Exmark Z CT User Manual

r

For Serial Nos.

670,000 & Highe

Part No. 109-6436 Rev A.

WARNING

POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating pr actices can result in serious

operator injury or even death.
HOW TO AVOID THE HAZARD
♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condit ion.
♦ Stop engine, wait for all moving part s t o st op, and engage

parking brake. Remove spark plug wire(s) or remove key before

adjusting, servicing, or performing maintenance.
♦ If mower deck becomes clogged, stop engine, wait for all moving

parts to stop, and engage par king brake. Remove spark plug

wire(s) or remove key before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts .
♦ Keep off mower unless seat platf o r m is pr ovided.
♦ Keep others off mower.

WARNING

POTENTIAL HAZARD
♦ Gasoline is harmful or f at a l if swallowed. Long-term exposure to

vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN
♦ Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD

♦ Avoid prolonged breathing of vapors.
♦ Keep face away from nozzle and gas tank/container opening.
♦ Keep away from eyes and skin.
♦ Never siphon by mouth.

IMPORTANT

When the mower is used or oper ated on any California forest, brush or grass covered land, a working
spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442
Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.

This spark ignition system complies with Canadian ICES-002
Ce système d’allumage par ètincelle de vèhicule est conform e à la norme NMB-002 du Canada

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and the California Emission Control Regulation of
emission systems, maintenance and warranty.

Keep this engine Owner’s M anual with your unit. Should this engine O wner’s Manual become
damaged or illegible, replace immediately. Replacements may be ordered through the engine
manufacturer.

Exmark reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products manufactured previously. Exmark, or its
distributors and dealers, accept no responsibility f or variat ions which may be evident in the actual
specifications of its product s and t he statements and descriptions contained in this publication.

i

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995
Program

If your Exmark dealer does not have the Exmark part in stock,
Exmark will get the parts to the dealer the next business day or
the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

2. Distributor ships part(s) to dealer or customer, as

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

5. The customer pays for the part

6. Who pays for the part
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus

®

shipment of six (6) line items or less.

requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.

®

order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus

®

order of six (6) line items or less.

distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.

and freight if it is shipped under the Exmark Parts Plus® and if it arrives in

accordance to the program.

and freight if it fails to arrive overnight in accordance to the program?

1. The dealer not submitting the Exmark Parts Plus

®

order to his Exmark distributor by 1:00 p.m., the dealer

pays for the part and freight.

®

order

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

Exmark pays for the part and freight.

pays for the part.

The following restrictions apply

-- The Exmark Parts Plus® Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available
only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental
United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air
charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no
responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by
3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus

®

Program are:
Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and
5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United
Parcel Service size and weight restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day
or Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be
ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

ii

CONGRATULATIONS on the purchase of your Exmark Mower. This product has been
carefully designed and manufactur ed to give you a maximum amount of dependability and
years of trouble-free oper at ion.

OPERATOR'S MANUAL

This manual contains operating, maintenance, adjustment, and safety instructions for
your Exmark mower.

BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.

By following the operating, m aintenance, and safety instructions, you will prolong the life
of your mower, maintain its maximum ef ficiency, and promote safe operation.

If additional information is needed, or should you require trained mechanic ser vice,
contact your authorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and distributors are kept infor med of the latest methods
of servicing and are equipped to provide prompt and efficient service in the f ield or at their
service stations. They carry ample stock of ser vice parts or can secur e t hem promptly for you
from the factor y.

All Exmark parts are thor oughly tested and inspected before leaving the factory,
however, attention is required on your part if you are t o obt ain the fullest measure of
satisfaction and performance.

iii

TABLE OF CONTENTS

1. SAFETY PAGE

1.1 Safety Alert Symbol............................................................................1

1.2 Training..............................................................................................1

1.3 Preparation......................................................................................1-4

1.4 Operation........................................................................................4-8

1.5 Maintenance & Storage................................................................... 8-9

1.6 Safety Signs..................................................................................9-11

2. SPECIFICATIONS

2.1 Model Numbers................................................................................12

2.2 Engine..............................................................................................12

2.3 Fuel System.....................................................................................12

2.4 Electrical System..............................................................................12

2.5 Operator Controls.............................................................................12

2.6 Seat.............................................................................................12-13

2.7 Hydrostatic Ground Drive System.....................................................13

2.8 Tires & Wheels.................................................................................13

2.9 Cutting Deck.....................................................................................13

2.10 Dimensions.......................................................................................14

2.11 Torque Requirements.......................................................................14

3. OPERATION INSTRUCTIONS

3.1 Controls.......................................................................................14-17

3.2 Pre-Start...........................................................................................17

3.3 Mowing........................................................................................17-18

3.4 Transporting................................................................................19-20

4. MAINTENANCE & ADJUSTMENTS

4.1 Periodic Maintenance..................................................................21-30

4.2 Adjustments ................................................................................30-35

5. WASTE DISPOSAL

5.1 Motor Oil Disposal............................................................................36

5.2 Battery Disposal...............................................................................36

6. TROUBLE SHOOTING........................................................................36-37

7. ELECTRICAL DIAGRAM .........................................................................38

8. HYDRAULIC DIAGRAM...........................................................................39

9. WARRANTY...............................................................................................40

iv

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the machine to
identify important safety messages which must be followed to avoid accidents. This
symbol means:

ATTENTION! BECOME ALERT!

The safety alert symbol appears above information which alerts you to unsafe actions or
situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lettering / Red background. Indicates an im m inent ly hazardous situat ion
which, if not avoided, WILL result in death or serious injur y.

WARNING: Black lettering / Or ange background. Indicates a potent ially hazardous
situation which, if not avoided, COULD result in deat h or serious injury.

CAUTION: Black lettering / Yellow background. Indicates a potentially hazardous
situation which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to
all who operate this unit.

1.2.2 Read the instructions carefully. Familiar ize yourself with the cont r ols and t he
proper use of the equipment. If the operator(s) or m echanic(s) can not read
English it is the owner’s responsibility to explain this material t o them.

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow
children, teenagers, or people unfamiliar with these instructions to use the mower.
Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind
that the operator or user is responsible for accidents or hazards occurring to other
people or their property.

YOUR SAFETY IS INVOLVED!

1.3 PREPARATION

1.3.1 Evaluate the terrain to determine what accessories and attachment s ar e needed

to properly and safely perform the job. Only use accessories and attachments
approved by Exmark.

1.3.2 The use of personal protective equipment, such as (but not limited to) prot ect ion

for the eyes, ears, feet , and head is r ecom m ended.

CAUTION

POTENTIAL HAZARD
♦ This machine produces sound levels in

excess of 85 dBA at the operator’s ear

when in operation.
WHAT CAN HAPPEN
♦ Exposure to sound levels of 85 dBA or

above for extended periods of time can

cause hearing loss.
HOW TO AVOID THE HAZARD
♦ Wear hearing protection when operating

this machine.

1

1.3.3 While mowing, always wear substantial f oot wear and long t rousers. Do not
operate equipment when barefoot or when wearing open sandals.

1.3.4 Thoroughly inspect the area where the equipment is t o be used and r e m ove all
stones, sticks, wires, bones, and other foreign objects which may damage the
equipment or cause personal injury to the operat or or bystander s.

WARNING

POTENTIAL HAZARD
♦ Engine exhaust contains carbon

monoxide, which is an odorless deadly

poison.
WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.
HOW TO AVOID THE HAZARD
♦ Do not run engine indoors or in a small

confined area where dangerous carbon

monoxide fumes can collect.

DANGER

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely

flammable and highly explosive.
WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can burn

you, others, and cause property damage.
HOW TO AVOID THE HAZARD

♦ DO NOT smoke while refueling , and stay

away from an open flame or where
gasoline fumes may be ignited by spark .

♦ Refuel only outdoors.
♦ Store gasoline in an approved container

and keep it out of the reach of children.

♦ Add fuel before start ing the engine.

Never remove the cap of the fuel t ank or

add fuel when engine is running or when
the engine is hot.

♦ Never fill the fuel tank so that the gasoline

level rises above a level that is 1/2” below
the bottom of the filler neck to allow for
gasoline expansion and prevent fuel
spillage.

♦ If fuel is spilled, DO NOT attempt to start

the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.

♦ Do not operate without entire exhaust

system in place and in proper working

condition.

2

DANGER

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely

flammable and highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite g asoline

vapors. A fire or explosion from g asoline

can burn you, others, and cause property

damage.
HOW TO AVOID THE HAZARD

♦ Purchase and store gasoline only in an

approved container.

♦ Always place gasoline containers on the

ground away from your vehicle before
filling.

♦ Do not fill gasoline containers inside a

vehicle or on a truck or trailer bed
because interior carpets or plastic truck
bed liners may insulate the container and
slow the loss of any static charge.

♦ When practical, r em ove g as- powered

equipment from t he t r uck or trailer and
refuel the equipment with its wheels on
the ground.

♦ If this is not possible, then refuel such

equipment on a truck or t r ailer from a
portable container, rather than from a
gasoline dispenser nozzle.

♦ If a gasoline dispenser nozzle must be

used, keep the nozzle in contact with the

rim of the fuel tank or container opening

at all times until fueling is com p let e.

3

WARNING

POTENTIAL HAZARD
♦ Gasoline vapor can collect inside

enclosed trailers and may be ignited by

electrical sparks or hot engine/ exhaust

components.
WHAT CAN HAPPEN
♦ Explosion and fire may occur, resulting in

property damage, personal injury, and/or

death.
HOW TO AVOID THE HAZARD

♦ Provide adequate ventilation of any

enclosed trailer to prevent build up of
gasoline vapors, especially at floor level.

♦ Refuel only outdoors, never inside an

enclosed trailer.

♦ Be sure all fuel tanks and gasoline

storage containers have proper caps
installed to prevent spillage and minimize
vapor escaping into the trailer.

♦ Do not place any equipment that is

leaking gasoline in an enclosed trailer.

1.4 OPERATION

Although hazard control and accident prevention parti al l y are dependent upon the

design and configuration of the equipment, these factors are also dependent upon
the awareness, concern, prudence, and proper training of t he personnel i nvolved
in the operation, transport, maintenance, and storage of the equipment. It is
essential that all Operator Safet y M echanisms be connected and in operating
condition prior to use for mowing.

WARNING

POTENTIAL HAZARD
♦ Operating engine parts, especially the

muffler, become extremely hot.
WHAT CAN HAPPEN

♦ Severe burns can occur on contact.
♦ Debris, such as leaves, grass, brush, etc.

can catch fire.
HOW TO AVOID THE HAZARD

♦ Allow engine parts, especially the muff ler ,

to cool before touching.

♦ Remove accumulated debris from muffler

and engine area.

♦ Install and maintain in working order a

spark arrester before using equipment on

forest-covered, grass-covered, or br ush-

covered unimproved land.

4

WARNING

POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories

can become entangled in rotating part s .
WHAT CAN HAPPEN
♦ Contact with rotating parts can cause

traumatic amputation or severe

lacerations.
HOW TO AVOID THE HAZARD

♦ Do not operate the machine without

guards, shields, and safety devices in
place and working properly.

♦ Keep hands, feet, hair, j ewelry, or clot hing

1.4.1 Give complete, undivided attention to the job at hand.

1.4.2 Mow only in daylight or good artificial light, keeping away from holes and hidden
hazards. NEVER carry passengers.

DO NOT operate the mower when children or others are in t he ar ea!

1.4.3 When feasible, avoid operating the equipment in wet gr ass.

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr action
and/or tip-over could occur. The operator is r esponsible for safe operation on
slopes.

away from rotating parts.

DANGER

POTENTIAL HAZARD
♦ Mowing on wet grass or steep slopes can

cause sliding and loss of control.
WHAT CAN HAPPEN
♦ Wheels dropping over edges, ditches,

steep banks, or water can cause

rollovers, which may result in serious

injury, death or drowning.
HOW TO AVOID THE HAZARD

♦ Do not mow slopes when grass is wet.
♦ Do not mow near drop-offs or near water.
♦ Do not mow slopes greater than 15

degrees.

♦ Reduce speed and use extreme caution

on slopes.

♦ Avoid sudden turns or rapid speed

changes.

• See inside the back cover to determine the approximate slope angle of t he
area to be mowed.

• Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep
banks or water. This area can be dangerous, see Figure 1.

5

FIGURE 1

• Progr essively great er care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. I f tires lose traction,

disengage the blades and proceed slowly off the slope.

• Avoid sudden starts when mowing uphill. Mower may tip backwards.

• Be aware that loss of traction may occur going downhill. Weight transf er to

the front wheels may cause drive wheels to slip and cause loss of braking
and steering.

• Watch for ditches, holes, rocks, dips, and rises that chang e t he oper ating
angle, as rough terrain could overtur n the machine.

• Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing
area. Tall grass can hide obstacles.

• Use extreme care with grass cat chers or attachments. These can change t he
stability of the machine and cause loss of control.

• Follow the manufact urer’s recommendations for wheel weights or
counterweights to improve stability.

1.4.5 A Rollover Protection System (roll bar) is installed on t he unit.

WARNING

POTENTIAL HAZARD
♦ There is no rollover protection when the

roll bar is down.
WHAT CAN HAPPEN
♦ Wheels dropping over edges, ditches,

steep banks, or water can cause

rollovers, which may result in serious

injury, death or drowning.
HOW TO AVOID THE HAZARD

♦ Keep the roll bar in the raised and locked

position and use seat belt.

♦ Lower the roll bar only when absolutely

necessary.

♦ Do not wear seat belt when the roll bar is

down.

♦ Drive slowly and carefully.
♦ Raise the roll bar as soon as clearance

permits.

6

• Be certain t hat the seat belt can be released quickly if the m achine is dr iven or
rolls into ponds of water.

• Check carefully for overhead clearances (i.e. branches, door ways, and
electrical wires) before driving under any objects and do not contact them.

1.4.6 Use EXTREME caution when backing up. LOOK BEHI ND YOU!!

1.4.7 Stop the blades when crossing surfaces other than grass and when transporting
the mower to and from the area to be m owed.

1.4.8 Never operate the mower with defective guards, shields, or covers. Always have
safety shields, guards, switches, and other devices in place and in proper
working condition.

1.4.9 DO NOT change the engine governor settings or overspeed the engine. Oper at ing
an engine at excessive speed may increase the hazard of personal injury.

1.4.10 Disengage PTO before starting engine.

1.4.11 Start

the engine carefully with feet well away from the blades.

1.4.12 Keep hands, feet, and clothing away from rotating par t s while the mower is being
operated.

1.4.13 Stop engine, wait for all moving parts to stop, and remove key:

• Before checking, cleaning or working on the m ower.

• After striking a foreign obj ect (inspect the mower for damage and make
repairs before restart ing and operating the mower).

• Before clearing blockages.

• Whenever you leave the mower.

Stop the engine and wait for all moving part s t o stop:

• Before refueling.

• Before dumping the grass catcher.

1.4.14 Before stopping the engine, place the throt t le cont r ol midway between the “slow”
and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop
the engine.

1.4.15 The f uel system is pr ovided with a shut-off valve. The fuel shut-off valve is used
to shut off the fuel:

• When the machine will not be used for a few days.

• During transport to and from the job.

• When parked inside a building.

1.4.16 This mower was designed fo r one oper at or only. Keep all others away from
mower during operation.

1.4.17 Do Not mow with the discharge deflector raised, removed, or altered unless
there is a grass collection system or mulch k it in place and work ing properly.

1.4.18 Be aware of the mower discharg e and dir ect discharge away from others.

1.4.19 Do Not operat e t he m ower under t he influence of alcohol or drugs.

1.4.20 Use extra care when approaching blind corners, shr ubs, trees, or other objects
that may obscure vision.

1.4.21 If jump starting is required:

a) connect the positive (+) power cable from the positive post on the boost er

battery to the positive terminal post on the star ter solenoid switch (this post
has the positive battery cable attached to it).

7

b) connect the neg ative or ground cable (-) f rom the negative post on the

booster battery to any engine deck gr ound, pr eferably the engine block as
far away from the battery as possible.

c) disconnect battery cables in the reverse order after starting.

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maintenance, follow the engine m anufacturer’s recommendations

precisely as stated in the engine manual.

1.5.2 Disconnect the battery cable from t he negative battery post when the unit will be

allowed to sit for more than 30 days without use.

1.5.3 Allowing batteries to stand for an extended period of time without recharging them

will result in reduced performance and service life. To preserve optimum battery
performance and life, recharge batteries in storage when the open circuit voltage
drops to 12.4 volts.

Note: To prevent damage due to freezing, bat t er y should be fully charged before

putting away for winter storage.

1.5.4 Keep engine, engine area, and hydraulic pump area free from accumulation of

grass, leaves, excessive grease or oil, and other debris which can accumulate in
these areas. These materials can become combust ible and may result in a fire.

1.5.5 Store fuel in a container specif ically desig ned for this purpose in a cool, dry place.

1.5.6 Keep the mower and fuel container in locked storage to prevent children from

playing or tampering with them.

1.5.7 Gasoline powered equipment or fuel containers should not be stored in a basement

or any enclosed area where open pilot lights or heat appliances are present.

1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly

maintained and operated correctly.

1.5.9 Check all bolts frequently to maintain proper tightness.

1.5.10 Keep all guards, shields and all safety devices in place and in safe working condit ion.

1.5.11 Frequently check for worn or deteriorating components that could create a hazard.

1.5.12 All replacement parts must be the same as or eq uivalent t o t he par ts supplied as

original equipment.

8

POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure

can penetrate skin and cause injury.
WHAT CAN HAPPEN
♦ Fluid accidentally injected into the skin

must be surgically removed within a few

hours by a doctor familiar with this for m of

injury or gangrene may result.
HOW TO AVOID THE HAZARD

♦ Make sure all hydraulic fluid hoses and

lines are in good condition an all hydraulic
connections and fittings are tight before
applying pressure to hydraulic system.

♦ Keep body and hands away from pinhole

leaks or nozzles that eject high pressure
hydraulic fluid.

♦ Use cardboard or paper, not your hands,

to find hydraulic leaks.

♦ Safely relieve all pressure in the hydraulic

system by placing the motion control

levers in neutral and shutting off the

engine before perfor ming any work on the

hydraulic system.

1.6 SAFETY SIGNS

1.6.1 Keep all safety signs legible. Remove all grease, dirt, and debris from safety signs
and instructional labels.

1.6.2 Safety signs must be replaced if they are missing or illegible.

1.6.3 When new components are installed, be sur e that current safety signs are affixed
to the replaced components.

1.6.4 New safety signs may be obtained from your authorized Exmark equipment dealer
or distributor or from Exmar k Mfg. Co. Inc.

1.6.5 Safety signs may be affixed by peeling off the backing to expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.

1.6.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They are
critical to the safe operation of your Exmark commercial mower.

PART NO. 108-5995
LOCATION: Top of Console Under Seat

WARNING

9

PART NO. 103-4891
LOCATION: Center of Console

PART NO. 103-4892
LOCATION: Right of Throttle

Control on RH Tank

PART NO. 109-1196
LOCATION: Top Front of RH

Tank

PART NO. 103-4930
LOCATION: Right of Choke

Control on RH Tank

PART NO. 1-303508
LOCATION: Front Right Corner
Top of Mower Deck

PART NO. 1-403005
LOCATION: Left and Right Corners

of Mower Deck

PART NO. 98-5954
LOCATION: Under Mower Deck

Belt Shield(s)

PART NO. 1-523552
LOCATION: Top of Hydraulic

Reservoir

10

PART NO. 107-2102
LOCATION: RH Inside Surface

of Upper Roll bar

PART NO. 1-633922
LOCATION: Front Left Corner Top

of Mower Deck

PART NO. 1-513742
LOCATION: On Top of Mower

Deck Belt Shields,
Left and Right Sides

PART NO. 103-9116
LOCATION: Bottom of Back Side of Seat

PART NO. 107-2112
LOCATION: Top Center of Floorpan

PART NO. 1-513746
LOCATION: On Engine

Blower Housing
PART NO. 103-2644
LOCATION: Top of Hydraulic

Reservoir

PART NO. 103-9287
LOCATION: Left of Center on Mower

Deck, Under Floor Pan

PART NO. 109-3148
LOCATION: On Top LH Side of Mower Deck

PART NO. 1-513748
LOCATION: Bottom of Floorpan

PART NO. 1-653147
LOCATION: Lefthand Side of Cutting

Height Adjustment Plate

11

2. SPECIFICATIONS

2.1 MODEL NUMBER:

Serial Nos. 670,000 & Higher: LCT18BV483; LCT21BV523; LCT23BV603

2.2 ENGINE:

2.2.1 Engine Specifications: See Your Engine O wner’s Manual

2.2.2 RPM: Full Speed: 3600 RPM (No Load) Idle: 1500 RPM

2.3 FUEL SYSTEM

2.3.1 Capacity: 5.8 gal. (21.9 L.)

2.3.2 Type of Fuel: Regular unleaded g asoline, 87 octane or higher.

2.3.3 Fuel Filter: Replaceable in- line Bri ggs and St rat ton P/N 493629

2.3.4 Fuel Shut-Off Valve: in-line, 1/4 turn

2.4 ELECTRICAL SYSTEM

2.4.1 Charging System: Flywheel Alternator

2.4.2 Charging Capacity: 15 amps

2.4.3 Battery Type: BCI Group U1

2.4.4 Battery Voltage: 12 Volt

2.4.5 Polarity: Negative Ground

2.4.6 Fuses: Two 20 amp blade type

2.4.7 Safety Interlock System:
PTO must be disengaged, brake engaged, and motion control levers out

(neutral lock) to start engi ne. (It is not necessary for the operator t o be in the
seat to start the engine.)

Operator must be in seat when PTO is engaged, brake is disengaged, or
motion control levers are moved in or engine will stop.

Engine will stop if either the left, the right, or both levers are moved from
neutral lock position while brake is engaged.

2.5 OPE RATOR CONTROLS

2.5.1 Steering and Motion Control:
Separate levers, on each side of the console, contr ol speed and dir ect ion of

travel of the respective drive wheels.
Steering is controlled by varying the position of the levers relative to each other.
Moving motion control levers outward
Motion control levers are adjustable to two heights.

2.5.2 PTO Switch

2.5.3 Parking Brake Lever

2.5.4 Deck Height Adjustment Lever

2.5.5 Deck Lift Assist Lever

: Engages electric clutch (t o dr ive belt) which engages mower blades.

: Engages parking brake.

2.6 SEAT

2.6.1 Type: Standard seat: high back, foam padded (int er nal spring

suspension) with armrests.

Optional Seat accessories:

• Custom ride suspension system to enhance Standard Seat.

• Deluxe suspension seat with high back, low profile foam-in-place cushion

(dampened, adjustable spring suspension) and arm r est s .

(in slots) locks the drive system in neutral.

: Sets cutting height to desired position.

: Foot pedal that assists in raising the deck.

12

2.6.2 Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other

components. Held in tilted position with prop rod. Adjustable fore and aft seat t r ack.

2.6.3 Armrests: Standard seat: foam padded flip-up armrests.

Optional suspension seat: molded flip-up armrests.

2.6.4 Seat Safety Switch: Incorporated into t he Safety Interlock System.

Time delay seat switch eliminates rough ground cut-outs.

2.7 HYDROS TATIC GROUND DRIVE SYSTEM

2.7.1 Hydrostatic Pumps: Two Hydro Gear variable displacement piston pumps.

2.7.2 Wheel Motors: Two Hydro Gear wheel drive motors with 1 1/4” tapered shafts.

2.7.3 Hydraulic Oil: Use Mobil 1 15W-50 Synthet ic Motor O il.

2.7.4 Hydraulic Oil Capacity: 2.1 qt. (2. 0 L.)

2.7.5 Hydraulic Filter: Replaceable cartridge type.

P/ N 109- 4180: 25 m icr ons, 10 psi bypass (Summer use above 32° F (0°C))
P/ N 1- 523541: 40 microns, 18 psi bypass (Winter use below 32° F(0°C))

2.7.6 Speeds: All units: 0 – 7.2 mph (11.6 km/hr) forward.

0 – 4.0 mph (6.4 km/hr) r everse.

2.7.7 Drive wheel release valves allow machine to be moved when the engine is not

running.

2.8 TIRES AND WHEELS

2.8.1 Tires:

Drive Tires 20 x 10-8 2 “Turf Mate” 4 13 psi (90 kPa)
Front Caster Tires 11 x 4.00-5 2 Smooth 4 16 psi (110 kPa)

Size Qty Tread Ply Inflation

2.9 CUTTING DE CK

2.9.1 Cutting Width:

48” deck 52” deck

47.2 in.

(120.0 cm)

52 in.

(132.1 cm)

2. 9. 2 Discharg e: Side (Optional Mulch or Bag)

2.9.3 Blade Size:
(3 ea.)

48” deck 52” deck

16.25 in.

(41.3 cm)

18.00 in.

(45.7 cm)

2.9.4 Blade Spindles: solid steel spindles with 1” (2.54 cm) I.D. bearings.

2.9.5 Deck Drive: Electric clutch mounted on vertical engine shaft. Blades are driven
by one “B” Section belt (w/self-tensioning idler) direct from the engine.

2.9.6 Deck: Full floating deck is attached to out-front suppor t frame.

Maximum turf protection is provided anti-scalp rollers:

48” Decks: Qty 3
52” Decks: Qty 5
60” Decks: Qty 6

Deck design allows for bagging, mulching or side discharge.

2.9.7 Cutting Height Adjustm ent : an extr a- long cushioned lever is used to adjust the
cutting height from 1-1/2” (3.8 cm) to 4-1/2” ( 11. 4 cm.) in 1/4” (.64 cm.)
increments.

The cutting height adjustment handle has a transport position and all adjustm ents

can be made while the operator remains seated. The foot operated deck lift assist
lever to aids in raising the deck.

2.9.8 Mulching Kit: Optional.

60” deck

60 in.

(152.4 cm)

60” deck

20.50 in.

(52.1 cm)

13

2.10 DIMENSIONS

2.10.1 Overall Width:

Without deck
Discharge chute up
Discharge chute down

2.10.2 Overall Length:

Roll Bar - Up 73.9 in.

Roll Bar - Down 79.6 in.

2.10.3 Overall Height:

w/48” Deck w/52” Deck

44 in.

(111.7 cm)

50.3 in.

(122.4 cm)

58.1 in.

(147.6 cm)

48” Deck 52” Deck 60” Deck

(187.7 cm)

(202.2 cm)

Roll Bar - Up Roll Bar - Down

69.4in. (176.3 cm) 51.3 in. (130.3 cm)

44 in.

(111.7 cm)

54.3 in.

(137.9 cm)

63.8 in.

(162.1 cm)

75.5 in.

(191.8 cm)

81.2 in.

(206.2 cm)

2. 10. 4 Tread Width: (center to center of tires, widthwise)

48” Deck 52” Deck

Drive Wheels

Front Casters

34.9 in.

(88.6 cm)

32.7 in.

(83.1 cm)

34.9 in.

(88.6 cm)

34.1 in.

(86.6 cm)

2. 10. 5 Wheel Base: ( center of caster tire to center of drive tire)

w/60” Deck

49.8 in.

(124.5 cm)

60.9 in.

(154.7 cm)

70.6 in.

(179.3 cm)

77 in.

(195.6 cm)

82.4 in.

(209.3 cm)

60” Deck

39.8 in.

(101.1 cm)

35.4 in.

(89.9 cm)

48” Deck 52” Deck 60” Deck

(117.3 cm)

2.10.6 Curb Weight : 48” Deck 52” Deck 60” Deck

874 lbs.

(396 kg)

2.11 TORQUE REQUIREMENTS

Bolt Location Torque

Cutter Housing Spindle Nut ............................................140-145 ft-lbs. (190-197 N-m)

Blade Mounting Bolt (lubricate w/anti-seize)............................55-60 ft-lbs. (75-81 N-m)

Engine Deck/Front Frame Mount Bolts...................................30-35 ft-lbs. (41-47 N-m)

Anti-Scalp Roller Nuts.............................................................40-45 ft-lbs. (54-61 N-m)

Engine Mounting Bolts ...........................................................25-30 ft-lbs. (34-41 N-m)

Wheel Motor Mounting Bolts.................................................72-77 ft-lbs. (98-104 N-m)

Wheel Hub Slotted Nut ..................................................minimum 125 ft-lbs. (169 N-m)

Wheel Lug Nuts ..................................................................90-95 ft-lbs. (122-129 N-m)

Rollover Protection System (roll bar) Mounting Bolts ..............30-35 ft -lbs. (41-47 N-m)

Clutch Retaining Bolt (secured with threadlocker)...................55-60 ft-lbs. (75-81 N-m)

3. OPERATION INSTRUCTIONS

46.2 in.

46.2 in.

(117.3 cm)

887 lbs.

(402 kg)

48.8 in.

(124 cm)

978 lbs.

(444 kg)

3.1 CONTROLS

3.1.1 Familiarize yourself with all controls before operat ing the mower.

3.1.2 Motion Control Levers

The left lever controls the flow of hydraulic oil from the left hydrost atic pump to
the left drive wheel motor. The r ight lever controls the flow of hydraulic oil f rom
the right hydrostatic pump to the right drive wheel motor.

: Located on each side of the console.

14

IMPORTANT: To begin movement (forward or backward) the operator must
be in the seat, the brake lever must be disengaged (pushed down) before
the motion control levers can be moved in or the engine will kill.

When levers are centered in the T-slot the drive system is in the neutral posit ion.
With levers moved out in t he T-slot the drive system is in the neutral lock
position (See Figure 2).

FIGURE 2

By moving both levers an equal amount forward or back from the neutral
position the machine can be caused to move forward or backward in a str aight
line.

Movement of the left lever forward will cause the left drive wheel to rotate in a
forward direction. Movement of the right lever f orw ard will cause the right
drive wheel to rotate in a forward direction. To stop forward travel, pull the
levers back to the neutral position.

To turn left while moving forward, move the left lever back toward neutral to
slow the left drive wheel. To turn right while moving forward, move the right
lever back toward neutral to slow the right drive wheel.

To make a zero turn to the left, pull the left lever back beyond neutral while
holding the right lever slight ly ahead of neutral.

To make a zero turn to the right, pull the right lever back beyond neutral while
holding the left lever slight ly ahead of neutral.

Pulling the levers back from t he neutral position will cause the respective drive
wheels to rotate in a reverse direction (spring tension can be felt when moving
into reverse from neutr al) .

To turn to the left while backing, move the left lever f o r ward toward neutral. To
turn to the right while backing , m ove the right lever forward toward neutral.

CAUTION

POTENTIAL HAZARD
♦ Machine can spin very rapidly by

positioning one lever too much ahead of

the other.
WHAT CAN HAPPEN
♦ Operator may lose control of the

machine, which may cause damage to

the machine or injury.
HOW TO AVOID THE HAZARD

♦ Use caution when making turns.
♦ Slow the machine down before making

sharp turns.

15

3.1.3 Tracking Adjustment Knob:
Rotating this knob allows fine tuning adj ustments so that the machine track s st r aight
with the drive levers in the full forward position.

Stop machine and wait for all moving parts t o stop. Engage park brake. Unhook
seat latch and tilt seat forward to gain access to the tracking k nob. Rotate the knob
counter-clockwise (as viewed from the rear of t he m achine) to cause the machine
to track more to the r ig ht and clockwise to cause the machine to track more to the
left. Adjust in quar ter-turn increments until the m achine t racks straight. Check that
the machine does not creep when in neutral with the park brakes disengaged.

IMPORTANT: Do not rotate the knob too far, as this may cause the machine
to creep in neutral. Refer to section 4.2. 10 f or cont rol l inkage adjustment.

3.1.4 PTO Engagement Switch

: Located on the right tank.

Switch must be pulled out to the “ROTATE” position to engage the blades.
Switch is pushed in to the “STOP” position to stop the blades.

3.1.5 Choke Control

: Located on the right fuel t ank.

Choke is used to aid in starting a cold engine. DO NOT run a warm engine with
choke in the “ON” position.

Moving the choke lever forward will put the choke in the “ON” position and
moving the choke lever to the rear, to the detent , will put the choke in the “OFF”
position.

3.1.6 Throttle Control

: Located on the right tank.

Throttle is used to control engine speed. Moving throttle lever forward will increase
engine speed and moving throttle lever to the rear will decrease engine speed.
Moving the throttle forward into the detent is full speed.

3.1.7 Brake Lever

: Located on left side of t he console. The brake lever engages a

parking brake on the drive wheels.

Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the brake.

The unit must be tied down and brake engaged when transpor ting.

3.1.8 Ignition Switch

: Located on the right tank.

The ignition switch is used to start and stop the engine. The switch has three
positions “OFF”, “ON” and “START”. Insert the key into switch and rotate
clockwise to the “ON” position.

Rotate clockwise to the next position to engage the starter (key must be held
against spring pressure in this position) .

Brake must be engaged, motion control levers out (neutr al l ock position)
and PTO switch “OFF” to start engine. (It is not necessary for the operator t o

be in the seat to start the engine. )

3.1.9 Hour Meter

: Located on the right tank.

The hour meter is connected to a pressur e switch installed in t he engine block
and it records the number of hour s t hat the engine has run. If ignit ion switch is
left on without engine running, hour m eter will not run.

NOTE: This switch is not a low oil sensor and will not alert the operator if the
engine oil is low.

3.1.10 Fuel Shut-Off Valve

: Located In the fuel line midway between the fuel tank and

the engine behind seat.
The fuel shut-off valve is used to shut off the fuel when the machine will not be

used for a few days, during transport to and from the jobsite, and when park ed
inside a building.

Located under the seat on the LH pump control link .

16

Rotate the valve 1/4 turn clockwise to shut off fuel. Rotate the valve 1/4 turn
counter-clockwise to turn on fuel.

3.1.11 Fuel Gauge
of fuel in the tank .

3.1.12 Drive Wheel Release Valves
pumps. Drive wheel release valves are used to release the hydrostatic drive
system to allow the machine to be pushed without the engine running. Unhook
seat latch and tilt seat up to gain access to pum ps.

With a 5/8 wrench, t ur n both valves one turn counter-clockwise to release drive
system.

Turn clockwise to reset system. DO NOT overtighten. DO NOT tow machine.

3.2 PRE-START

3.2.1 Fill fuel tank. For best r esults use only clean, fresh regular gr ade unleaded gasoline

with an octane rating of 87 or higher . Regular grade leaded gasoline may also be
used; however, combustion chamber and cylinder head will require more fr equent
service. See Engine Owner's Manual. DO NOT add oil to gasoline.

Do Not overfill fuel tank . Never fill the fuel tank so t hat the fuel level rises above a
level that is 1/2” below the bottom of the filler neck to allow for fuel expansion and
prevent fuel spillage.

3.2.2 Make sure you understand the controls, their locations, their functions, and their

safety requirements.

3.2.3 Refer to Maintenance, Section 4, and perf orm all the necessary inspection and

maintenance steps.

3.3 MOWING

3.3.1 Operate units with the roll bar in the raised and locked position and use seat belt.

There is no rollover protection when the roll bar is down. If it is necessary to lower
roll bar do not wear the seat belt. Raise the roll bar as soon as clear ance permits.

3.3.2 Open fuel shut-off valve.

The fuel shut-off valve is located under the seat in the fuel line between the left

fuel tank and the engine.

3.3.3 Starting Engine:

Brake must be engaged, t he PTO switch disengaged, and the motion control

levers out (neutral lock position). ( The operator does not need to be in the seat
to start the engine.)

On a cold engine, place the throttle midway between the “SLOW” and “FAST”
positions and place the choke to the “ON” position. Turn ignition switch to the
“start” position. Release the switch as soon as the eng ine starts.

IMPORTANT:
seconds at a time. If the engine does not st art , allow a 60 second cool-down
period between starting at t empt s. Fai lure to follow these guidel ines can
burn out the starter motor.

After starting a cold engine, gradually return choke to the “OFF” position as the
engine warms up.

On a warm engine, place the throttle midway between the “SLOW” and “FAST”
positions and leave the choke in the “OFF” position.

: Located on the left f uel t ank. The fuel gaug e m onitors the amount

: Located on the right front corner of the hydrostatic

DO NOT crank the engine continuously for more than ten (10)

17

3.3.4 Engaging PTO

DANGER

POTENTIAL HAZARD
♦ The rotating blades under the mower

deck are dangerous.
WHAT CAN HAPPEN
♦ Blade contact can cause serious injury or

kill you.
HOW TO AVOID THE HAZARD
♦ DO NOT put hands or feet under t he

mower or mower deck when the blades

are engaged.

DANGER

POTENTIAL HAZARD
♦ An uncovered discharge opening will

allow objects to be thrown in an

operator’s or bystander’s direction. Also,

contact with the blade could occur.
WHAT CAN HAPPEN
♦ Thrown objects or blade contact can

cause serious injury or death.
HOW TO AVOID THE HAZARD
♦ Never operate the mower with the

discharge deflector raised, r emoved, or

altered unless there is a grass collection

system or mulch kit in place and working

properly.

The PTO clutch push-pull switch engages t he cutting blades. Be sure that all
persons are clear of mower deck and discharge area before engaging PTO.

IMPORTANT

: Operator must be in seat before the PTO can be engaged.

Set throttle to "midway" position. Pull outward on the switch to the “ROTATE”
position. Accelerate to full throttle to begin mowing.

3.3.5 Stopping PTO

: Set the throttle to the “midway” position. Push in on the switch to

the “STOP” position stopping t he PTO.

3.3.6 Stopping Engine

: Bring unit to a full stop. Disengage the PTO, move motion

control levers out to the neutral lock position and engage parking brake.
Before stopping the eng ine, place t he throttle control midway between the “slow”

and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then
stop the engine.

Rotate ignition switch to “OFF” posit ion. Rem o ve the key to prevent children or
other unauthorized persons from star t ing engine.

Close fuel shut-off valve when machine will not be used for a few days, when
transporting, and when the unit is park ed inside a building.

18

3.4 TRANSPORTING

3.4.1 Transport ing a Unit: Use a heavy-duty trailer or truck to t ransport the machine.
Lock brake and block wheels. Securely fasten the machine to the trailer or truck
with straps, chains, cable, or ropes. Be sure that t he t railer or truck has all
necessary lighting and marking as required by law.

Secure a trailer with a safety chain.

POTENTIAL HAZARD
♦ This unit does not have proper turn

WHAT CAN HAPPEN

♦ Driving on a street or roadway without

♦ Driving on a street or roadway without

CAUTION

signals, lights, reflective markings, or a
slow moving vehicle emblem. These
items are required to drive on a public
street or roadway.

such equipment is dangerous and can
lead to accidents causing personal injury.

such equipment may also be a violation of
State laws and the operator may be

subject to traff ic tickets and/or fines.
HOW TO AVOID THE HAZARD
♦ Do not drive a unit on a public street or

roadway.

19

WARNING

POTENTIAL HAZARD
♦ Loading a unit on a trailer or truck

increases the possibility of backward tip-

over.
WHAT CAN HAPPEN
♦ Backward tip-over of the unit could cause

serious injury or death.
HOW TO AVOID THE HAZARD

♦ Use extreme caution when operating a

unit on a ramp.

♦ Use only a single, full width ramp; DO

NOT use individual ramps for each side of
the unit.

♦ If individual ramps must be used, use

enough ramps to create an unbroken
ramp surface wider than the unit.

♦ DO NOT exceed a 15° angle between

ramp and ground or between ramp and
trailer or truck.

♦ Avoid sudden acceleration while driving

unit up a ramp to avoid tipping backward.

♦ Avoid sudden deceleration while backing

unit down a ramp to avoid tipping

3.4.2 Loading a Unit: Use extr em e caution when loading units on trailers or truck s.
One full width ramp that is wide enough to extend beyond the rear tire s is
recommended instead of individual ramps f or each side of the unit. The lower
rear section of the tractor frame extends back between the rear wheels and
serves as a stop for tipping backward. Having a full width ramp provides a
surface for the frame members to contact if the unit starts to tip backward. I f it is
not possible to use one full width ramp, use enough individual ramps t o sim ulate
a full width continuous ramp.

Ramp should be long enough so that the angles between the ramp and the
ground and the ramp and the trailer or truck do not exceed 15°. A steeper angle
may cause mower deck components to get caught as the unit moves from ramp
to trailer or truck. St eeper angles may also cause the unit to tip backward. If
loading on or near a slope, position the trailer or truck so it is on the down side of
the slope and the ramp extends up the slope. This will minimize the ramp angle.
The trailer or truck should be as level as possible.

backward.

DO NOT attempt to turn the unit while on the ramp, you may lose control and
drive off the side.

Avoid sudden acceleration when driving up a ramp and sudden deceleration when
backing down a ramp. Both maneuvers can cause the unit to tip backward.

20

4. MAINTENANCE & ADJUSTMENTS

WARNING

POTENTIAL HAZARD
♦ While maintenance or adjustments are

being made, someone could start the

engine.
WHAT CAN HAPPEN
♦ Accidental starting of the engine could

seriously injure you or other bystanders.
HOW TO AVOID THE HAZARD
♦ Remove the key from the ignition switch

and pull the wire(s) off the spar k plug(s)

before you do any maintenance. Also

push the wire(s) aside so it does not

accidentally contact the spark plug(s) .

WARNING

POTENTIAL HAZARD
♦ The engine can become very hot.
WHAT CAN HAPPEN
♦ Touching a hot engine can cause severe

burns.
HOW TO AVOID THE HAZARD
♦ Allow the engine to cool completely before

service or making repairs around the

engine area.

4.1 PERIODIC MAINTENANCE

4.1.1 Check engine oil level:

Service Interval: Daily

a) Stop engine, wait for all moving parts to stop and mak e sur e unit is on a

level surface.
b) Check with engine cold.
c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the

dipstick. Screw dipstick into place. Remove the dipstick and read the oil

level.
d) If t he oil level is low, wipe off the area around the oil fill cap, remove cap,

and fill to the “FULL” mark on the dipstick. Use oil as specified in t he

Engine Owner’s Manual.

DO NOT overfill.

IMPORTANT: DO NOT operate the engine with the oil level below the
“LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

21

4.1.2 Clean engine air cooling system

:

Service Interval: Dail y or more of t en in dry conditions

CAUTION

POTENTIAL HAZARD
♦ Excessive debris can cause the engine

and hydraulic system to overheat.
WHAT CAN HAPPEN
♦ Excessive debris around the engine

cooling air intake and inside of t he pump

compartment can create a fire hazard.
HOW TO AVOID THE HAZARD
♦ Clean all debris from around the eng ine

a) Stop eng ine, wait for all moving parts to stop, and r emove key. Engage

parking brake.

b) Clean all debris from rotating engine air intake screen and from around

engine shrouding.

4.1.3 Check battery charge

Service Interval: Monthly

Allowing batteries to stand for an extended period without rechar ging them will
result in reduced performance and ser vice life. To preserve optimum battery
performance and life, recharge batteries in storage when the open circuit voltage
drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged before
putting away for winter storage.

a) Check the voltage of the battery with a digital voltmeter. Locate the voltage

reading of the batter y in the t able below and charge the battery for the
recommended time interval to bring t he charge up to a full charge of 12.6 volts
or greater.

and hydraulic pumps daily.

:

IMPORTANT: Make sure the negative battery cables are disconnected
and the battery charger used for char ging the battery has an output of 16
volts and 7 amps or less to avoid damaging the batter y (see char t below f or
recommended charger settings).

Voltage

Reading

Percent
Charge

Maximum

Charger Settings

Charging Interval

12.6 or greater 100% 16 volts/7 amps No Charging Required

12.4 – 12.6 75 – 100% 16 volts/7 amps 30 Minutes

12.2 – 12.4 50 – 75% 16 volts/7 amps 1 Hour

12.0 – 12.2 25 – 50% 14.4 volts/4 amps 2 Hours

11.7 – 12.0 0 – 25% 14.4 volts/4 amps 3 Hours

11.7 or less 0% 14.4 volts/2 amps 6 Hours or More

4. 1. 4 Clean grass build-up under deck.
Service Interval: Daily

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

22

b) Raise deck t o t he transport (4.5” (11.4cm) cut ting height) position. Lif t the

front of unit and support unit using jack stands or eq uivalent support.

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous.
WHAT CAN HAPPEN
♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

could cause injury.
HOW TO AVOID THE HAZARD
♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

c) Clean out any grass build-up f r om underside of deck and in discharge chute.

4.1.5 Check mower blades

Service Interval: Daily

a) Stop eng ine, wait for all moving parts to stop, and r emove key. Engage

parking brake.
b) Lift deck and secure in raised position as stated in Section 4.1. 4.
c) Inspect blades and sharpen or replace as required.
d) Re-install t he blades ( if they were removed) in the following order (See

Figure 3):

jack stands or equivalent support.

.

1) Install bushing thr ough blade with bushing flange on bottom (grass)
side of blade.

2) Install bushing/ blade assem bly into spindle.

3) Install blade bolt and spring disc washer. Be sure the spring disc
washer cone is installed towards the bolt head. Place wrench on the top
spindle nut torque the blade bolts to 55-60 ft-lbs. (75-81 N-m).

FIGURE 3

23

WARNING

POTENTIAL HAZARD

♦ Incorrect installation of the blade or

components used to retain the blade can be
dangerous.

WHAT CAN HAPPEN

♦ Failure to use all original components and

assembled as shown could allow a blade or
blade component to be thrown out from
under the deck resulting in serious personal
injury or death.

HOW TO AVOID THE HAZARD

Always install the original Exmark blades,

♦

blade bushings, spring disc washers, and
blade bolts as shown.

4.1.6 Check safety interlock system.

Service Interval: Daily

NOTE: To prevent engine cut-outs on rough terrain the seat kill
switch has a 1/2 second delay.

a) Check start ing circuit. Starter should crank with parking brake engaged,

PTO disengaged and motion contro l levers m oved out in t he neut ral lock
position. The operator does not need to be in t he seat to start the engine.

Try to start with operator in seat, parking brak e disengaged, PTO

disengaged and motion control levers in the neutral lock posit ion - starter
must not crank.

Try to start with operator in seat, parking brak e engaged, PTO engaged
and motion control levers in the neutral lock position - starter must not
crank.

Try to start with operator in seat, parking brak e engaged, PTO
disengaged, and the left motion control lever in, starter must not crank,
repeat again with the right lever in, then with both levers i n - starter must

not crank.

b) Check kill cir cuits. Run engine at one-third throttle, disengage parking

brake and raise off of seat ( but do not get off of machine) engine must
initiate shutdown after approx. 1/2 second has elapsed (seat has t im e
delay kill switch to prevent cut-outs on rough terrain).

Run engine at one-third throttle, engage PTO and raise off of seat ( but do
not get off of machine) engine must initiate shutdown after 1/2 second
has elapsed.

Run engine at one-third throttle, with brake disengaged, move levers in and
raise off seat (but do not get off of machine) engine must initiate
shutdown after 1/2 second has elapsed.

Again, run engine at one-thir d throttle, brake engaged, and m ove left
motion control lever in - engine must initiate shutdown.

Repeat again moving the right lever in, t hen m oving bot h l evers in ­engine must initiate shutdown whether operator is on seat or not.

NOTE: If machine does not pass any of these tests, do not operate.
Contact your authorized EXMARK SERVICE DEALER.

24

IMPORTANT: It is essential that operator safety mechanisms be connected
and in proper operating condition prior to use for mowing.

4.1.7 Check rollover protections systems (roll bar) pins

Service Interval: Daily

a) Make sure latch pin and hair pin are fully installed and lanyard is in good

condition.

4.1.8 Check seat belt
Service Interval: Daily
a) Visually inspect seat for wear, cuts, and proper oper ation of retractor and

buckle. Replace before operating if damaged.

4.1.9 Check for loose har dware

.

Service Interval: Daily

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten hardware or correct the problem before operating .

4.1.10 Service air cleaner

.

Service Interval: See Engine Owner’s Manual

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) See Eng ine Owner’s Manual for cleaning instructions.

4.1.11 Change engine oil

:
Service I nt erval: See Engine Owner’s Manual.
NOTE: Change oil and filter after first fi ve ( 5) hrs. of operation. Follow

engine manufacturer’s recommendations for future oil changes.
a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.
b) Drain oil while engine is warm from operation.
c) Oil drain hose is located on left hand side of the engine.

Place pan under machine to catch oil. Remove oil drain plug. Allow oil to

drain and replace oil drain plug. Torque plug to 20-24 ft-lbs.
d) Replace the oil filter as per the Engine Owner’s Manual. Clean around oil

filter and unscrew filter t o remove.

Before reinstalling new filt er , apply a thin coating of oil on the surface of the

rubber seal. Turn filt er clockwise until rubber seal contacts the filt er adapt er

then tighten filter an addit ional 2/ 3 to 3/4 turn.
e) Clean around oil fill cap and remove cap. Fill to specified capacity and replace

cap. Use oil recommended in engine owner’s manual. DO NO T overfill.
f) Start the engine and check for leaks. Stop engine and recheck oil level.

4.1.12 Check hydraulic oil level:

Service Interval: 40 hr.

a) Stop engine and wait for all m oving par ts to stop.
b) Clean area around hydraulic reservoir cap and remove cap.
c) Oil level should be to the top of the baffle inside the tank. If not add oil. Use

only Mobil 1 15W-50 synthetic motor oil. Replace hydraulic reservoir cap

and tighten until snug. Do not overt i ght en.

NOTE: The baffle is labeled “HOT” and “COLD”. The oil level varies with the

temperature of the oil. The “HOT” level shows the level of oil when it is at

25

225°F (107°C). The “COLD” level shows the level of the oil when it is at 75°F

(24°C). Fill to the appropriate level depending upon the temperature of t he oil.

For example: If the oil is about 150° F ( 65° C) , fill to halfway between the “HOT”

and “COLD” levels. If the oil is at room temperature (about 75° F (24°C)), fill

only to the “COLD” level.

4.1.13 Check tire pressures

Service Interval: 40 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Eng age

parking brake.

b) Check tire pressure in all four tires.
c) Inflate caster tires to 16 psi (110 k Pa) .
d) Inflate drive tires to 13 psi (90 kPa).

NOTE: Do not add any type of tire liner or foam fill material to the tires.

Excessive loads created by foam filled tires may cause failures to the hydro drive
system, frame and other components. Foam filling tires will void the warranty.

4.1.14 Check condition of belts

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake.
b) Check under engine deck to check pump drive belt.
c) Remove left and right belt shields on deck and lift up floor pan to inspect

deck drive belt.
d) See Sections 4.2.3 and 4.2.4, for belt adjustment.

4.1.15 Lubricate grease fitt ing s
Service Interval: Refer to chart.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Lubricat e fittings with one to two pumps of NGLI grade #2 multi-purpose

gun grease.

Refer to the following chart for fitting locat ions and lubrication schedule.

:

:

Service Interval: 40 hrs.

:

LUBRICATION CHART

FITTING

LOCATIONS

1. Front Caster wheel hubs w/o Zerk

2. Front Caster Pivots

3. Height Adjustment Shaft Bearings 1 5 40 hours

4. Deck Drive Belt Idler Arm 1 1 yearly

5. Pump Drive Belt Idler Arm 1 1 yearly
∗ See 4.1.14 Section c) for special lubrication instructions on the f ront caster pivots and

Section 4.1.15 for special lubrication inst r uctions on the front caster wheel hubs.

No. 5 (Pump Dri ve Bel t Idler Arm)
Located Under Engine Frame - Grease
through hole in top of engine frame, between
pumps.

26

INITIAL

PUMPS

∗0
∗0

NO. of

PLACES

2
2

SERVICE

INTERVAL

∗yearly

∗yearly

c) Lubricate front caster pivots once a year. Remove hex plug and cap. Thread

grease zerk in hole and pump with grease until it oozes out around top
bearing. Remove grease zerk and thr ead plug back in. Place cap back on.

4.1.16 Lubricate caster wheel hubs:

Service Interval: Once Yearly

a) Stop engine, wait for all moving parts t o

stop, and remove key. Engage park ing
brake.

b) Remove caster bolt and caster wheel from

caster fork. Remove seal g uar ds from the
wheel hub.

c) Remove one of the spacer nuts from t he

axle assembly in the caster wheel. Note
that thread locking adhesive has been
applied to lock the spacer nuts to the axle.
Remove the axle (with the other spacer
nut still assembled to it) f r om the wheel
assembly.

d) Pry out seals, and inspect bearings for

wear or damage and replace if necessary.

e) Pack t he bearings with a NGLI grade #1

multi-purpose grease.

f) Insert (1) bearing, (1) new seal into the

wheel.

NOTE: Seals (Exmark PN 103-0063) must be replaced.

g) If the axle assembly has had both spacer nuts removed (or broken loose),

apply a thread locking adhesive to (1) spacer nut and thr ead onto the axle
with the wrench flats facing outward. Do not thr ead spacer nut all of the
way onto the end of the axle. Leave approximately 1/8” (3 mm) f r om the
outer surface of the spacer nut to the end of the axle inside the nut.

h) Inser t the assembled nut and axle into the wheel on the side of the wheel

with the new seal and bearing.

i) With the open end of the wheel facing up, fill the area inside the wheel

around the axle full of NGLI grade #1 multi-purpose grease.

j) Insert the second bearing and new seal into the wheel.

nd

k) Apply a thread locking adhesive to the 2

spacer nut and thread onto the

axle with the wrench flats facing outward.

l) Torq ue the nut to 75-80 in-lbs. (8-9 N-m) , loosen, then re-torque to 20-25

in-lbs. (2-3 N-m). Make sure axle does not extend beyond either nut.

m) Re-install the seal guards over the wheel hub and insert wheel into caster

fork. Re-install cast er bolt and tighten nut fully.
IMPORTANT: To prevent seal and bearing damage, check the bearing

adjustment often. Spin t he caster tire. The tire should not spin freely
(more than 1 or 2 revolutions) or have any side play. If the wheel spins
freely adjust torque on spacer nut unt il there is a slight amount of dr ag.

4.1.17 Lubricate seat switch actuator

:

Service Interval: 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Unhook seat latch and tilt seat up.

FIGURE 4

27

c) Lubricate switch actuator rod with spray type lubricant or light oil.

4.1.18 Lubricate brake handle pivot

:

Service I nt erval : 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

b) Lubricat e br onze bushing s on br ake handle pivot with a spray type lubricant

or light oil.

4.1.19 Lubricate brake rod bushings

:

Service I nt erval : 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.
b) Unhook seat latch and tilt seat up.
c) Lubricate bronze bushings on each end of brake r od shaft with a spray type

lubricant or a light oil. Shaf t is located under the console.

4.1.20 Lubricate motion control bronze bushings

:

Service I nt erval : 160 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.
b) Unhook seat latch and tilt seat up.
c) Lubricate bronze bushings on flange bearings securing the motion control

arm shafts with a light oil or a spr ay type lubricant .

4.1.21 Remove engine shrouds and clean cooling fins

:

Service Interval: 80 hrs.

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.
b) Remove cooling shr ouds from engine and clean cooling f ins. Also clean

dust, dirt and oil from external sur faces of engine, which can cause

improper cooling.
c) Make sure cooling shrouds are properly reinstalled. Operating the engine

without cooling shrouds will cause engine damage due to overheating.

4.1.22 Check spark plug

:

Service Interval: 160 hrs.

a) Remove spark plug, check condition and reset gap, or replace with new plug.

See Engine Owners Manual.

4.1.23 Change fuel filt er

:

Service I nt erval: As Required

a) A fuel f ilter is installed between the fuel tanks and the engine. Replace when

necessary.
Briggs & Stratton P/N 493629

4.1.24 Change hydraulic system filter

:

Service I nt erval : Af t er Fi rst 250 hrs.
Then yearl y t hereaft er

NOTE: Use only Exmark Part No. 109- 4180 for Summer use above

(0°C) or Part No. 1-523541 f or Winter use below 32°

F (0°C).

a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

28

32° F

b) Locate filter under left rear cor ner of engine deck.
c) Carefully clean area around filter. It is important that no dirt or

contamination enter hydraulic system.
d) Unscrew f ilt er to remove and allow oil to drain from reservoir.

IMPORTANT: Before reinstalling new filter, fill it with Mobil 1 15W-50 and

apply a thin coat of oil on the surface of the rubber seal.

Turn the filter clockwise until rubber seal contacts the filter adapter then

tighten the filter an addit ional 2/ 3 to 3/4 turn.
e) Fill reser voir as st at ed in Section 4.1.10.
f) Raise the rear of machine up and support with jack stands (or equivalent

support) just high enough t o allow drive wheels to turn freely.
g) Star t engine and move throttle control ahead to full throttle position. Move

the speed control levers to the full speed and run for several minutes. Shut

down machine and recheck oil level.

Do not change hydraulic system oil (except for what can be drained when

changing filter), unless it is felt the oil has been contaminat ed or been

extremely hot.

Changing oil unnecessarily could damage hydraulic system by

introducing contaminates into the system.

4.1.25 Wheel hub

- slotted nut torque specification

Service Interval: After First 100 hrs.
Then 500 hrs t hereaf t er

When tig ht ening the slotted nut on the wheel motor tapered shaft:
a) To r que the slotted nut to 125 ft. lbs (169 N-M).
b) Check dist ance from bottom of slot in nut to inside edge of hole. Two

threads (0.1”) or less should be showing.
c) If more than two threads (0. 1”) are showing remove nut and install washer

(PN 1-523157) between hub and nut.
d) To r que the slotted nut to 125 ft. lbs (169 N-M)
e) Then tighten the nut until the next set of slots line up with the cross hole in

the shaft.
f) Replace cotter pin.
Note: Do not use antiseize on the wheel hub.

4.1.26 Fuel Tank

– mounting hardware specification.

When installing the nuts onto the fuel tank st uds, fully tighten the nyloc nut and
back off 1/2 t ur n. This allows for normal fuel tank expansion and contraction with
changes in temperature and fuel levels.

4.1.27 Thread locking adhesives such as “Loctite 242” or “ Fel-Pro, Pro-Lock Nut Type”
are used on the following fasteners:

a) Pump drive sheave setscrews.
b) Square head setscrews on hydro pump control arms.
c) Clutch retaining bolt in the end of engine crankshaft.
d) Caster wheel spacer nuts.
e) Fuel tank bulk head fitting nuts.
f) Cutter housing spindle nut

29

Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pr o Pr o- Lock Retaining I
or Retaining II” are used on the following:

a) Fuel tank studs where studs are inserted into tank.

4.1.28 Mobil HTS grease (or food-grade antisieze) is used in the f ollowing locat ions:

a) Between the cutt er housing spindle and bearings.
b) Between the cutt er housing spindle and sheave.
c) Under top cutter housing bearing guard.

4.1.29 Dielectric grease
corrosion and loss of contact.

4.2 ADJUSTMENTS

IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop,
and remove key before servicing, cleaning or making adjustments to the unit.

4.2.1 Cutting Height Adjustment

a) Stop m achine and move drive levers out to neutral lock position.
b) Disengage PTO.
c) Raise the deck lever to the transport position (also the 4.5” (11.4 cm)

cutting height position). See Figure 5.

NOTE: When changing cutting height positions, al ways come to a
complete stop and disengage the PTO.

is used on all blade type electrical connections to prevent

.

FIGURE 5

d) Inser t height adjustment pin into hole corresponding to desired cutting

height and install hairpin cotter. See decal on deck lift plate.

e) Move lever out of transpor t (or 4.5” (11.4 cm) cutt ing height) position and

down onto height

adjustment pin to mow at selected height.

f) To transport, move lever back up to transport (or 4.5” (11.4 cm) cutting height)

position.

g) Adju st anti-scalp rollers for Norm al O perating Conditions. Stop engine, wait

for all moving parts to stop, and remove key. Engage parking brake. Place
rollers in one of the positions shown in Figure 6. Rollers will maintain 3/4 in.
(19 mm) clearance to the gr ound t o minimize gouging and roller wear or
damage.

For Maximum Deck Flotation, place rollers one hole posit ion lower. Roller s
should maintain 1/4 in. (6.4 mm) minimum clearance to ground. Do Not
adjust rollers to support the deck. Be sure bolt is tightened properly or loss
of anti-scalp roller may result. Torque the whizlock nuts on each end to
40-45 ft-lbs (54-61 N-m).

30

FIGURE 6

4.2.2 Deck Leveling:
a) Position mower on a flat surface.
b) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.

c) Check tire pressure in drive tires. Proper inflation pressure for drive tires is

13 psi (90 kPa). Proper inflat ion for caster tires is 16 psi (110 kPa) . Adjust if

necessary.
d) Set ant i-scalp rollers to top holes or remove completely f or this adjustment.
e) Raise the deck to the 4.5” (11.4 cm) heig ht position and take as much force

as possible off of the two large deck lift springs by loosening t he nut s at the

front of each spring . See Figure 7.
f) Lower the deck to the 1-1/2” (3.8 cm) height position. Place two 1-5/16”

(3.3 cm) thick blocks under t he r ear edge of the cutting deck skirt; one on

each side of the cutting deck. Place a 1-1/8” (2.9 cm) block under the

center front edge, but not

under the anti-scalp roller brackets.

g) Loosen the t wo (2) bot t om chain bolts in slots at the rear of the cut t ing

deck. Loosen four (4) nut s which secure front swivels (two per side), until

front chains are loose and front of deck is supported by the 1-1/8” (2. 9 cm )

block. Do not loosen front chain har dware.
h) When hardware is loosened, remaining t ension in the large support springs

will tend to rotate the deck lif t handle up, out of the 1 1/2” (3.8 cm) position.

Press down on the rear deck support arm (as shown in Figure 7) t o firmly

return the deck lift handle to the 1 1/2” (3.8 cm) position. DO NOT push on

deck lift handle. While continuing to press down,

rear chains and tighten hardware at the bottom of

Downward pressure may now be released.
i) On lef t side, adjust front swivel using the locking nut behind the swivel until

the front chain is tight and all slack is removed from linkage. Do not lift

front of deck off 1-1/8” (2.9 cm ) block. Secure front swivel using locking

nut in front of swivel. Repeat for right side.

FIGURE 7

take the slack out of the

the rear chains.

31

j) Recheck that blocks fit just snugly under the deck skirt and that the tension

on all the chains are approximately equal. Make sure all chain attachm ent

bolts are tight.
k) Raise deck lift lever to the 4. 5” (11.4 cm) cutting height position (also

transport position, See Figure 6. Adjust spring compression until proper

distance is obtained between the two washers (See Figure 7) by turning the

nut at the front of each spring. Lock nuts in position with jam nuts.
l) Reposition anti-scalp r o ller s and t ighten securely.

NO TE: When above adjustments have been made, the fr ont of

the deck will be slightly lower than the rear of the deck.

4.2.3 Pump Drive Belt Tension

.

Self-tensioning - No adjustment necessary.

4.2.4 Deck Belt Tension

.

Self-tensioning - No adjustment necessary.

4.2.5 Adjust Seat Switch

.

a) If necessary, adj ust the seat actuator rod length t o where the m achine will

shut off when the operator raises off the seat (with brake disengaged or
PTO engaged) but will continue to run with operator in seat (a slight shift in
weight should not shut machine off ) . Nor mal adjustment is when length of
spring is 2.09” (5.3 cm ) (with seat up) .

NO TE: To prevent rough ground cut-outs the uni t is equipped with a

time delayed seat switch. When the operator raises of f the seat with

either the brake disengaged or the PTO engaged, the engine should

stop after 1/2 second has elapsed.

b) To adjust seat switch, loosen lock nut on bottom of the actuator rod (5/16 x 7”

bolt) and adjust the nuts to move the actuat or plate up or down on the rod.

4.2.6 Park Brake Adjustment

.

a) Stop engine, wait for all m oving par t s t o st op, and remove key. Engage

parking brake.

b) Check tire pressure. I nflate tires to 13 psi (90kpa).
c) Disengage the park brake.
d) Loosen the jam nuts next to the yoke at each end of the park brake link age.

See Figure 8.

e) Place a wrench on one of the two nuts near the front of the park brake

linkage.

f) Turn t he linkage until the distance fr om t he lower front corner of the brake bar

measures 1” (2.5 cm) to 1 5/16”( 3.3 cm) with the park brake disengag ed See

Figure 8.

g) Tighten the jam nuts loosened in st ep d) .

32

4.2.7 Elect ric Clutch Adjustment

:

No adjustment necessary.

4.2.8 Reverse I ndicat or Adjustment
a) Stop engine, wait for all moving parts to stop, and remove key. Engage

parking brake.
b) Unhook seat latch and t ilt seat forward.
c) Begin with either the left or right motion control lever. Move lever to the

neutral position and pull lever back until the clevis pin (on arm below pivot

shaft) contacts the end of the slot (just beginning t o put pr essure on spring),

See Figure 9.
d) Check where lever is relative to notch in console (should be centered

allowing lever to pivot outward to the neutral lock position) .
e) If adjustment is needed, loosen the nut against the yok e and while applying

slight rearward pressure on the motion contr ol lever, turn the head of the

adjustment bolt in the appropriat e dir ection until lever is centered (keeping

rearward pressure on the lever will keep the pin at the end of the slot and

allow the adjustment bolt to move the lever to the appr opr iate position).

Tighten lock nut.
f) Repeat on opposite side of unit.

4.2.9 Motion control linkage adjustment

FIGURE 8

:

WARNING

POTENTIAL HAZARD
♦ Engine must be running and drive wheels

must be turning so motion control

adjustment can be performed.
WHAT CAN HAPPEN
♦ Contact with moving parts or hot surfaces

may cause personal injury.
HOW TO AVOID THE HAZARD
♦ Keep fingers, hands, and clothing clear of

rotating components and hot surf aces.

33

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous.
WHAT CAN HAPPEN
♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

could cause injury.
HOW TO AVOID THE HAZARD
♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

a) This adjustment must be made with the drive wheels turning. First raise the

frame and block up so that dr ive wheels can rotate freely.

b) Remove the electrical connection from the seat safety switch, located directly to

the left of the seat switch assembly beside the hydraulic oil r eser voir.

Temporarily install a jumper wire across the terminals in the connector of

the wiring harness.

c) Run the unit at least 5 minutes with the drive levers at full forward speed to

bring hydraulic system oil up to operating tem per ature.
d) Unhook seat latch and t ilt seat forward.
e) Loosen lock nuts from the ball joints at each end of the RH pump control

linkage (See Figure 9).

jack stands or equivalent support.

NO TE: The nuts to the rear of the unit on each rod have left-hand threads.

TURN BOLT

HERE

REVERSE

INDICATOR

LOOSEN

HERE

YOKE

END OF

SLOT

LOOSEN HER E

(LEFT HA ND THR E AD)

TURN HERE

TO ADJUST

LOOSEN HERE

(RIGHTHAND THREAD)

FIGURE 9

f) Start engine. Brake must be engaged and motion control levers out t o

start engine. Operator does not have to be in the seat because of the

jumper wire being used. Run engine at full throttle and release brake.

g) The reverse indicator spring must be correct before t he following

adjustments can be made. See Section 4.2.8.

34

h) Bring the RH m ot ion control lever into the neutral position. Adju st RH pump

control rod length by rotating t he double nuts on the rod in the appropriate

direction until the wheels slightly creep in reverse (See Figur e 9) . Move the

motion control lever to the reverse position and while applying slight pr essure

to the lever, allow the reverse indicator spring to br ing the levers back to

neutral. The wheel must stop turning or slightly creep in reverse.

NOTE: The motion control lever needs to be in neutral while making

any necessary adjustments.

The left rod assembly controls the left wheel and the right rod assembly

controls the right wheel.
i) Bring t he LH m otion control lever into the neutral position. Adjust the LH

pump control rod length by rotating t he t racking adjustment knob in the

appropriate direction until the wheels slightly creep in reverse. Move the

motion control lever to the reverse position and while applying slight

pressure to the lever allow the reverse indicator spring to br ing the levers

back to neutral. The wheel must stop t urning or slightly creep in reverse.

See Figure 10.

FIGURE 10

j) Shut off unit. Remove jumper wire from wire harness connector and plug

connector into seat switch.

35

5. WASTE DISPOSAL

5.1 MOTOR OIL DISPOSAL

Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil at

a certified recycling center or accor ding to your state and local regulations.

5.2 BATTERY DISPOSAL

DANGER

POTENTIAL HAZARD
♦ Battery electrolyte contains sulfuric acid,

which is poisonous and can cause severe

burns
WHAT CAN HAPPEN
♦ Swallowing electrolyte can be fatal or if it

touches skin can cause severe burns.
HOW TO AVOID THE HAZARD

♦ Wear safety glasses to shield eyes, and

rubber gloves to protect skin and clothing
when handling electrolyte.

Federal law states that batteries should not be placed in the garbage. Management and disposal
practices must be within relevant federal, state or local laws.

If a battery is being replaced or if the unit containing the batt ery is no longer operating and
is being scrapped, take the battery to a local certified recycling center. I f no local
recycling is available, return the battery to any cert ified battery reseller.

♦ Do not swallow electrolyte.

6. TROUBLE SHOOTING

6.1 MOWER PULLS LEFT OR RIGHT (W/LEVERS FULLY FORWARD).

a) Refer to Tracking Adjustment Sect ion 3. 1. 3.
b) Check air pressure in t ir es; 13 psi/drive, 16 psi/pneumatic casters.
c) Check reverse indicator and motion control linkage adjustment. See

Section 4.2.8 and 4.2.9.

6.2 MOWER CUTS UNEVENLY.

a) Check air pressure in tires; 13 psi/drive, 16 psi/pneumatic casters. A m ore

uniform cutting heig ht may be obtained with higher tire pressure on rough
terrain. A lower tire pressure provides more flotation. Higher pressures in

front casters may cause them to shimm y on hard surfaces.
b) Check deck support chains.
c) Check deck leveling

Not e: The front of t he m ower deck will be approximately 1/4” ( 6 . 4 mm)

lower than the back of the mower deck. This is the “rake” of t he deck.

d) Check blades tip to tip f or st raightness (they should be within 3/16"

(4.8 mm) or one blade width from being in line.)

6.3 ENGINE WILL NOT START.

a) Make sure battery is at a full char ge.

(See Adjustments Section 4.2.2.)

36

b) Be sure the throt t le cont r ol is m idway between the “SLOW” and “FAST”

positions, and the choke is in the “ON” position for a cold engine or the

“OFF” position for a warm eng ine.
c) Make sure there is fuel in the fuel tank and that the fuel valve is open.
d) Be sure the seat switch is properly adjusted. See Section 4.2.5.
e) Make sure the parking br ake is set and motion control levers are moved out

(neutral lock position).
f) Check that the PTO is disengaged.
g) Check that the spark plug wires are properly connected.
h) Check for loose or faulty wiring connections.
i) Check for corrosion at all wiring connections. Even minor corrosion may

cause a faulty connection. Clean connector terminals t hor oughly with

electrical contact cleaner, apply dielectric grease and r econnect.

NOTE: When disconnecting electrical connectors DO NO T pull on the wires
to separate the connectors.

NOTE: After carefully checking the above steps, attempt to start the engine. If
it does not start, contact your authorized Exmark service dealer.

IMPORTANT: It is essential that all operator safety mechanisms be
connected and in proper operating condition prior to mower use.

When a problem occur s , do not overlook the simple causes. For example,
starting problems could be caused by an empty fuel tank.

The following table lists some of t he common causes of trouble. Do not att em pt
to service or replace major items or any item s t hat call for special timing of
adjustments procedures (such as valves, governor, etc. ) . Have this work done
by your Engine Service Dealer.

PROBLEM

Will not start
Hard starting

Stops suddenly

Lacks power

Operates

erratically
Knocks or pings
Skips or misfires

Backfires

Overheats

High fuel

consumption

ENGINE TROUBLESHOOTING TABLE

NO

FUEL

IMPROPER

FUEL

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

X X XXXX
X X X X X X X

X X X X X X X

X X X X X X X X
X X X X X X X
X X X

X X X X X
X X X X X

XX X X X
X X X X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

AIR

SCREEN

37

7. BRIGGS & STRATTON ELECTRICAL DIAGRAM

38

8. HYDRAULIC DIAGRAM

39

9. 2-Year Limited Warranty

Exmark Turf Equipment

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 manufactured by Exmark 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 turf equipment purchased on
or after October 1, 2004 sold in the US 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.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 and Metro 26 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet. We are not authorized
to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

• Any damage or deterioration due to normal use, wear

• Cost of regular maintenance service or parts, such as

• Any product or part which has been altered or misused

• Any repairs necessary due to use of parts, accessories

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

1. 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. Customers
may also call 402-223-6375.

2. Bring the product and your proof of purchase (sales
receipt) to the Exmark Service Dealer.

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]

Warranty Period

Items and Conditions Not Covered

Exmark Service Dealer.
and tear, or exposure.
filters, fuel, lubricants, tune-up parts, and adjustments.
or required replacement or repair due to normal wear,

accidents, or lack of proper maintenance.
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.

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

Owner’s Responsibilities

The Exmark turf equipment, including any defective
part, must be returned to an authorized Exmark service
dealer within the warranty period. This warranty
extends only to turf equipment operated under normal
conditions. You must 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.

As a condition to this warranty, customer shall have
read the operator's manual and shall have completed
and submitted to Exmark Warranty Company, within
the prescribed time, the Exmark warranty registration.

General Conditions

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

nor Exmark Warranty Company shall have any
liability for any other cost, loss or damage, including
but not limited to, any incidental or consequential
loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge 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.

There are no understandings, agreements,
representations, or warranties, express or implied,
including but not limited to any regarding the
merchantability (that product is fit for ordinary use) or
fitness for use (that product is fit for a particular
purpose), not specified herein, respecting the equipment
which is the subject of this 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.

40

SERVICE RECORD

Date Description of Work Done Service Done By

41

ALIGN THIS EDGE WITH A VERTICAL SURFACE

(TREE, BUILDING, FENCE POST, POLE ETC.)

T
H

I

S

I

S

A

5

°
S
L

O

P
E

T

H

I

S

I

S

A

1

0

°

S

L

O

P

E

T

H

I

S

I

S

A

1

5

°

S

L

O

P

E

E

T

HI

S

I

S

A

2

0

°

S

L

O

P

FOLD ALONG APPROPRIATE LINE

EDGE.

EXAMPLE: COMPARE

SLOPE WITH FOLDED

42

M

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

STANDON

Check us out on the Web:

www.exmark.com

WARNING

The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.

© 2004-2007 EXMARK MFG. CO. INC. PART NO. 109-6436 Rev A.
INDUSTRIAL PARK BOX 808 [phone]
BEATRICE, NE 68310 FAX [phone]

ALL RIGHTS RESERVED PRINTED IN U.S.A.

FG. CO. INC.

®