighthanddriveleverbackintothe reversepositionwhiletheoppositedriveleverisin aforwardpositionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine, avoidquick,jerkymovementsofthedrivelevers. Movethedriveleverssmoothlyanddeliberately.

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

DrivinginReverse

Tomoverearwardinastraightline,squeezedrive leversintothereverseposition.

Toturnleftorright,squeezetherighthanddrivelever toturnleftandthelefthanddrivelevertoturnright.

Tomakea“zeroturn”,squeezeeitherthelefthand ortherighthanddriveleverbackintothereverse positionwhiletheoppositedriveleverisinaforward positionatanequalbutoppositespeed.

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

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

AdjustingtheCuttingHeight

WARNING

Whenthetwofrontsupportrodhairpinsare removedfromthemowerdeck,theweightofthe tractorsectionmaycausethefrontframeofthe unittorisesuddenly.Iftheunitrisessuddenly, injurymayoccur.

Securelyholddownthefrontoftheunitwhenthe frontsupportrodhairpinsareremoved.

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

1.Stopthemachineandmovethedriveleverstothe neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Installhairpinclipsintheholesforthedesired cuttingheight.SeeFigure6.

Important:T omaintaincorrectcutting heightandrake,checkthefollowingfor properadjustment.

A.Thefrontandrearhairpinsareinthesame

holeswiththeproperspacersunderthehair pins.SeeFigure6.

Page 22

Operation

Figure6

1.Decksupportpin

2.CuttingHeight

B.ThetirepressuresaresetasdirectedinCheck

TirePressuresintheMaintenancesection.

C.Thelengthofthereardecksupportlink

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

Figure7.

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

Figure7

LeftHandSideShown

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller positionwhentheheightofcuthaschanged.

1.Stopthemachineandmovethedriveleversto theneutrallockposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingthewhizlocknut andspringdiscwasher.

6.Adjustanti-scalprollersforNormalOperating Conditions.Placerollersinoneofthepositions shownin

Figure8.Rollerswillmaintain3/4 inches(19mm)clearancetothegroundto minimizegougingandrollerwearordamage.

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

Figure8

Forcuttingheightsabove3.5inches(38mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

7.Torquethe3/8–16whizlocknutto30-35ft-lb (41-47N-m)(Figure9).

8.Ifthe3/8nylocnuthasbeenremoved,reinstall andtorqueto30–35ft-lb(41-47N-m)(Figure9).

Page 23

Operation

Figure9

1.Springdiscwasher (conetowardsnut)

3.3/8nyloc-torqueto30-35 ft-lb(41-47N-m)

2.Frontrightanti-scalp bracketshown

4.3/8-16whizlocknut torqueto30-35ft-lb (41-47N-m)

Transporting

TransportingaUnit

WARNING

Loadingthemowerontoatrailerwithoutstrong enoughorproperlysupportedrampscouldbe dangerous.Therampscouldcollapsecausing theunittofall,whichcouldcauseinjury.

•Useproperrampsthataresecuredtothe truckortrailer.

•Keepfeetandlegsoutfromundertheunit whenloadingandunloading.

•Ifnecessary,useassistancewhenloading.

Besurethefuelshut-offvalveisclosed.

Useaheavydutytrailertotransportthemachine. Engageneutrallocklatchesandparkbrake,then blockwheels.

Securelyfastenthemachinetothetrailerwithstraps, chains,cables,orropes.

DoNotrelysolelyontheparkingbraketoholdthe machineonthetrailer.

Besurethatthetrailerhasallnecessarylightingand markingasrequiredbylawanduseasafetychain.

Page 24

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

Removethekeyfromtheignitionswitch,engage parkingbrake,andpullthewire(s)offthespark plug(s)beforeyoudoanymaintenance.Also pushthewire(s)asidesoitdoesnotaccidentally contactthesparkplug(s).

WARNING

Theenginecanbecomeveryhot.T ouchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst2hours

•InspectPTOclutchingbelttension.Checkevery2hoursfortherst8hoursofoperation.

Aftertherst5hours

•Changetheengineoil.

Aftertherst100hours

•Checkwheelhub-slottedtorquespecication.

Aftertherst250hours

•Changethehydrauliclter.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Greasethecasterwheelbearings.

•Greasecasterpivots.

•Cleantheengineandexhaustsystemarea.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthedeck.

Every25hours

•Servicethefoamelement.(Mayneedmoreoftenundersevereconditions.SeetheEngine Owner'smanualforadditionalinformation.)

Every40hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethepumpdriveidlerpivot.

•Greasetheclutcharmpivot.

•Greasethepumpcontrolbearings.

•Greasethemowerdeckidlerpivot.

•InspectPTOclutchingbelttension.

Every100hours

•Servicethepaperelement.(Mayneedmoreoftenundersevereconditions.SeetheEngine Owner'smanualforadditionalinformation.)

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Removeengineshroudsandcleancoolingns.

Every160hours

•Checkthesparkplugs.

Every200hours

•Replacethepaperelement.

Page 25

Maintenance

MaintenanceService

Interval

MaintenanceProcedure

Every500hours

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Replacetheemissionsairintakelter.

•Checkwheelhub-slottedtorquespecication.

Monthly

•Checkthebatterycharge.

•GreasethePTOengagementbellcrank.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

4.Iftheoillevelislow,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Exmark4-CyclePremium EngineOilisrecommended;refertotheEngine Owner'smanualforanacceptablealternative.Do Notoverll.

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

CheckBatteryCharge (ElectricStartUnitsOnly)

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof timewithoutrechargingthemwillresultinreduced

performanceandservicelife.Topreserveoptimum batteryperformanceandlife,rechargebatteriesin storagewhentheopencircuitvoltagedropsto12.4 volts.

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Checkthevoltageofthebatterywithadigital voltmeter.Locatethevoltagereadingofthebatteryin thetableandchargethebatteryfortherecommended timeintervaltobringthechargeuptoafullcharge of12.6voltsorgreater.

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

Voltage Reading

Percent Charge

Maximum Charger Settings

Charging Interval

12.6or greater

100%

16volts/7 amps

No Charging Required

12.4–12.675–100%

16volts/7 amps

30Minutes

12.2–12.450–75%

16volts/7 amps

1Hour

12.0–12.225–50%

14.4volts/4 amps

2Hours

11.7–12.00–25%

14.4volts/4 amps

3Hours

11.7orless

14.4volts/2 amps

6Hoursor More

Page 26

Maintenance

RecommendedJump StartingProcedure(Electric StartUnitsOnly)

ServiceInterval:Asrequired

1.Checktheweakbatteryforterminalcorrosion (white,green,orblue“snow”),itmustbecleaned offpriortojumpstarting.Cleanandtighten connectionsasnecessary.

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe enginemayoccur.

DANGER

Jumpstartingaweakbatterythatiscracked, frozen,haslowelectrolytelevel,oran open/shortedbatterycell,cancausean explosionresultinginseriouspersonalinjury.

DoNotjumpstartaweakbatteryifthese conditionsexist.

2.Makesuretheboosterisagoodandfullycharged leadacidbatteryat12.6voltsorgreater.Use properlysizedjumpercables(4to6AWG)with shortlengthstoreducevoltagedropbetween systems.Makesurethecablesarecolorcodedor labeledforthecorrectpolarity .

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricalsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

Note:Thefollowinginstructionsareadapted fromtheSAEJ1494Rev.Dec.2001–Battery BoosterCables–SurfaceV ehicleRecommended Practice(SAE–SocietyofAutomotive Engineers).

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

Note:Besuretheventcapsaretightandlevel. Placeadampcloth,ifavailable,overanyvent capsonbothbatteries.Besurethevehiclesdo nottouchandthatbothelectricalsystemsare offandatthesameratedsystemvoltage.These instructionsarefornegativegroundsystemsonly .

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure10.

Figure10

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

5.Connecttheblacknegative(–)cabletotheother terminal(negative)oftheboosterbattery.

6.MAKETHEFINALCONNECTIONON THEENGINEBLOCKOFTHESTALLED VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK.

7.Startthevehicleandremovethecablesinthe reverseorderofconnection(theengineblock (black)connectionisthersttodisconnect).

Page 27

Maintenance

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure11

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

Figure12

1.Usewrenchherefor bladeinstallation.This nuthasbeentorquedto 140–145ft-lb(190–197 N-m)

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

C.Applylubricanttothreadsofbladeboltas

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

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

Page 28

Maintenance

ReplacingtheDischarge Deector

ServiceInterval:Asrequired

DANGER

Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator’sor bystander’sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.

Neveroperatethelawnmowerunlessyouinstall amulchplate,dischargedeector,orgrass collectionsystem.

1.Toremoveadamagedorworndischargedeector, liftthelegofthespringwiththeloopoutofthe notchinthedischargedeectorandslidethe rodoutofthedischargedeectorbrackets,and dischargedeector.

2.Toinstallnewdischargedeector,orientthe springontherodasshownin

Figure13.Slidethe rodthroughthefrontdischargedeectorbracket, dischargedeector,andreardeectorbracket.

Figure13

1.Rod4.Mowerdeck

2.Spring5.Dischargedeector bracket

3.Dischargedeector

6.Assembledview

3.Hookthebentendoftherodaroundthefront dischargedeectorbrackettoretainitfrom slidingout.Placethelegofthespringwiththe loopinthenotchinthedischargedeectorto holdthedischargedeectorinthedownposition (see

Figure13).

Important:Thedischargedeectormustbe springloadedinthedownposition.Liftthe deectoruptotestthatitsnapstothefull downposition.

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

1.ForElectricStartUnitsOnly:Checkstarting circuit.Startershouldcrankwith:Operator PresenceControlleversdepressed,speedcontrol leverinneutral,andPTOdisengaged.

TrytostarttheenginewithOPClevers disengaged,speedcontrolleverinneutraland PTOdisengaged–startermustnotcrank.

Page 29

Maintenance

Trytostartwith,OPCleversdepressed,speed controlleverinanyspeedbutneutralandPTO

disengaged–startermustnotcrank.

TrytostartwithOPCleversdepressed, speedcontrolleverinneutralandPTO engaged–startermustnotcrank..

2.ForAllUnits:CheckOPCcircuits.Clearthe area.Disengagetheparkbrake.Runengineat one-thirdthrottle,then,withdriveleversand neutrallocklatchesinneutrallockposition, movethespeedcontrolleveroutofneutraland releaseOPClevers–enginemuststop.Again, runengineatone-thirdthrottle,movethespeed controllevertoneutral,engagePTOandrelease OPClevers–enginemuststop.

Note:Parkbrakemustbedisengagedbeforethe speedcontrolleverismovedoutofneutralorengine willkill.

ForManualStartEngines:Theparkbrakemustbe disengagedbeforethePTOisengagedortheengine willkill.

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every25hours—Service

thefoamelement.(May needmoreoftenunder severeconditions.See theEngineOwner's manualforadditional information.)

Every100hours—Service thepaperelement.(May

needmoreoftenunder severeconditions.Seethe EngineOwner'smanual foradditionalinformation.)

Every200hours/Yearly (whichevercomes rst)—Replacethepaper element.

1.Stopengine,waitforallmovingpartstostop,and removekeyorsparkplugwire(s).Engageparking brake.

2.SeetheEngineOwner'sManualformaintenance instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May needmoreoftenunder severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseassemblyislocatedontheleft sideoftheengine.

Placepanundermachinetocatchoil.Removeoil drainplug.Allowoiltodrainandreplaceoildrain plug.Torqueplugto20-24ft-lb(27-33N-m).

4.ReplacetheoillterpertheEngineOwner's Manual.Cleanaroundoillterandunscrewlter toremove.Beforethenewlterisinstalled, applyathincoatingofExmark4–CyclePremium EngineOilonthesurfaceoftherubberseal. Turnlterclockwiseuntilrubbersealcontacts thelteradapter,thentightenlteranadditional 2/3to3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

6.UseoilrecommendedintheCheckEngineOil Levelsection.DoNotoverll.Starttheengine andcheckforleaks.Stopengineandrecheckoil level.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

Page 30

Maintenance

1.Stopengineandwaitforallmovingpartstostop, andremovekey.Engageparkingbrake.

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

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

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto12–16psi(83–110kPa).

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

5.Semi-pneumaticcastertiresdonotneedtobe inated.

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removethemowerdeckbeltshieldtocheck mowerbladedrivebeltcondition.

3.Lookunderenginedecktocheckthepumpdrive beltcondition.

4.Checkallidlerarmstobesuretheypivotfreely. Disassemble,cleanandgreasepivotbushingsif necessary.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.LubricatettingswithNGLIgrade#2 multi-purposegungrease.

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

NumberofPlacesService

Interval

36inch

Deck

48inch

Deck

52inch

Deck

1.Caster Wheel Bearings

12222

Daily

2.Caster Pivots

2222

Daily

3.PTO Engagement Bellcrank

1111

40hours

4.Pump DriveIdler Pivot

2111

Yearly

5.Clutch ArmPivot

1111

40hours

6.Pump Control Bearings

2222

40hours

7.Mower DeckIdler Pivots

2111

Yearly

Number4IdlerPivot(PumpDrive)Located

underenginedeck.

Number5(ClutchArmPivot)Locatedunder

enginedeck.

3.Lubricatepivotpointswithaspraypenetrating lubricantasshownintheSprayLubricantChart.

SprayLubricantChart

Page 31

Maintenance

PivotPoint

NumberofPlaces

ServiceInterval

1.PTOLever

40hours

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner's Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledinthefuellinebetweenthe fueltankandtheengine.Replacewhennecessary.

ChangeHydraulicSystem Filter

ServiceInterval:Aftertherst250hours

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

Note:UseonlyExmarkPartNo.109-4180for

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Carefullycleanareaaroundlter.Itisimportant thatnodirtorcontaminationenterhydraulic system.

3.Unscrewltertoremoveandallowoiltodrain fromreservoir.

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

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

4.FillreservoirasstatedinCheckHydraulicOil

Level.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ChangeInterval

ExmarkPremiumHydro Oil(Preferred)

500Hours

Mobil115W50

250Hours

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

6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

7.Ifeitherdrivewheeldoesnotrotate,oneorboth ofthechargepumps(locatedonthetopofthe mainpumpasshowninFigure14)mayhavelost their“prime”.RefertoHydraulicSystemAir Purgesection.

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

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

HydraulicSystemAirPurge

ServiceInterval:Asrequired

Airmustbepurgedfromthehydraulicsystem whenanyhydrauliccomponents,includingoil lter,areremovedoranyofthehydrauliclinesare disconnected.

Page 32

Maintenance

Thecriticalareaforpurgingairfromthehydraulic systemisbetweentheoilreservoirandeach chargepumplocatedonthetopofeachvariable displacementpump(

Figure14).Airinotherpartsof thehydraulicsystemwillbepurgedthroughnormal operationoncethechargepumpis“primed”.

Figure14

1.Chargepumpcap2.Loosen11/2turnsonly

1.Stopengineandwaitforallmovingpartstostop.

Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsoffthe ground.

2.CheckoillevelasstatedinCheckHydraulicOil

Levelsection.

3.Startengineandmovethrottlecontrolaheadto

fullthrottleposition.Movethespeedcontrol levertothemiddlespeedpositionandplacethe driveleversinthe“drive”position.

Ifeitherdrivewheeldoesnotrotate,itispossible toassistthepurgingofthechargepumpby carefullyrotatingthetireintheforwardposition.

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

Ifeitherdrivewheelstilldoesnotrotatecontinue withstep

4.Thoroughlycleantheareaaroundeachofthe chargepumphousings.

5.To“prime”chargepump,loosentwohexsocket headcapscrews(showninFigure14)11/2turns only.Makesureengineisnotrunning.Lift thechargepumphousingupwardandwaitfor asteadyowofoiltoowoutfromunderthe housing.Retightenthecapscrews.Dothisfor bothpumps.

Note:Hydraulicreservoircanbepressurizedup to5psitospeedthisprocess.

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

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

8.Checkhydrodrivelinkageadjustmentasstatedin HydroDriveLinkageAdjustmentsectionin Adjustments.

ReplaceEmissionsAirIntake Filter

ServiceInterval:Every500hours

1.Stopengine,waitforallmovingpartstostop,and removekeyorsparkplugwire(s).Engageparking brake.

2.Removethelterfromtheventhose.

3.Insertanewlterintotheendoftheventhose.

WheelHub-SlottedNut TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Torquetheslottednutto140-155ft-lb(190-210 N-m).

Note:DoNotuseanti-seizeonwheelhub.

Page 33

Maintenance

InspectPTOClutchingBelt Tension

ServiceInterval:Aftertherst2hours

Checkevery2hours fortherst8hoursof operation.

Every40hoursthereafter.

1.Stopengineandwaitforallmovingpartstostop.

2.EngagePTOlever.

3.Lookthroughtheroundholeintheleftrear corneroftheenginedecktoinspectblade clutchingbelttension.Boltonbladeengagement linkagebellcrankandindicatorarmshouldalign within1/16inch(1.6mm)(see

Figure15).Refer

toPTOEngagementLinkageforadjustment.

Figure15

1.Enginedeck3.Alignbolttoindicator within1/16inch(1.6 mm)

2.Indicator4.Turnbuckle

ThreadLockingAdhesives

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

•Pumpsheavesetscrews.

•Squareheadsetscrewsonhydropumpcontrol arms.

•OPCleversetscrews.

•Lowersheaveretainingboltonclutcharm.

•Shoulderboltsinendsofspeedcontrolcrank.

•Sheaveretainingboltinendofenginecrankshaft.

•Fueltankbulkheadttingthreads

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

•OPCleverhubsandcross-shaft.

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

•Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing locations:

•OnthreadsofBladeBolts.SeeCheckMower Bladessection.

•Betweenenginecrankshaftandpumpandblade drivesheaves.

•Onclutcharmassemblybetweenbearingsand shaftandbetweenlowersheaveandshaft.

•Betweenpumpshaftsandsheaves.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact. Dielectricgreaseshouldnotbeappliedtosealed connectors.

Page 34

Maintenance

Adjustments

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

DeckLeveling

SeeAdjustingtheCuttingHeightsectionin Operation.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

PTOClutchingBeltTension

SeeInspectPTOClutchingBeltTensionsection.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

ParkBrakeAdjustment

1.Shutoffengineandwaitforallmovingpartsto stop.

2.Disengagetheparkbrake.

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

HydroDriveLinkage Adjustment

•AdjustSpeedControlLinkageandNeutral SafetySwitch:

1.Stopengineandwaitforallmovingpartsto

stop.Engageparkingbrake.Removekeyor sparkplugwire(s).

2.Movethespeedcontrollever(locatedon

theconsole)tothefullforwardpositionand checktheorientationofthetabsontheends ofthespeedcontrolcrank(see

Figure16). Thesetabsshouldbepointingstraightdown atthe6o’clockpositionorslightlyforward.

Adjustthethreadedyokeatthebottomofthe speedcontrollinkage(see

Figure16)untilthe

tabsarepositionedcorrectly.

Figure16

ViewedfromLeftSideofUnit

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

2.ActuatingTab

3.Pullthespeedcontrolleverbacktoneutral. Checkthattheneutralsafetyswitchactuating tabhasdepressedtheplungeroftheswitchso thatthereisabout5/16inch(7.9cm)between thetabandtheswitch(see

Figure16).If

necessary,movetheswitchforeandaft.

•AdjustNeutralControlLinkages:

1.Raisetherearofthemachineupontojack standshighenoughtoraisethedrivewheels offoftheground.

2.Starttheengineandmovethethrottleahead tothefullthrottleposition.Placetheneutral locklatchesinthe“forward”positionas shownin

Figure4.Releasetheparkbrake andmovethespeedcontrollevertothe “mid-speed”position.

Note:TheOPCleversmustbehelddown andtheparkbrakemustbedisengaged wheneverthespeedcontrolleverismoved outofneutralortheenginewillkill.

3.Squeezetherespectivedriveleveruntilan increasedresistanceisfelt,thisiswhere neutralshouldbe.

Ifthewheelturnswhileholdingthedrive leverinneutral,theneutralcontrollinkages needtobeadjusted.Ifthewheelstopsthen gotostep7.

Page 35

Maintenance

Figure17

ViewedfromLeftSideofUnit

1.NeutralControlLinkage5.SpeedControlLinkage

2.HydroControlLinkage

6.Adjusthere-rotateat approximately1/4 turnincrementsand re-check.

3.DriveLeverLinkage7.Loosennut

4.SpeedControlCrank

8.Yoke

4.Loosenthenutagainsttheneutralcontrol linkageyokeasshowninFigure17.

5.Adjusttheneutralcontrollinkageuntil therespectivedrivewheelstopswhenthe leverispulledagainsttheneutralspring (neutralposition).Turntheadjustingbolt approximately1/4turnclockwiseifthe wheelisturninginreverseorturnthebolt approximately1/4turncounterclockwiseif thewheelisturningforward.Releasethe drivelevertotheforwarddrivepositionand squeezebackintotheneutralposition.Check toseeifthewheelstops.Ifnot,repeatthe aboveadjustmentprocedure.

6.Makethisadjustmentonbothsides.

7.Afteradjustmentsaremadeandthewheels stopwhenthedriveleversareintheneutral position,tightenthenutsagainsttheyokes.

•AdjustHydroControlLinkages:

1.Placethespeedcontrolleverinthe“neutral” position.Thisadjustmentisagainmadewith rearofmachineonjackstandsandengine runningatfullthrottle.OPCleverswillhave

tobehelddownandtheparkbrakemustbe disengagedwheneverspeedcontrolleversare movedoutoftheneutralposition.

Note:Theneutrallocklatchesshouldbe “unlocked”andintheforwardposition.

2.Loosenthefrontnutonlefthydrocontrol linkageasshowninFigure17.Turntherear controllinkageadjustingnutcounterclockwise untilwheelrotatesforward.Turntherearnut ofleftcontrollinkageclockwise1/4ofaturn atatime,stoppingtomovethespeedcontrol forwardandbacktoneutral,untilleftwheel stopsrotatingforward.

Turntherearnutanadditional1/2turnand tightenthefrontnutmakingsurenottoput abindonthelinkage.Makesureatpartof linkageisperpendiculartopinpartofswivel (see

Figure18).

Figure18

1.LeftHydroControlLink (leftsideshown)

4.Linkageisperpendicular topin(correctposition)

2.Frontnut5.Linkageinincorrect position

3.Rearnut

6.Endviewofswivel

Afteradjustingthelefthydrocontrollinkage, movethespeedcontrollevertothemid-speed positionandthenbacktotheneutralposition. Rechecktheleftdrivewheelrotationtoseeif furtheradjustmentisnecessary-besurethe speedcontrolleverisintheneutralposition.

Important:Ifinconsistentneutraloccurs, checktobesurebothspringsareproperly tightenedonthespeedcontrolleverunder theconsole–especiallytherearpivot spring.

Repeataboveadjustmentsifnecessary.

3.Placethespeedcontrolleverinneutral.Adjust therightsidelinkagebyturningthequicktrack knobcounterclockwiseuntilthetirebeginsto rotateforward.Begintoretightentheknob

Page 36

Maintenance

clockwiseabout1/4turnatatime,stopping tomovethespeedcontrolforwardandback toneutral.Recheckthedrivewheelrotation toseeiffurtheradjustmentisnecessary.

4.Thespringthatkeepstensionontheknob shouldnormallynotneedadjustment. However,ifadjustmentisneeded,adjustto wherelengthofspringisabout1inch(2.5cm) betweenthewashers.Adjustspringlengthby turningnutatfrontofspring.

•DriveLeverLinkageAdjustment:

1.Withrearofmachinestillonjackstandsand enginerunningatfullthrottle,disengage theparkbrakeandmovethespeedcontrol levertothemidwayposition.Movethe respectivedriveleverupwarduntilitreaches theneutralpositionandengageneutrallock latches(

Figure19).Ifthetirerotatesineither direction,thelengthofthedriveleverlinkwill needtobeadjusted.

Figure19

2.Adjustthelinkagelengthbylooseningthejam nutsatbothendsofthelinkageandrotating thelinkageintheballjoints.Lengthenthe linkageifthetireisturninginreverseand shortenthelinkageifthetireiscreeping forward.Tightenthejamnutsatbothends. Releaseandre-engagetheneutrallocklatch checkingthatthetirestops.Continuethis processuntilthetireisatadeadstop.

3.Makethisadjustmentforbothsides.

4.Stopengineandwaitforallmovingparts tostop.Raiserearofmachine,removejack

stands,andcarefullylowermachinetothe ground.

TrackingAdjustment

1.Stopengineandwaitforallmovingpartstostop.

2.Checkthedrivetirepressuresandtire circumferencesasstatedinChecktheTire PressuressectioninMaintenance.

3.Runtheunitandobservethetrackingonalevel, smooth,hardsurfacesuchasconcreteorasphalt.

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

HydroPumpSpringTension Setting

1.Formediumorheavydutydriveconditionssuch asoperationwithasulkyonsteepslopes,ahigher springforcemayberequiredonthehydropump controlarmstopreventthedrivesystemfrom stalling.

2.Foraheavierdrivesetting,relocatethespring anchorlinkasshowninFigure13.Thespring anchorlinksarelocatedundertheenginedeckon theleftandrighthandsides.

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

Figure20

1.Heavyduty

3.Standard

2.Mediumduty4.Retainingbolt

Page 37

Maintenance

PTOSafetySwitch

Mountedtoatabontheinsideleftsideofthefuel tanksupport.

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removeignitionkeyor sparkplugwire(s).

2.WithPTOdisengagedandthebellcranktouching therearoftheslotintheenginedeck,adjustthe PTOsafetyswitch(ifneeded)untilthebellcrank armis5/16inch(7.9mm)fromtheswitchbody.

3.BesurethebellcrankDoesNottouchtheswitch bodyordamagetotheswitchcouldoccur.

4.RetightenPTOswitchmountinghardware.

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancauseengine, exhaustarea,andhydraulicsystemtooverheat whichcancreatearehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

3.Makesurecoolingshroudsareproperlyreinstalled. Operatingtheenginewithoutcoolingshroudswill causeenginedamageduetooverheating.

Page 38

Maintenance

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanoffanyoil,debris,orgrassbuild-uponthe machineandcuttingdeck,especiallyunderdeck beltshields,aroundthefueltank,aroundengine andexhaustarea.

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which ispoisonousandcancausesevereburns. Swallowingelectrolytecanbefatalorifittouches skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber glovestoprotectskinandclothingwhen handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately.

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

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

Page 39

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.PTOisengaged.

1.DisengagethePTO.

2.Speedcontrolleverisarenotinneutral lockposition.

2.Ensurethespeedcontrolleverisinthe neutrallockposition.

3.OPCleversarereleased.

3.DepressOPClevers.

4.Batterydoesnothaveafullcharge.

Chargethebattery.SeeCheck

BatteryChargeandRecommended JumpStartingProceduresectionsin

Maintenance.

5.Electricalconnectionsarecorroded,loose orfaulty.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

6.Fuseisblown.6.Replacetheblownfuse.

Starterdoesnotcrank(ElectricStartUnits).

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

2.Openthefuelshutoffvalve.

3.Thethrottleandchokearenotinthe correctposition.

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

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

5.Dirt,water,orstalefuelisinthefuel system.

5.ContactanAuthorizedServiceDealer.

6.Aircleanerisdirty .

6.Cleanorreplacetheaircleanerelement.

7.Electricalconnectionsarecorroded,loose orfaulty.

7.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Faultysparkplug.

9.Clean,adjustorreplacesparkplug.

Enginewillnotstart,startshard,orfailsto keeprunning

10.Sparkplugwireisnotconnected.

10.Checkthesparkplugwireconnection.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty .

2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow .

3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe engineareplugged.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.V entholeinthefuelcapisplugged.

5.Cleanorreplacethefuelcap.

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

Enginelosespower

7.Dirt,water,orstalefuelisinthefuel system.

7.ContactanAuthorizedServiceDealer.

Page 40

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

Engineoverheats

3.Coolingnsandairpassagesforthe engineareplugged.

3.Removetheobstructionsfromthecooling nsandairpassages.

1.Trackingneedsadjustment.1.Adjustthetrackingbyturningknobonthe righthydrocontrollinkageinthedirection thatthemowerneedstobeadjustedto . Turntheknobin1/4turnincrements untilthemowertrackscorrectly.

Mowerpullsleftorright(withleversfully forward).

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor

broken.

2.Changethebelt.

Machinedoesnotdrive.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

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

2.Cuttingblade(s)is/arebent.

2.Installnewcuttingblade(s).

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand front-to-rear.

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

Unevencuttingheight.

7.Tipsofadjacentbladesareatanuneven

cuttingheight.Bladestipsshouldbeeven within3/16inchwhichisapproximately onebladethickness.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

1.Cuttingblade(s)is/arebentorunbalanced.

1.Installnewcuttingblade(s).

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade pulley.

4.Tightentheappropriatepulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

Abnormalvibration

7.Beltisdamaged.7.Installnewbelt.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Drivebeltisoffpulley.2.Checkbeltfordamage;replaceif

necessary.Installdrivebeltandcheck adjustingshaftsandbeltguidesforcorrect position.

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler

pulley,idlerarmandspringforcorrect positionandfunction.

5.Brokenormissingidlerspring.

5.Replacethespring.

Bladesdonotrotate.

6.PTOclutchdoesnotengage.6.ContactanAuthorizedServiceDealer.

Page 41

Schematics

ElectricalDiagram

MANUAL START

SAFETY INTERLOCK MODULE

TRANSMISSION

SWITCH

N.O.

PARK BRAKE

SWITCH N.O.

BLADE

SWITCH

N.O.

OPC SWITCH

N.O.

KEY SWITCH

ENGINE

GROUND

ENGINE KILL

CONNECTORS ARE VIEWED FROM WIRE END N.C. = NORMALLY CLOSED N.O. = NORMALLY OPEN

GREEN

BLUE

ORANGE

GREEN

YELLOW

RED

BLACK

RED

BLACK

BROWN

G016896

Page 42

Schematics

ElectricalDiagram

FUSE

NEUTRAL

PTO SWITCH

GROUND

OPERATOR PRESENCE

SWITCH

KILL RELAY

SWITCH

BRAKE

IGNITION SWITCH

ENGINE

1 2 5 4 3

1 2

1 1

2 1

ORANGE

BLACK

MAG

REGULATOR

SOLENOID (-)

FUEL SOLENOID

B+

START

GREEN

YELLOW

GREEN

WHITE WHITE ORANGE

BLUE RED

RED

PINK PINK

VIOLET

A S B X Y

4 1 2

1 1

34 1

5 2 3 4 6 1

G016897

ELECTRIC START

TERMINAL CONNECTIONS

IGNITION SWITCH

B + I + A

NONE

X + Y

CIRCUIT "MAKE"

B + I + S

2. RUN

1. OFF

POSITION

3. START

TERMINAL A ENGINE KILL

TERMINAL B BATTERY

TERMINAL I PTO/NEUTRAL SAFETY CIRCUIT

TERMINAL S START

TERMINAL X REGULATOR

TERMINAL Y BATTERY

TERMINAL X

TERMINAL Y

TERMINAL A

TERMINAL B

TERMINAL S

TERMINAL I

NOTE: CONNECTORS VIEWED FROM MATING COMPONENT

Page 43

Schematics

HydraulicDiagram

Page 44

Conditions and Products Covered

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

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

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine *

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

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

 Exmark Customer Service Department  The Exmark Warranty Company  2101 Ashland Avenue  Beatrice, NE 68310  402-223-6375 or  service@exmark.com

Owner’s Responsibilities

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

General Conditions

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

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

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

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

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-589_C

Page 45

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

Page 46

Page 47

G011841

Figure21

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopeindicatortodeterminethe degreeofslopeofhillsbeforeoperating.DoNotoperatethismachineonaslopegreaterthan20degrees.Fold alongtheappropriatelinetomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

Page 48

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT R IDING ACCESSORIES A ND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

PartNo.4500-955Rev.A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark TTS481KA363, TTS481KA483CA, TTS481KA363CA, TTS481KA483, TTS541KA523 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual