Exmark TURF TRACER, Turf Tracer TT24KAE, Turf Tracer TT24KAECA Operator's Manual

TURFTRACER®

ForSerialNos.
850,000&Higher

PartNo.4500-528Rev.B

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:IMPORTANTTheengineinthis
productisnotequippedwithasparkarrester
mufer.ItisaviolationofCaliforniaPublic
ResourceCode(CPRC)Section4442touse
oroperatethisengineonanyforest-covered,
brush-covered,orgrass-coveredlandasdened
inCPRC4126.Otherstatesorfederalareasmay
havesimilarlaws.

Toacquireasparkarresterforyourunit,seeyour
EngineServiceDealer.

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

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

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

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

©2010ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

2

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

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

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,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.

3

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Transporting.................................................20

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

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

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

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

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

CheckMowerBlades.....................................24

CheckSafetyInterlockSystem.......................25

CheckforLooseHardware............................26

ServiceAirCleaner........................................26

ChangeEngineOil........................................26

CheckHydraulicOilLevel.............................26

CheckTirePressures.....................................26

CheckConditionOfBelts..............................27

LubricateGreaseFittings...............................27

LubricateCasterWheelHubs........................27

RemoveEngineShroudsandCleanCooling

Fins...........................................................28

CheckSparkPlugs.........................................28

ChangeHydraulicSystemFilter.....................29

ThreadLockingAdhesives.............................30

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................31

Copper-BasedAnti-seize..............................31

DielectricGrease...........................................31

Adjustments.....................................................31

DeckLeveling...............................................31

PumpDriveBeltTension...............................31

DeckBeltTension.........................................31

BladeDriveBeltTension..............................31

ParkBrakeAdjustment..................................31

HydroDriveLinkageAdjustment..................31

TrackingAdjustment.....................................33

HydroPumpSpringTensionSetting..............34

ElectricClutchAdjustment............................34

Cleaning...........................................................34

CleanGrassBuild-UpUnderDeck................34

WasteDisposal..............................................34

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

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

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

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.

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

5

Safety

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
infuelleakageordamagetotheengineor
emissionsystem(ifequipped).

•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.

6

Safety

Operation

WARNING

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

•Allowengineparts,especiallythemufer,to
coolbeforetouching.

•Removeaccumulateddebrisfrommufer
andenginearea.

•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.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

damageandmakerepairsbeforerestarting
andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

–Beforemakingheightadjustments.

WARNING

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

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

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

•DONOToperatethemowerwhenpeople,
especiallychildren,orpetsareinthearea.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

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

7

Safety

DANGER

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Lossofcontrol
and/orlossofoperator’sfootingcouldresultina
fallwithanarmorleggettingunderthemower
orenginedeckwhichmayresultinserious
injury,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.

8

Safety

DANGER

Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith
waterandcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagement
ofcomponents.Sparkscouldcausean
explosionormovingpartscouldaccidentally
engagecausingpersonalinjury

Besureignitionswitchisinthe“OFF”
positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipmentparts,
orusingnon-Exmarkreplacementpartsand
accessoriesmayalterthewarranty,traction,and
safetyofthemachine.Failuretouseoriginal
Exmarkpartscouldcauseseriousinjuryor
death.

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.

9

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.

1-303517

1-403143

1-413214

103–1541

10

Safety

103–2242

103–2243

103-4935

103-2432

116-0404

117–2718

11

Specications

Specications

ModelNumbers

SerialNos:850,000andHigher

TT20KCE,TT24KAE,TT24KAECA

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s
Manual

•RPM:FullSpeed:3600(NoLoad)

FuelSystem

•Capacity:5.0gal.(18.9L)

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

•FuelFilter:ReplaceableIn-line

•FuelShut-OffValve:1/4turnincrements

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:BCIGroupU1235amps0°F

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:Twobladetype,20amptochargingcircuit;
20amptoelectricclutch

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

•TwoHydroGearvariabledisplacementpiston
pumpsindependentlycoupledtotwohigh
efciencyParkerwheeldrivemotors.

•HydraulicOil:UseExmarkPremiumHydroOil.

•HydraulicOilCapacity:2.4qt.(2.2L)

•HydraulicFilterisreplaceablecartridgetype.

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

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

•Speeds:

–0-6.75mph(10.9km/hr)forward.

–0-2.25mph(3.6km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.

WheelDriveSystem

DrivewheelsaredirectcoupledtoParkerwheeldrive
motorswith1inch(25.4mm)taperedshaft.

12

Specications

Tires&Wheels

DriveFrontCaster

Pneumatic
(Air-Filled)

Pneumatic
(Air-Filled)

Semi­Pneumatic

AllSerial
Nos.

SN599,999
&Lower

SN600,000
&Higher

Quantity

222

Tread

TurfMasterSmoothSmooth

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

PlyRating

44

Pressure

14psi(96
kPa)

16psi(110
kPa)

CuttingDeck

•ModelNumbers:

–FMD524

–FMD604

•CuttingWidth:

–52inch(132.1cm)

–60inch(152.4cm)

•Discharge:Side

•BladeSize:(3ea.)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

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

•DeckDrive:

–Electricclutchmountedonengineshaft.

–Bladesdrivenbytwobelts(w/self-tensioning

idlers).

•Deck:

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

•DeckDepth:

–52inchDeck:5.5inches(14.0cm)

–60inchDeck:5.5inches(14.0cm)

•CuttingHeightAdjustment:

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

•MulchingKit:Optional

•Bagger:Optional

Dimensions

OverallWidth:

52inchDeck60inchDeck

DeectorUp53.4inches

(135.6cm)

61.4inches
(156.0cm)

DeectorDown64.8inches

(164.6cm)

73.0inches
(185.4cm)

OverallLength:

52inchDeck60inchDeck

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

OverallHeight:

52inchDeck60inchDeck

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

TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)

52inchDeck60inchDeck

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

WheelBase:(CenterofCasterTireto
CenterofDriveTire)

52inchDeck60inchDeck

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

CurbWeight:

52inchDeck60inchDeck

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

13

ProductOverview

TorqueRequirements

BoltLocation

Torque

CutterHousingSpindle
Nut

140–145ft-lb(190–197
N-m)

BladeMountingBolt
(lubricatewithanti-seize)

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

EngineDeck/Mower
DeckSupportMount
Bolts

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

Type1Hardware
–Anti-ScalpRoller
WhizlockNutSeeFigure9

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

Type2
Hardware–Anti-Scalp
RollerNylocNutSee
Figure9

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

Type2&3Hardware
–Anti-ScalpRollerHex
CapscrewSeeFigure9

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

Type3
Hardware–Anti-Scalp
RollerFlangedNylocNut
SeeFigure9

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

Type4
Hardware–Anti-Scalp
RollerWhizlockNutSee
Figure9

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

Type4
Hardware–Anti-Scalp
RollerNylocNutSee
Figure9

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

EngineMountingBolts—
Kohler

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

EngineMountingBolts—
Kawasaki

17–23ft-lb(23-31N-m)

WheelLugNuts

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

WheelHubSlottedNutsminimum100ft-lb(136

N-m)

ClutchRetainingBolt
(securedwiththreadlocker)

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

WheelMotorMounting
Bolts

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

ProductOverview

Figure3

1.Controls

3.ParkBrakeLever

2.FuelCap4.Height-of-CutPins

14

Operation

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

Locatedonthecontrolconsolefrontrighthandside.

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

ThrottleControl

Locatedonthecontrolconsole’srightside.

Thethrottleisusedtocontrolenginespeed.Moving
thethrottlecontrolforwardwillincreaseengine
speedandmovingittotherearwilldecreaseengine
speed.Movingthethrottleforwardintothedetent
isfullposition.

SpeedControlLever

Locatedinmiddleofcontrolconsole.

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

Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.

BrakeLever

Locatedontheleftsideoftheunitabovethe
hydraulictank.

15

Operation

Thebrakeleverengagestheparkbrakeonthedrive
wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe
brake.

Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
engaged.Theunitmustbetieddownandbrake
engagedwhentransporting.

Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.

IgnitionSwitch

Locatedontheleftsideofthecontrolconsole.

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

HourMeter

Locatedonthefrontlefthandsideofconsolejust
abovethePTOswitch.

Thehourmeterisconnectedtoapressureswitch
installedintheengineblockanditrecordsthe
numberofhoursthattheenginehasrun.Ifignition
switchisleftonwithoutenginerunning,hourmeter
willnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot
alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locatedinthefuellinemidwaybetweenthetank
andengine.

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

Rotatevalve1/4turnclockwisetoshutfueloff.
Rotatevalve1/4turncounterclockwisetoturnfuel
on.

DriveWheelReleaseValves

Locatedontheleftrearcornerofthehydrostatic
pumps.

Drivewheelreleasevalvesareusedtoreleasethe
hydro-staticdrivesystemtoallowthemachinetobe
movedbyhandwithouttheenginerunning.

Witha5/8wrench,turnbothvalvesoneturn
counterclockwisetoreleasethedrivesystem.

Turnclockwisetoresetthedrivesystem.DoNot

overtighten.

TrackingAdjustmentKnob

Locatedontheright-handsideoftherearofthefuel
tanksupport.

Theknobcanbeadjustedsothatmachinewill
“track”straightaheadwiththedriveleversreleased.

PTOEngagementSwitch

Switchislocatedonleftsideofcontrolconsole.

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

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.

16

Operation

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethevalve1/4turncounterclockwisetoturn
fuelon.

StartingtheEngine

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

2.Turnignitionswitchto“Start”position.Release
theswitchassoonastheenginestarts.

3.Onacoldengine,graduallyreturnchoketothe
“Off”positionafterenginestartsandwarmsup.

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

Note:Itishelpfultohavetheleftandright
neutrallocklatcheslockedinneutralwhen
startingtheengine.RefertoNeutralLock
LatchessectioninControls.

EngagingthePTO

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.PullthePTOswitchoutwardtothe“ROTATE”
positiontoengagetheblades.

3.Placethethrottleinthe“FAST”positiontobegin
mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushthePTOswitchintothe“STOP”position
todisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Lockdriveleversinneutral.

3.DisengagethePTO.

4.Movespeedcontrollevertoneutral.

5.Engagetheparkingbrake.

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

7.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.

8.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.

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

17

Operation

DrivingtheMachine

DriveLever/NeutralLockLatchOperation

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

CAUTION

Iftheneutrallocklatchesarenotcompletely
engagedthedriveleverscouldunexpectedlyslip
intotheforwarddriveposition.Ifthedrivelevers
slipintothedrivepositiontheunitcouldlurch
forwardandcauseinjuryorpropertydamage.

Besurethedriveleversarepasttherollerand
securelyseatedatthebottomoftheneutrallock
latches.

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

Figure5position3.

Toplacethedriveleversinthe“reverse”position,
squeezethedriveleverspasttheneutralposition.See
Figure5position4.

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.

18

Operation

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.

Figure6

1.Decksupportpin

2.CuttingHeight

B.ThetirepressuresaresetasdirectedinCheck

TirePressuresintheMaintenancesection.

C.Thelengthofthereardecksupportlink

assembliesaverage6.89inches(approximately

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

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

Figure7

LeftHandSideShown

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller
position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethedriveleversto
theneutrallockposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

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

6.Adjustanti-scalprollersforNormalOperating
Conditions.Placerollersinoneofthepositions
shownin

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

Note:ForMaximumDeckFlotation,place
rollersoneholepositionlower.Rollersshould

19

Operation

maintain1/4inch(6.35mm)clearancetoground.
DoNotadjustrollerstosupportthedeck.Be
surerollerboltsareinstalledwiththespringdisc
washerbetweenheadoftheboltandmounting
bracket.

Figure8

Forcuttingheightsabove3.5inches(38mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller
mountingbracket

2.Cuttingheight

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

Figure9.

Figure9

Frontleftanti-scalpbracketshown

1.Type1hardware

2.Type2hardware

3.Type3hardware

4.Type4hardware

5.(Type1)3/8–16x4hexscrew

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

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

(41–47N-m)

8.Springdiscwasher(conetowardsbolthead)

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

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

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

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

(41–47N-m).

Transporting

TransportingaUnit

WARNING

Loadingthemowerontoatrailerwithoutstrong
enoughorproperlysupportedrampscouldbe
dangerous.Therampscouldcollapsecausing
theunittofall,whichcouldcauseinjury.

•Useproperrampsthataresecuredtothe

truckortrailer.

•Keepfeetandlegsoutfromundertheunit

whenloadingandunloading.

•Ifnecessary,useassistancewhenloading.

Besurethefuelshut-offvalveisclosed.

Useaheavydutytrailertotransportthemachine.
Engageneutrallocklatchesandparkbrake,then
blockwheels.

20

Operation

Securelyfastenthemachinetothetrailerwithstraps,
chains,cables,orropes.

DoNotrelysolelyontheparkingbraketoholdthe
machineonthetrailer.

Besurethatthetrailerhasallnecessarylightingand
markingasrequiredbylawanduseasafetychain.

21

Maintenance

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rst5hours

•Changetheengineoil.

Aftertherst250hours

•Changethehydrauliclter.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Cleanthegrassbuild-upfromunderthedeck.

Every40hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethehydrocontrolarmsupportbushings.

Every80hours

•Removeengineshroudsandcleancoolingns.

Every100hours

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

Every160hours

•Checkthesparkplugs.

Every250hours

•Replacetheprimaryaircleanerelement—checksecondaryaircleanerelement;replaceif
dirty.(Mayneedmoreoftenundersevereconditions.SeetheEnginemanualforadditional
information.)

Every500hours

•Replacethesecondaryaircleanerelement.(Mayneedmoreoftenundersevereconditions.
SeetheEnginemanualforadditionalinformation.)

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

Monthly

•Checkthebatterycharge.

Yearly

•Greasethefrontcasterwheelhubs.

•Greasefrontcasterpivots.

•Greasetheidlerpivots(MowerDeck).

•Greasetheidlerpivot(PumpDrive).

•Lubricatethecasterwheelhubs.

22

Maintenance

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Checkwithenginecold.

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

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

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

CheckBatteryCharge

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof
timewithoutrechargingthemwillresultinreduced
performanceandservicelife.T opreserveoptimum
batteryperformanceandlife,rechargebatteriesin
storagewhentheopencircuitvoltagedropsto12.4
volts.

Note:Topreventdamageduetofreezing,battery
shouldbefullychargedbeforeputtingawayfor
winterstorage.

Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebatteryin
thetableandchargethebatteryfortherecommended
timeintervaltobringthechargeuptoafullcharge
of12.6voltsorgreater.

Important:Makesurethenegativebatterycable
isdisconnectedandthebatterychargerusedfor
chargingthebatteryhasanoutputof16voltsand
7ampsorlesstoavoiddamagingthebattery(see
chartforrecommendedchargersettings).

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

0%

14.4volts/2
amps

6Hoursor
More

RecommendedJump
StartingProcedure

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.

23

Maintenance

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–SurfaceVehicleRecommended
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
thestarterorsolenoidasshownin

Figure10.

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).

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstated
intheCleanGrassBuild-UpUnderDeck
procedure.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstallblades(iftheywereremoved)inthe
followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

24

Maintenance

Figure11

1.Installbushinginbladepriortoinstallingbushingin
spindle.

B.Installbushing/bladecombointospindle.

Figure12

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

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

C.Applylubricanttothreadsofbladeboltas

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

WARNING

Incorrectinstallationofthebladeor
componentsusedtoretainthebladecan
bedangerous.Failuretousealloriginal
componentsandassembledasshowncould
allowabladeorbladecomponenttobe
thrownoutfromunderthedeckresultingin
seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,
bladebushings,andbladeboltsasshown.

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

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

TrytostarttheenginewithOPClevers
disengaged,speedcontrolleverinneutraland
PTOdisengaged-startermustnotcrank.

Trytostartwith,OPCleversdepressed,speed
controlleverinanyspeedbutneutralandPTO

disengaged-startermustnotcrank.

TrytostartwithOPCleversdepressed,
speedcontrolleverinneutralandPTO
engaged-startermustnotcrank..

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

Note:Parkbrakemustbedisengagedbeforethe
speedcontrolleverismovedoutofneutralorengine
willkill.

Note:Ifmachinedoesnotpassanyofthesetests,
donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing .

25

Maintenance

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every250hours—Replace

theprimaryaircleaner
element—check
secondaryaircleaner
element;replaceifdirty.
(Mayneedmoreoften
undersevereconditions.
SeetheEnginemanualfor
additionalinformation.)

Every500hours—
Replacethesecondary
aircleanerelement.(May
needmoreoftenunder
severeconditions.See
theEnginemanualfor
additionalinformation.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.SeetheEngineOwner’sManualformaintenance
instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May
needmoreoftenunder
severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseislocatedonrighthandsideof
engineforKohlerorlefthandsideforKawasaki.
Placepanundermachinetocatchoil.Remove
plugfromendofdrainhose.Allowoiltodrain
andreplaceoildrainplug.Torqueplugto20-24
ft-lb.

4.Replacetheoilltereveryotheroilchange.Clean
aroundoillterandunscrewltertoremove.

Beforereinstallingnewlter,applyathincoating
ofoilonthesurfaceoftherubberseal.Turn
lterclockwiseuntilrubbersealcontactsthelter
adapterthentightenlteranadditional1/2to
3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto
speciedcapacityandreplacecap.

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

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop,
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atedrivetiresto12–14psi(83–97kPa).

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

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

26

Maintenance

Note:Frontcastertireshavepermanenttire

sealantinstalled.

ForSerialNos.600,000andHigher:

Semi-pneumaticcastertiresdonotneedtobe
inated.

Note:DoNotaddanytypeoftirelinerorfoam
llmaterialtothetires.Excessiveloadscreatedby

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

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removethethreemowerdeckbeltshields
tocheckmowerprimaryandsecondarybelt
condition.

3.Lookunderenginedecktocheckthepumpdrive
beltcondition.

4.Checkallidlerarmstobesuretheypivotfreely.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

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

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.Front
Caster
WheelHubs

*0

2

*Yearly

2.Front
Caster
Pivots

*0

2

*Yearly

3.Idler
Pivots
(Mower
Deck)

12

Yearly

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

4.Idler
Pivot(Pump
Drive)

21

Yearly

5.Hydro
Control
Arm
Support
Bushings

22

40Hours

*Seestep3forspeciallubricationinstructionson
thefrontcasterpivotsandtheLubricateCaster
WheelHubssectionforspeciallubrication
instructionsonthefrontcasterswheelhubs.

Number4(IdlerPivot(PumpDrive)Located

UnderEngineDeck

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

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

27

Maintenance

Figure13

1.Sealguard2.Spacernutwithwrench
ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor
damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1
multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Seals(ExmarkP/N103-0063)mustbe
replaced.

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

9.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.

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

11.Insertthesecondbearingandnewsealintothe
wheel.

12.Applyathreadlockingadhesivetothe2ndspacer
nutandthreadontotheaxlewiththewrenchats
facingoutward.

13.Torquethenutto75-80in-lb(8-9N-m),loosen,
thenre-torqueto20-25in-lb(2-3N-m).Make
sureaxledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband
insertwheelintocasterfork.Reinstallcasterbolt
andtightennutfully.

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

RemoveEngineShroudsand
CleanCoolingFins

ServiceInterval:Every80hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

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

3.Makesurecoolingshroudsareproperly
reinstalled.Operatingtheenginewithout
coolingshroudswillcauseenginedamagedueto
overheating.

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps,
orreplacewithnewplugs.SeeEngineOwner’ s
Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledinthefuellinebetweenthe
fueltankandtheengine.Replacewhennecessary.

ReplacementFilters

Kawasaki

KawasakiP/N
49019–7001

28

Maintenance

ChangeHydraulicSystem
Filter

ServiceInterval:Aftertherst250hours

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

Note:UseonlyExmarkPartNo.109-4180for

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

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Carefullycleanareaaroundlter.Itisimportant
thatnodirtorcontaminationenterhydraulic
system.

3.Unscrewltertoremoveandallowoiltodrain
fromreservoir.

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

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

Raisingthemowerforserviceormaintenance
relyingsolelyonmechanicalorhydraulic
jackscouldbedangerous.Themechanicalor
hydraulicjacksmaynotbeenoughsupport
ormaymalfunctionallowingtheunittofall,
whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

7.Ifeitherdrivewheeldoesnotrotate,oneorboth
ofthechargepumps(locatedonthetopofthe
mainpumpasshownin

Figure14)mayhavelost
their“prime”.RefertoHydraulicSystemAir
Purgesection.

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

Changingoilunnecessarilycoulddamagehydraulic
systembyintroducingcontaminatesintothesystem.

HydraulicSystemAirPurge

ServiceInterval:Asrequired

Airmustbepurgedfromthehydraulicsystem
whenanyhydrauliccomponents,includingoil
lter,areremovedoranyofthehydrauliclinesare
disconnected.

Thecriticalareaforpurgingairfromthehydraulic
systemisbetweentheoilreservoirandeach
chargepumplocatedonthetopofeachvariable
displacementpump(

Figure14).Airinotherpartsof
thehydraulicsystemwillbepurgedthroughnormal
operationoncethechargepumpis“primed”.

29

Maintenance

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.

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.

FuelTank—Mounting
HardwareSpecications

ServiceInterval:Asrequired

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

ThreadLockingAdhesives

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

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol
arms.

•Shoulderboltsinendsofspeedcontrolcrank.

•OPCleversetscrews.

•Electricclutchretainingbolt.

•Pumpdriveidlerpivotbolt.

•Thumblatchscrewthreadsonhandles.

•Casterwheelspacernuts.

•Fueltankbulkheadttingnuts.

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

30

Maintenance

•OPCleverhubsandcross-shaft

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

•Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or
Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused
inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing
locations:

OnthreadsofBladeBoltsSerialNos.540,000and
Higher.SeeCheckMowerBladessectionfor
instructions.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.

Adjustments

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

DeckLeveling

SeeAdjustingtheCuttingHeightsectionin
Operation.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

DeckBeltTension

Self-tensioning-Noadjustmentnecessary.

BladeDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

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(seeFigure15).
Thesetabsshouldbepointingstraightdown
atthe6o’clockpositionorslightlyforward.
Adjustthethreadedyokeatthebottomofthe

31

Maintenance

speedcontrollinkage(seeFigure15)untilthe
tabsarepositionedcorrectly.

Figure15

ViewedfromLeftSideofUnit

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

2.ActuatingTabinneutral
position

3.Pullthespeedcontrolleverbacktoneutral.
Checkthattheneutralsafetyswitchactuating
tabhasdepressedtheplungeroftheswitch
sothatthereisabout5/16inch(7.9mm)
betweenthetabandtheswitch(see

Figure15).

Ifnecessary,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.

Figure16

ViewedfromLeftSideofUnit

1.NeutralControlLinkage5.SpeedControlLinkage

2.HydroControlLinkage

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

3.DriveLeverLinkage7.Loosennut

4.SpeedControlCrank

8.Yoke

4.Loosenthenutagainsttheneutralcontrol
linkageyokeasshownin

Figure16.

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.

32

Maintenance

Note:Theneutrallocklatchesshouldbe

“unlocked”andintheforwardposition.

2.Loosenthefrontnutonlefthydrocontrol
linkageasshownin

Figure16.Turntherear
controllinkageadjustingnutcounterclockwise
untilwheelrotatesforward.Turntherearnut
ofleftcontrollinkageclockwise1/4ofaturn
atatime,stoppingtomovethespeedcontrol
forwardandbacktoneutral,untilleftwheel
stopsrotatingforward.

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

Figure17).

Figure17

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
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(

Figure18).Ifthetirerotatesineither
direction,thelengthofthedriveleverlinkwill
needtobeadjusted.

Figure18

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.

33

Maintenance

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.

Figure19

1.Heavyduty

3.Standard

2.Mediumduty4.Retainingbolt

ElectricClutchAdjustment

Noadjustmentnecessary.

Cleaning

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.

34

Troubleshooting

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.

4.

Chargethebattery.SeeCheck

BatteryChargeandRecommended
JumpStartingProceduresectionsin

Maintenance.

5.Electricalconnectionsarecorroded,loose
orfaulty.

5.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

6.Fuseisblown.6.Replacetheblownfuse.

Starterdoesnotcrank.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

2.Openthefuelshutoffvalve.

3.Thethrottleandchokearenotinthe
correctposition.

3.Besurethethrottlecontrolismidway
betweenthe“SLOW”and“F AST”
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.

35

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.

36

Schematics

Schematics

ElectricalDiagram

37

Schematics

ElectricalLogicSchematic

38

Schematics

HydraulicDiagram

39

Conditions and Products Covered

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

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

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine 2 years*

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

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

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

Instructions for Obtaining Warranty Service

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

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

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

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

Owner’s Responsibilities

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_B

40

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

41

42

G011841

Figure20

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

43

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT R IDING ACCE SSORIES AND 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.

©2010ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved

PartNo.4500-528Rev .B
[phone]
Fax[phone]
PrintedintheUSA

www.exmark.com