Exmark Lawn Mower FMD 604 User Manual

For Turf Ranger  
Serial Nos. 440,000 & Higher  
and  
FMD524 & FMD604  
Serial Nos. 440,000 & Higher  
Part No. 103-4867  
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EXMARK PARTS PLUSÒ PROGRAM  
EFFECTIVE DATE: September 1, 1995  
Program  
If your Exmark dealer does not have the Exmark part in stock,  
Exmark will get the parts to the dealer the next business day or  
the part will be FREE* Guaranteed!!  
How the Program Works  
1.  
If dealer does not have part in stock for a "down" unit at  
the time of request by customer, the dealer contacts his  
distributor by 1:00 p.m., local time, and requests Exmark  
Parts PlusÒ shipment of six (6) line items or less.  
2.  
Distributor ships part(s) to dealer or customer, as  
requested by dealer, same day, overnight UPS  
Distributor bills dealer for part and freight charges where  
applicable.  
3.  
4.  
5.  
6.  
If distributor does not have the part(s) in stock to satisfy Exmark Parts PlusÒ order, he contacts Exmark by 3:00 p.m.,  
central time, with an Exmark Parts PlusÒ order of six (6) line items or less.  
If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by  
distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.  
The customer pays for the part and freight if it is shipped under the Exmark Parts PlusÒ and if it arrives in  
accordance to the program.  
Who pays for the part and freight if it fails to arrive overnight in accordance to the program?  
A. Under any circumstance the customer does not pay.  
B. If the part does not arrive overnight due to:  
1. The dealer not submitting the Exmark Parts PlusÒ order to his Exmark distributor by 1:00 p.m., the dealer  
pays for the part and freight.  
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts PlusÒ order  
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.  
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,  
Exmark pays for the part and freight.  
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark  
pays for the part.  
The following restrictions apply -- The Exmark Parts PlusÒ 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 PlusÒ 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 PlusÒ 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.  
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CONGRATULATIONS on the purchase of your Exmark Mower. This product has been  
carefully designed and manufactured to give you a maximum amount of dependability and  
years of trouble-free operation.  
OPERATOR'S MANUAL  
This manual contains assembly, 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, maintenance, and safety instructions, you will prolong the life  
of your mower, maintain its maximum efficiency, and promote safe operation.  
If additional information is needed, or should you require trained mechanic service,  
contact your authorized Exmark equipment dealer or distributor.  
All Exmark equipment dealers and distributors are kept informed of the latest methods  
of servicing and are equipped to provide prompt and efficient service in the field or at their  
service stations. They carry ample stock of service parts or can secure them promptly for you  
from the factory.  
All Exmark parts are thoroughly tested and inspected before leaving the factory,  
however, attention is required on your part if you are to obtain the fullest measure of  
satisfaction and performance.  
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TABLE OF CONTENTS  
1. SAFETY  
PAGE  
1.1 Safety Alert Symbol...................................................................................... 1  
1.2 Training........................................................................................................ 1  
1.3 Preparation ............................................................................................... 1-3  
1.4 Operation .................................................................................................. 4-6  
1.5 Maintenance & Storage................................................................................ 7  
1.6 Safety Signs.............................................................................................. 8-9  
2. SPECIFICATIONS  
2.1 Model Number............................................................................................ 10  
2.2 Engine........................................................................................................ 10  
2.3 Fuel System ............................................................................................... 10  
2.4 Electrical System........................................................................................ 10  
2.5 Operator Controls....................................................................................... 10  
2.6 Seat ........................................................................................................... 10  
2.7 Hydrostatic Ground Drive System .............................................................. 10  
2.8 Tires........................................................................................................... 11  
2.9 Deck........................................................................................................... 11  
2.10 Dimensions ............................................................................................... 11  
2.11 Torque Requirements ............................................................................... 11  
3. ASSEMBLY INSTRUCTIONS  
3.1 to 3.8 Assembly..................................................................................... 12-15  
4. CONTROLS .............................................................................................. 15-17  
5. OPERATION INSTRUCTIONS  
5.1 Pre-Start..................................................................................................... 17  
5.2 Mowing.................................................................................................. 17-18  
5.3 Transporting.......................................................................................... 18-19  
6. MAINTENANCE & ADJUSTMENTS  
6.1 Periodic Maintenance............................................................................ 19-27  
6.2 Adjustments .......................................................................................... 27-33  
7. WASTE DISPOSAL  
7.1 Motor Oil Disposal...................................................................................... 34  
7.2 Battery Disposal......................................................................................... 34  
8. TROUBLE SHOOTING  
8.1 Mower Cuts Unevenly ................................................................................ 34  
8.2 Engine Will Not Start............................................................................. 34-35  
9. WIRING DIAGRAMS..................................................................................... 36  
10. WARRANTY................................................................................................. 37  
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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!  
YOUR SAFETY IS INVOLVED!  
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 imminently hazardous  
situation which, if not avoided, WILL result in death or serious injury.  
WARNING: Black lettering / Orange background. Indicates a potentially hazardous  
situation which, if not avoided, COULD result in death 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. Familiarize yourself with the controls and the  
proper use of the equipment. If the operator(s) or mechanic(s) can not read  
English, it is the owner’s responsibility to explain this material to them.  
1.2.3  
1.2.4  
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.  
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.  
1.3 PREPARATION  
1.3.1  
Evaluate the terrain to determine what accessories and attachments are  
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)  
protection for the eyes, ears, feet, and head is recommended.  
CAUTION  
POTENTIAL HAZARD  
¨
This machine produces sound levels in excess of 85  
dBA at the operator’s ear when in operation.  
WHAT CAN HAPPEN  
¨
Exposure to sound levels of 85 dBA or above for  
extended periods of time can cause hearing loss.  
HOW TO AVOID THE HAZARD  
Wear hearing protection when operating this machine.  
¨
1.3.3  
While mowing, always wear substantial footwear and long trousers. Do not  
operate equipment when barefoot or when wearing open sandals.  
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1.3.4  
1.3.5  
Thoroughly inspect the area where the equipment is to be used and remove all  
stones, sticks, wires, bones, and other foreign objects, which may damage the  
equipment or cause personal injury to the operator or bystanders.  
Always set the park brake before starting the engine.  
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 starting the engine. Never remove the  
cap of the fuel tank or add fuel when engine is running  
or when the engine is hot.  
Never fill the fuel tank so that the gasoline level rises  
above a level that is 1/2” below the bottom of the filler  
neck to allow for gasoline expansion and prevent fuel  
spillage.  
¨
¨
If fuel is spilled, DO NOT attempt to start the engine.  
Move away from the area of the spill and avoid  
creating any source of ignition until fuel vapors have  
dissipated.  
Do not operate without the entire exhaust system in  
place and in proper working condition.  
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DANGER  
POTENTIAL HAZARD  
¨
In certain conditions gasoline is extremely flammable  
and highly explosive.  
WHAT CAN HAPPEN  
¨
A static charge can ignite gasoline vapors. A fire or  
explosion from gasoline can burn you, others, and  
cause property damage.  
HOW TO AVOID THE HAZARD  
¨
¨
¨
Purchase and store gasoline only in an approved  
container.  
Always place gasoline containers on the ground away  
from your vehicle before 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, remove gas-powered equipment from  
the truck or trailer and refuel the equipment with its  
wheels on the ground.  
If this is not possible, then refuel such equipment on a  
truck or trailer from a portable container, rather than  
from a gasoline dispenser nozzle.  
If a gasoline dispenser nozzle must be used, keep the  
nozzle in contact with the rim of the fuel tank or  
container opening at all times until fueling is complete.  
WARNING  
POTENTIAL HAZARD  
¨
Gasoline vapor can collect inside enclosed trailers and  
may be ignited by electrical sparks or hot  
engine/exhaust components.  
WHAT CAN HAPPEN  
¨
Explosion and fire may occur, resulting in 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.  
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1.4 OPERATION  
Although hazard control and accident prevention are partially dependent upon the  
design and configuration of the equipment, these factors are also dependent  
upon the awareness, concern, prudence, and proper training of the personnel  
involved in the operation, transport, maintenance, and storage of the equipment.  
It is essential that all Operator Safety Mechanisms 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 muffler, 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  
brush-covered unimproved land.  
WARNING  
POTENTIAL HAZARD  
¨
Hands, feet, hair, clothing, or accessories can become  
entangled in rotating parts.  
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, jewelry, or clothing away from  
rotating parts.  
¨
1.4.1  
1.4.2  
Give complete, undivided attention to the job at hand.  
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 the area.  
1.4.3  
1.4.4  
When feasible, avoid operating the equipment in wet grass.  
Use EXTREME caution when mowing and/or turning on slopes as loss of traction  
and/or tip-over could occur. The operator is responsible for safe operation on  
slopes.  
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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  
¨
¨
¨
¨
¨
¨
Mow up and down slopes.  
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 the  
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.  
G0083  
Figure 1  
SAFE ZONE FOR MOWING  
·
·
·
Progressively greater care is needed as the slope increases.  
Always avoid sudden starts and turns.  
Be aware that loss of traction may occur going downhill. Weight transfer to  
the front wheels may cause rear wheel to lift off ground cause loss of  
steering.  
·
·
·
Watch for ditches, holes, rocks, dips, and rises that change the operating  
angle, as rough terrain could overturn 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 catchers or attachments. These can change  
the stability of the machine and cause loss of control.  
1.4.5  
1.4.6  
Use EXTREME caution when backing up. LOOK BEHIND YOU!  
Stop the blades when crossing surfaces other than grass and when  
transporting the mower to and from the area to be mowed.  
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1.4.7  
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.  
1.4.8  
1.4.9  
Do Not change the engine governor settings or overspeed the engine. Operating  
an engine at excessive speed may increase the hazard of personal injury.  
Disengage PTO before starting engine.  
1.4.10 Start the engine carefully with feet well away from the blades.  
1.4.11 Keep hands, feet, and clothing away from rotating parts while the mower is  
being operated.  
1.4.12 Stop the engine, wait for all moving parts to stop, and remove key:  
a) Before checking, cleaning, or working on the mower.  
b) After striking a foreign object (inspect the mower for damage and  
make repairs before restarting and operating the mower).  
c) Before clearing blockages.  
d) Whenever you leave the mower.  
1.4.13 Stop the engine and wait for all moving parts to stop:  
a) Before refueling.  
b) Before making height adjustments.  
c) Before dumping the grass catcher.  
1.4.14 Before stopping the engine, place the throttle control midway between the  
“slow” and “fast” positions. Allow the engine to run a minimum of 15 seconds,  
then stop the engine.  
1.4.15 The fuel system is provided with a shut-off valve. The fuel shut-off valve is  
used to shut off the fuel when:  
a) The machine will not be used for a few days.  
b) During transport to and from the job.  
c) When parking inside a building.  
1.4.16 This mower was designed for one operator 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 kit in place and working properly.  
1.4.18 Be aware of the mower discharge and direct discharge away from others.  
1.4.19 Do NOT operate the mower under the influence of alcohol or drugs.  
1.4.20 Use care when approaching blind corners, shrubs, trees, other objects that  
may obscure vision.  
1.4.21 If jump starting is required:  
a)  
b)  
c)  
Connect the positive (+) power cable from the positive post on the  
booster battery to the positive terminal post on the starter solenoid switch  
(this post has the positive battery cable attached to it).  
Connect the negative or ground cable (-) to the negative post on the battery  
to any engine deck ground, preferably the engine block as far away from  
the battery as possible.  
Disconnect battery cables in the reverse order after starting.  
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1.5 MAINTENANCE AND STORAGE  
1.5.1  
1.5.2  
1.5.3  
For engine maintenance, follow the engine manufacturer’s recommendations  
precisely as stated in the engine manual.  
Disconnect the battery cable form the negative battery post when the unit will  
be allowed to sit for more than 30 days without use.  
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, battery should be fully charged  
before putting away for winter storage.  
1.5.4  
Keep engine and engine area free from accumulation of grass, leaves,  
excessive grease or oil, and other debris, which can accumulate in these  
areas. These materials can become combustible and may result in a fire.  
1.5.5  
1.5.6  
Store fuel in a container specifically designed for this purpose in a cool, dry place.  
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  
1.5.9  
Maximum mowing results and safety can only be achieved if the mower is  
properly maintained and operated correctly.  
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  
condition.  
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 equivalent to the parts supplied  
as original equipment.  
WARNING  
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 form 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  
letting the foot pedal return to neutral and shutting off  
the engine before performing any work on the  
hydraulic system.  
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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  
1.6.3  
Safety signs must be replaced if they are missing or illegible.  
When new components are installed, be sure that current safety signs are  
affixed to the replaced components.  
1.6.4  
1.6.5  
1.6.6  
New safety signs may be obtained from your authorized Exmark equipment  
dealer or distributor or from Exmark Mfg. Co. Inc.  
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.  
Familiarize yourself with the following safety signs and instruction labels. They  
are critical to the safe operation of your Exmark commercial mower.  
PART NO. 1-543624  
LOCATION: Front Right  
Foot Support  
PART NO. 1-553049  
LOCATION: On Top Front LH  
Surface of Mower Deck  
PART NO. 103-2432  
LOCATION: Left Side of  
Brake Lever  
PART NO. 1-513746  
LOCATION: Surface of Engine  
Deck Next to Muffler  
PART NO. 1-553040  
LOCATION: Top Surface of Hydraulic  
Reservoir  
PART NO. 1-513747  
LOCATION: Top Front of Battery Cover  
PART NO. 103-1077  
LOCATION: Front RH Side of  
Mower Deck  
FMD524 & FMD604 units only  
PART NO. 103-2239  
LOCATION: Top of Mower Deck  
Beneath Center Shield  
PART NO. 1-303508  
LOCATION: On Top RH Surface  
of Mower Deck  
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PART NO. 98-5954  
LOCATION: Under Belt Shields  
PART NO. 1-403005  
LOCATION: LH & RH Front Top  
Surface of Mower Deck  
PART NO. 1-543620  
LOCATION: On Intake Screen Below Fuel Tank  
PART NO. 1-323540  
LOCATION: Front of Mower Deck, Top Surface  
PART NO. 1-543896  
LOCATION: Under Engine Deck on  
Wood Blocks for Shipping  
PART NO. 103-2248  
LOCATION: Steering Console  
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2. SPECIFICATIONS  
2.1 MODEL NUMBER: TR23KC  
2.2 ENGINE  
2.2.1  
2.2.2  
Engine Specifications: See your engine owners manual.  
3600 RPM (No Load)  
2.3 FUEL SYSTEM  
2.3.1  
2.3.2  
Capacity: 5.0 gal. (18.9 L.)  
Type of Fuel: Regular unleaded gasoline 87 octane or higher. In countries  
using the research method, it should be a 90 octane minimum.  
2.3.3  
2.3.4  
Fuel Filter: Replaceable in-line  
Fuel Shut-Off Valve: 1/4 turn  
2.4 ELECTRICAL SYSTEM  
2.4.1  
2.4.2  
2.4.3  
2.4.4  
2.4.5  
Charging System: Flywheel alternator  
Charging Capacity: 15 amp  
Battery Type: BCI Group U1, 235 amps at 0° F  
Battery Voltage: 12 Volt Polarity: Negative ground  
Fuses: 20, and 30 amp blade type, 20 amp to charging circuit; 20 amp to  
electric clutch; 30 amp to electro-mechanical actuator.  
2.4.6  
Safety Interlock System: Operator must be positioned in the seat with PTO  
disengaged and brake engaged to start engine. Operator must be in seat  
when PTO is engaged or when brake is disengaged or the engine will stop.  
2.5 OPERATOR CONTROLS  
2.5.1  
2.5.2  
Steering Control: Aircraft-style steering yoke.  
Motion Control: Single foot pedal operated by the right foot. Provides forward  
and reverse speed control with little effort. Motion control pedal and linkages  
are protected by the motion override device when the parking brake is engaged.  
2.5.3  
Parking Brake Lever: Engages park brake and locks drive system in neutral.  
Neutral lockout system prevents accidental engagement of drive system when  
park brake is engaged and protects hydro-transaxle from potential damage.  
2.6 SEAT  
2.6.1  
Type: high back, foam padded (internal suspension) with standard arm rests.  
2.6.2  
Mounting: Attached to activate a seat switch and attached to a seat spring for  
maximum comfort over rough terrain. Adjustable fore and aft.  
2.6.3  
2.6.4  
Armrests: foam padded flip-up armrests with height adjustment standard.  
Seat Safety switch: Incorporated into the Safety Interlock System. Time  
delay seat switch eliminates rough ground cut-outs.  
2.7 HYDROSTATIC GROUND DRIVE SYSTEM  
2.7.1  
2.7.2  
2.7.3  
2.7.4  
2.7.5  
Hydrostatic transmission: Eaton 851 transaxle with 23:1 reduction ratio.  
Hydrostatic direction control system is protected by a neutral lockout system.  
Hydraulic Oil Type: Synthetic Mobil 1 15W-50  
Hydraulic Oil Capacity: 8.5 qts. (8.0 L.)  
Filter: Replaceable cartridge type  
Exmark P/N 1-513211: 10 micron, 18 psi bypass  
2.7.6  
2.7.7  
Speeds: 0 - 6.4 mph (10.2 km/hr) forward; 0 - 3.2 mph (5.1 km/hr) reverse  
Drive wheel release lever allows machine to be moved when engine is not  
running.  
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Front Caster  
(FMD Units)  
2.8 TIRES  
Rear  
Drive  
Type  
Size  
Quantity  
Tread  
Ply Rating  
Pressure  
Pneumatic  
18 x 7.50-8  
1
Turfsaver  
4
Pneumatic  
20 x 10.00-8  
2
Turfmate  
4
Pneumatic  
11 x 4-5  
2
Smooth  
4
14 psi (97 kPa)  
20 psi (138 kPa)  
16 psi (110 kPa)  
2.9 MOWER DECK  
2.9.1  
Model Numbers: FMD604 and FMD 524  
2.9.1  
Cutting Width: 60 in. (152.4 cm.)  
52 in. (132.1 cm.)  
2.9.2  
2.9.3  
2.9.4  
Discharge: Right Side  
Optional Mulch Kit and Bagger available.  
Blade Size: 60" - (3 ea.) 20.50 in. (52.1 cm.)  
52" - (3 ea.) 18.00 in. (45.72 cm.)  
2.9.5  
Type of Drive: Electric clutch mounted on engine shaft. Blades driven by two  
belts with self tensioning idlers.  
2.9.6  
2.9.7  
Adjustable anti-scalp rollers (6 ea.)  
Cutting Height: Adjusts in 1/2” (1.3 cm) increments from 1 1/2” (3.8 cm) to 4  
1/2” (11.5 cm).  
2.9.8  
Deck Mounting: Full floating deck is attached to out-front support frame.  
Removable for servicing. Can be raised by one-touch electro-mechanical ball  
screw deck lift system for servicing and cleaning or to transfer weight to drive  
wheels which aides in climbing hills.  
2.10 DIMENSIONS  
without deck  
deflector up  
deflector down  
2.10.1  
Overall Width  
Turf Ranger with FMD524 49.9” (126.8 cm)  
Turf Ranger with FMD604 49.9” (126.8 cm)  
53.4” (135.6 cm) 64.2” (163.1 cm)  
61.4” (156.0 cm) 72.2” (183.4 cm)  
without deck  
with deck  
2.10.2  
Overall Length  
Turf Ranger with FMD524 70.2” (178.3 cm) 112.4” (285.5 cm)  
Turf Ranger with FMD604 70.2” (178.3 cm) 112.4” (285.5 cm)  
2.10.3 Curb Weight:  
Turf Ranger with FMD524  
931 lbs. (422 kg)  
Turf Ranger with FMD604 972 lbs. (441 kg)  
2.10.4  
2.10.5  
2.10.6  
Overall Height: 44.0” (111.8)  
Wheel Base: (center of caster tire to center of drive tire) 50.5” (128.3 cm)  
Tread Width (center to center of drive wheels): 39.75” (101 cm)  
2.11 TORQUE REQUIREMENTS  
Bolt Location  
Torque  
Cutter Housing Spindle Nut ........................................140-145 ft-lbs. (190-197 N-m)  
Blade Mounting Bolt....................................................115-120 ft-lbs. (156-163 N-m)  
Engine Deck/Front Frame Mount........................................30-35 ft-lbs. (41-47 N-m)  
Anti-Scalp Roller Bolts ........................................................40-45 ft-lbs. (54-61 N-m)  
Engine Mounting Bolts .......................................................25-30 ft-lbs. (34-41 N-m)  
Wheel Lug Nuts..............................................................90-95 ft-lbs. (122-129 N-m)  
Wheel Hub Slotted Nut ...............................................minimum100 ft-lbs. (136 N-m)  
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3. ASSEMBLY INSTRUCTIONS  
3.1 Uncrate tractor and mower deck.  
3.2 SERVICE BATTERY:  
WARNING: Battery posts, terminals, and related accessories contain lead compounds, chemicals known  
to the State of California to cause cancer and reproductive harm. Wash hands after handling.  
The machine is shipped with a filled lead acid battery.  
3.2.1  
Remove battery cover from machine.  
DANGER  
POTENTIAL HAZARD  
¨
Charging the battery may produce explosive gasses  
WHAT CAN HAPPEN  
Battery gasses can explode causing serious injury.  
HOW TO AVOID THE HAZARD  
¨
¨
¨
Keep sparks, flames, or cigarettes away from battery.  
Ventilate when charging or using battery in an  
enclosed space.  
¨
Make sure venting path of battery is always open once  
battery is filled with acid.  
3.2.2  
Check the voltage of the battery with a digital voltmeter. Locate the voltage reading  
of the battery in the table below and charge the battery for the recommended time  
interval to bring the charge up to a full charge of 12.6 volts or greater.  
IMPORTANT: Make sure the negative battery cables are disconnected and  
the battery charger used for charging the battery has an output of 16 volts and  
7 amps or less to avoid damaging the battery (see chart below for  
recommended charger settings).  
Voltage  
Reading  
12.6 or greater 100%  
12.4 – 12.6  
12.2 – 12.4  
12.0 – 12.2  
11.7 – 12.0  
11.7 or less  
Percent  
Charge  
Maximum  
Charger Settings  
16 volts/7 amps  
Charging Interval  
No Charging Required  
30 Minutes  
1 Hour  
2 Hours  
3 Hours  
75 – 100% 16 volts/7 amps  
50 – 75%  
25 – 50%  
0 – 25%  
0%  
16 volts/7 amps  
14.4 volts/4 amps  
14.4 volts/4 amps  
14.4 volts/2 amps  
6 Hours or More  
CAUTION  
POTENTIAL HAZARD  
¨
If the ignition is in the “ON” position there is potential  
for sparks and engagement of components.  
WHAT CAN HAPPEN  
¨
Sparks could cause an explosion or moving parts  
could accidentally engage causing personal injury.  
HOW TO AVOID THE HAZARD  
¨
Be sure ignition switch is in the “OFF” position before  
charging the battery.  
3.2.3  
Connect the negative battery cables.  
NOTE: If the positive cable is also disconnected, connect the positive (red)  
cable to the positive terminal on the battery first, then connect the negative  
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(black) cable to the negative terminal on the battery. Reinstall insulator boots.  
Reinstall battery cover.  
NOTE: If time does not permit charging the battery, or if charging equipment  
is not available, connect the negative battery cables and run the vehicle  
continuously for 20 to 30 minutes to sufficiently charge the battery.  
PART NO. 1-513747  
3.3 INSTALL SEAT:  
LOCATION: Battery Cover  
Remove seat cushion from seat frame. Remove seat frame from crate and discard  
mounting hardware. Mount seat to unit using two 5/16-18 x 3/4” bolts, two 3/8 flat  
washers and whizlock nuts from bolt bag in front two holes. Install flat washers between  
seat frame and seat rails. Mount seat to two rear bolts (which have springs on them), by  
removing the top whizlock nuts, installing seat frame, and replacing nuts. Reinstall  
cushion to seat frame.  
3.4 INSTALL REAR STEERING WHEEL:  
Mount the rear tire and wheel assembly with a 5/8-11 x 10-1/2” bolt and torque nut.  
Tighten torque nut just enough to create a slight drag on the wheel while the wheel is  
being rotated. Inflate tire to 14 psi (95 kPa).  
3.5 INSTALL DRIVE WHEELS:  
Mount both drive wheels securing them with four (4) wheel nuts each. Torque to 90-95  
ft. lbs. (122-129 N-m). Inflate tires to 20 psi (138 kPa).  
3.6 INSTALL HANDLE BAR:  
Install steering handle bar with two 3/8-16 x 1-1/4” bolts and two 3/8 spring disc washers.  
3.7 INSTALL CANISTER AIR CLEANER:  
a) Remove air cleaner (with bracket attached) from crate. Keep air cleaner and  
mounting bracket together.  
b) Cut plastic tie holding air cleaner cap to engine and install cap to the air cleaner.  
c) Remove the top two throttle plate mounting screws from the engine. Keep  
screws for re-attaching air cleaner.  
d) Position the air cleaner assembly over the engine, aligning air cleaner bracket  
holes with top holes in the throttle plate. Reinstall throttle plate screws through  
air cleaner bracket and throttle plate.  
e) Mount lower holes in air cleaner bracket to holes in engine air cleaner bracket  
using (2) M6x1.0x16mm Hex flange capscrews, (2) .216 I.D. x 1.0 O.D.  
washers, and (2) M6x1.0 nyloc nuts from bolt bag. Be sure to install the head of  
the capscrew to the front of the unit and the washer next to the nyloc nut to the  
rear of the unit on the other side of the air cleaner bracket.  
f) Remove plastic plugs from air intake elbow on engine and air cleaner hose. Adjust  
the air cleaner and hose as required and connect intake hose to air cleaner outlet.  
Position and tighten the two hose clamps to secure the hose connections.  
3.8 INSTALL MOWER DECK TO TRACTOR:  
3.8.1 Rotate drive wheel release lever into position shown in Figure 4 to release drive  
system (Refer to Section 4.11). Roll tractor to mower deck and mower deck  
support aligning them so the tractor is positioned for ease of mounting the deck  
support. Remove center belt shield.  
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3.8.2 Remove mower deck support frame from mower deck by removing the two  
hairpins and spacers from the front deck support pins and remove the hairpins  
and spacers from the rear deck support pins.  
3.8.3 Lift up on support frame until it clears the support pins. Position support frame  
so the arms are on each side of the tractor engine deck and secure.  
Secure using eight (8) 3/8-16 x 1 1/4” bolts, disc spring washers, and whizlock nuts.  
NOTE: Place spring washer cone side against bolt head (cupped side away from  
head) and install to outside of support frame (as shown in Figure 2). Install with  
whizlock nuts to the inside of engine deck. Tighten until spring washers are flat.  
FIGURE 2  
HARDWARE AND SUPPORT PIN  
LOCATION FOR DECK SUPPORT FRAME  
3.8.4 Position tractor, with mower deck support frame in place, over the mower deck.  
Align support frame above mower deck and position it so the support pins on the  
deck align with the mounting holes in the support frame. Lower support frame onto  
deck and Reinstall the two hairpins and spacers on the front support pins and the  
two hairpins and spacers onto the rear support pins (See Figure 1).  
3.8.5 After the mower deck support frame and the attached mower deck are in place, it  
is necessary to remove the two wooden blocks under the engine deck pivot stops.  
CAUTION  
POTENTIAL HAZARD  
¨
Removing the two blocks prior to installing the mower  
deck and support for counter balance will allow the  
engine deck to flip backwards.  
WHAT CAN HAPPEN  
¨
If the engine flips backwards pinch points are created,  
which may cause injury.  
HOW TO AVOID THE HAZARD  
¨
Keep hands clear from the engine deck when  
removing the blocks.  
3.8.6 Install mower deck stationary idler. Idler components are located in the Turf  
Ranger bolt bag.  
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Locate two holes along the back center section of the mower deck. Install the  
stationary idler and related parts in the left hand hole location as shown in Figure  
3. See the belt routing decal on deck. Be sure the coned end of the disc spring  
is against the head of the bolt as illustrated (See Figure 3).  
3/8 WHIZLOCK NUT  
3/8 HEX CAP  
SCREW  
FIGURE 3  
IDLER PULLEY KIT AND LOCATION  
3.8.7 Install mower deck drive belt.  
NOTE: Make sure to use proper belt for your deck. The belt (Part #1-543523)  
that is installed on the unit is for 60”decks only. For 52” decks, the belt (Part #1-  
543749) from the bolt bag must be used. Refer to belt routing decal on deck.  
Slip belt between clutch drive sheave and drive wheel release rod (make sure  
belt is in the sheave groove).  
Install the deck drive belt around the clutch. Refer to belt routing decal. Be sure belt  
is in the clutch drive sheave groove. Place the other end of the belt into the V-  
groove of the stationary idler, move the spring loaded idler outward and route the  
belt around the inside of the spring loaded idler. Position the belt into the V-  
groove of the mower deck drive sheave. Carefully release the spring loaded idler.  
Install the center belt shield.  
3.8.8 Adjust cutting height of deck and anti-scalp rollers. (See Section 6.2.1.)  
3.9 POSITION DISCHARGE CHUTE:  
Loosen two (2) 5/16” nyloc nuts attaching discharge chute. Lower the discharge chute  
into position. Retighten nyloc nuts until chute is snug but can pivot freely.  
3.10 SERVICE ENGINE: See Engine Operator's Manual.  
4. CONTROLS  
Familiarize yourself with all controls before operating the mower.  
4.1 Steering Handle Bar: Located in center of steering console in front of operator’s seat.  
During forward operation of the machine, movement of the steering handle to the right  
will cause the machine to turn to the right and vice versa. The steering system is chain  
connected from the steering shaft sprocket to the yoke sprocket. The chain has two  
adjustable connectors.  
4.2 Motion Control Pedal: Located on the right side of steering console. The foot pedal  
controls the forward and reverse operation with foot motion. To increase forward speed  
press front pedal down until desired speed is obtained, to increase reverse speed press  
back pedal down until desired speed is obtained. Movement of the front pedal down will  
cause the machine to go forward. To stop forward travel, remove foot from pedal. The  
neutral centering device moves the motion pedal back to the neutral position.  
For reverse motion, place foot heel on the rear pedal pad and press downward.  
Remove foot from pedal to stop reverse motion. The pedal automatically returns to  
neutral. When parking brake is engaged, the motion control pedal can be moved but  
will not function.  
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4.3 Electro-mechanical deck lift control: Switch is located on left side of control console.  
Moving the toggle switch lever forward will lower the cutting deck. Moving the lever  
backward will raise the deck. Normal operation is with the actuator fully extended. The  
actuator has an internal clutch to protect it from excessive loads. When raising or  
lowering the deck and the actuator has reached it’s limit, a "ratcheting" sound is  
heard. When this ratcheting sound is heard, release switch lever, momentarily reverse  
switch to move actuator just off the fully extended or retracted position.  
4.4 PTO Engagement: Located on right side of control console. The switch must be pulled  
out to the “ROTATE” position to engage the blades. The switch is pushed in to the  
STOP” position to stop the blades. Operator must be in the seat when blades are  
engaged or engine will stop.  
4.5 Choke Control: Located on the left side of the control console. The choke control is  
used to aid in starting a cold engine. The choke control is pulled out to be in the “ON”  
position and pushed in to be in the “OFF” position. DO NOT run a warm engine with  
the choke in the “ON” position.  
4.6 Throttle Control: Located on the control console right side. Throttle is used to control  
engine speed. Moving throttle control ahead will increase engine speed and moving it  
to the rear will decrease engine speed.  
4.7 Park Brake Lever: Located ahead and near the right side of control console. Park  
brake lever engages a parking brake on the drive wheels and also locks the hydrostatic  
drive system in neutral. Moving the lever rearward will engage the brake. To  
disengage brake, lift finger latch and move brake ahead. Operator must be in the seat  
when brake is disengaged or engine will stop.  
4.8 Ignition Switch: Located on the control console just ahead of the steering handle. The  
ignition switch is used to start and stop the engine. The switch has three positions  
“OFF”, “ON” and “START”. Insert key into switch and rotate to the right to the "ON"  
position. Rotate clockwise to the next position to engage the starter (key must be held  
against spring pressure in this position). Operator must be in seat with brake engaged  
and PTO disengaged to start engine. When engine starts, release key. DO NOT leave  
key in the “ON” position without engine running, this will run down the battery.  
4.9 Hour Meter: Located on the steering console just below the steering wheel. The hour  
meter is connected to a pressure switch installed in the engine block and it records the  
number of hours that the engine has run. If ignition switch is left on without engine  
running, hour meter will not run.  
NOTE: This switch is not a low oil sensor and will not alert the operator if the engine oil  
is low.  
4.10 Fuel Shut-Off Valve: Located in the fuel line near the right rear corner of the engine.  
The fuel shut-off valve is used to shut off the flow of fuel when parking inside a  
building, during transportation to and from job sites and when the machine will not be  
used for a few days. Rotate valve 1/4 turn clockwise to shut fuel off. Rotate valve 1/4  
turn counter-clockwise to turn fuel on.  
4.11 Drive Wheel Release Lever: Located under the lower left rear corner of the engine deck  
(See Figure 4). The drive wheel release lever is used to release the hydrostatic drive  
system to allow machine to be pushed while the engine is not running. Rotate lever 1/8  
turn counter-clockwise until caught under spring latch to release drive system. Pull  
spring latch out far enough to allow lever to rotate 1/8 turn clockwise to engage drive  
system.  
NOTE: Do Not tow machine or transmission damage may result.  
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FIGURE 4  
DRIVE WHEEL RELEASE LEVER  
5. OPERATION INSTRUCTIONS  
5.1 PRE-START  
5.1.1 Fill fuel tank. For best results use only clean, fresh regular grade unleaded  
gasoline with an octane rating of 87 or higher. Regular grade leaded gasoline  
may also be used; however, combustion chamber and cylinder head will require  
more frequent service. See Engine Owner's Manual.  
Note: Fuel tank may appear loose at set-up, however, once fuel is added, tank  
will slowly expand to fit tank straps.  
Do not add oil to gasoline.  
Never fill the fuel tank so that 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.  
5.1.2 Make sure you understand the controls, their locations, their functions, and their  
safety requirements.  
5.1.3 Refer to the Maintenance Section, and perform all of the necessary inspection  
and maintenance steps.  
5.2 MOWING  
5.2.1 Starting Engine: Operator must be in the seat with the parking brake engaged  
and the PTO disengaged.  
Open fuel shut-off value.  
On a cold engine, place the throttle midway between the "SLOW" and "FAST"  
positions and place the choke in the "ON" position. On a warm engine, place the  
throttle midway between the "SLOW" and "FAST" positions and leave the choke  
in the "OFF" position.  
Turn ignition switch to "START" position. Release the switch as soon as the  
engine starts.  
After starting a cold engine, gradually return choke to the "OFF" position after  
engine warms up.  
IMPORTANT: Do not crank the engine continuously for more than ten (10)  
seconds at a time. If the engine does not start, allow a 60 second starter cool-  
down period between starting attempts. Failure to follow these guidelines can  
burn out the starter motor.  
5.2.2 Stopping Engine: Bring unit to a full stop. Disengage the PTO and engage the  
park brake.  
Before stopping the engine, place the throttle control midway between the “slow”  
and “fast” positions. Allow the engine to run a minimum of 15 seconds; then stop  
the engine.  
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Rotate ignition switch to “OFF” position. Remove the key to prevent children or  
other unauthorized persons from starting engine.  
Close fuel shut-off valve when machine will not be used for a few days, when  
transporting, and when the unit is parked inside a building.  
5.2.3 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 the 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, removed, or altered unless there is a grass  
collection system or mulch kit in place and working  
properly.  
The PTO switch engages the cutting blades. Be sure that all persons are clear  
of mower deck and discharge area before engaging the PTO.  
IMPORTANT: Operator must be in seat before the PTO can be engaged.  
Set throttle to "midway" position. The switch must be pulled out to the "ROTATE"  
position to engage the blades. Accelerate to full throttle to begin mowing.  
5.2.4 Stopping PTO: Set throttle to “idle” position. Push in on the switch to the “STOP”  
position to stop the blades.  
5.3 TRANSPORTING  
5.3.1 Transporting a Unit: Use a heavy duty trailer to transport the machine. When the  
machine is on the trailer lower the cutting deck and fully extend the actuator.  
Never transport machine with mower deck supported by actuator, damage to the  
actuator or other components may occur. Engage the park brake and block the  
wheels. Securely fasten the machine to the trailer or truck with straps, chains,  
cables, or ropes. Be sure that the trailer or truck has all necessary lighting and  
marking as required by law. Secure to trailer with a safety chain.  
5.3.2 Loading a Unit: Use caution when loading units on a trailer or truck. Use  
actuator to lift cutting deck off of the ground to provide more traction on the drive  
tires while loading the unit. One full width ramp that is wide enough to extend  
beyond the drive tires is recommended. If it is not possible to use one full width  
ramp, multiple ramps may be used, but should be spaced close enough together  
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to simulate a full width ramp. Drive forward to load and drive backward to unload  
from a trailer. Do not drive backward to load or drive forward to unload a trailer.  
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°. After unit is  
loaded on the trailer lower the cutting deck and fully extend actuator for transport.  
CAUTION  
POTENTIAL HAZARD  
¨
This unit does not have proper turn signals, lights,  
reflective markings, or a slow moving vehicle emblem.  
These items are required to drive on a public street or  
roadway.  
WHAT CAN HAPPEN  
¨
Driving on a street or roadway without such equipment  
is dangerous and can lead to accidents causing  
personal injury.  
¨
Driving on a street or roadway without such equipment  
may also be a violation of State laws and the operator  
may be subject to traffic tickets and/or fines.  
HOW TO AVOID THE HAZARD  
Do not drive a unit on a public street or roadway.  
¨
6. 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 spark plug(s) before you do any  
maintenance. Also push the wire(s) aside so it does  
not accidentally contact the spark plug(s).  
WARNING  
POTENTIAL HAZARD  
¨
The engine can become very hot.  
WHAT CAN HAPPEN  
Touching a hot engine can cause severe burns.  
HOW TO AVOID THE HAZARD  
¨
¨
Allow the engine to cool completely before service or  
making repairs around the engine area.  
6.1 PERIODIC MAINTENANCE  
6.1.1 Check engine oil level:  
Service Interval: Daily  
a)  
Stop engine and wait for all moving parts to stop. Make sure machine is on  
a level surface.  
b)  
Check with engine cold.  
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c)  
d)  
Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the  
dipstick. Do not screw into place. Remove dipstick and read the oil level.  
If the oil level is low, add oil to bring the oil up to the “FULL” mark on the  
dipstick. Use oil as specified in 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.  
6.1.2 Clean engine air cooling system:  
Service Interval: See Engine Owner's Manual  
CAUTION  
POTENTIAL HAZARD  
¨
Excessive debris can cause the engine and hydraulic  
system to overheat.  
WHAT CAN HAPPEN  
¨
Excessive debris around the engine and inside the  
transmission cooling compartment can create a fire  
hazard.  
HOW TO AVOID THE HAZARD  
¨
Clean all debris from around the engine and  
transmission daily.  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
Clean all debris from engine air intake screen and from around engine  
shrouding.  
6.1.3 Clean transmission cooling compartment:  
Service Interval: Daily  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
Clean all debris from screens that encompass cooling compartment, and  
then remove the compartment screen.  
c)  
d)  
Clean all debris from the fan blades and the cooling fins for the transmission.  
Replace the compartment screen.  
6.1.4 Clean grass build-up under mower deck and check mower blades.  
Service Interval: Daily  
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 jack stands or equivalent  
support.  
a)  
b)  
Disengage PTO.  
Raise deck using lift actuator.  
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c)  
d)  
e)  
Stop engine, wait for all moving parts to stop, and remove key.  
Block up using proper safety precautions.  
Clean out any grass build-up from underside of deck and in deck discharge  
chute.  
f)  
Inspect blades and sharpen or replace as required.  
g)  
If blade removal is necessary, be careful for the sharp cutting edges of the  
blades.  
h)  
Re-install the blades (if they were removed) by placing a block of wood  
between the front or rear baffles and the blade then torquing the blade  
bolts to 115-120 ft. lbs. Be sure the spring disk washer cone is installed  
toward the bolt head (See Figure 5).  
CAUTION  
POTENTIAL HAZARD  
¨
Operating a mower deck with loose or weakened  
blade bolts can be dangerous.  
WHAT CAN HAPPEN  
¨
A loose or weakened blade bolt could allow a blade  
rotating at a high speed to come out from under the  
deck, causing serious injury or property damage.  
HOW TO AVOID THE HAZARD  
¨
Replace the blade bolt after striking a foreign object.  
(Use only Exmark replacement parts PN 103-0862 –  
blade bolt and PN 103-0865 – spring disc washer).  
DO NOT lubricate the threads of the bolt or spindle  
before assembly.  
¨
¨
Torque the blade bolt to 115-120 ft. lbs.  
i)  
Remove jack stands (or equivalent support) and lower deck to ground.  
DO NOT USE WRENCH HERE.  
FOR BLADE INSTALLATION MAINTAIN  
140-145 ft-lbs. (190-197 N-m) ON THIS NUT  
FIGURE 5  
BLADE BOLT INSTALLATION  
6.1.5 Check safety interlock system:  
Service Interval: Daily  
a)  
Check starting circuit. Starter should crank with operator in seat; parking  
brake engaged, and with PTO disengaged. Try to start with operator out of  
seat; parking brake engaged, and PTO disengaged; starter must not  
crank. Try to start with operator in seat, parking brake disengaged and  
PTO disengaged; starter must not crank. Try to start with operator in seat,  
parking brake engaged and PTO engaged; starter must not crank.  
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b)  
c)  
Check kill circuits: Run engine at one-third throttle with PTO and parking  
brake disengaged; lift yourself off the seat (but do not get off the machine)  
engine must stop after 1/2 second has elapsed.  
Run engine at one-third throttle with PTO and parking brake engaged; lift  
yourself off the seat (but do not get off the machine) engine must stop after  
1/2 second has elapsed.  
NOTE: If machine does not pass any of these tests, Do Not operate. Contact  
your authorized EXMARK Servicing Dealer.  
IMPORTANT: It is essential that all Operator Safety Mechanism be connected  
and in proper working condition prior to use for mowing.  
6.1.6 Check for loose hardware:  
Service Interval: Daily  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
Visually inspect machine for any loose hardware or any other possible  
problem. Tighten hardware or correct the problem before operating.  
6.1.7 Service air cleaner.  
Service Interval: 50 hrs.  
More often under severe conditions.  
See Engine manual for additional information.  
a)  
b)  
c)  
Stop engine, wait for all moving parts to stop, and remove key.  
Loosen retaining clips and remove air cleaner compartment cover.  
Remove paper element. Check the condition of the paper element.  
Replace if dirty, bent or damaged.  
d)  
Check the condition of the inner element. Replace whenever it appears  
dirty, typically every other time the paper element is replaced. Clean the  
base around the inner element before removing, so dirt does not get into  
the engine.  
e)  
f)  
DO NOT wash or use pressurized air to clean paper element or inner element.  
Reinstall elements. Position the cover so that the rubber dust ejector is  
pointing downward and secure with retaining clips.  
6.1.8 Change engine oil:  
Service Interval: See Engine Owner’s Manual  
NOTE: Change oil after first five (5) hours of operation, then refer to engine  
manual for future oil change frequencies.  
a)  
b)  
c)  
Stop engine, wait for all moving parts to stop, and remove key.  
Drain oil while engine is warm from operation.  
Oil drain is located on the left side of the engine. Place pan under machine  
to catch oil and open valve with a 10 mm wrench. Allow oil to drain then  
close valve.  
d)  
Replace the oil filter as per Engine Owner's Manual. Clean around oil filter  
and unscrew filter to remove. Before reinstalling new filter, apply a thin  
coating of oil on the surface of the rubber seal. Turn filter clockwise until  
rubber seal contacts the filter adapter then tighten filter an additional 2/3 to  
3/4 turn.  
e)  
f)  
Clean around oil fill cap and remove cap. Fill to specified capacity and  
replace cap. Use oil as directed in Engine Owner's Manual. Do Not overfill.  
Start the engine and check for leaks. Stop engine and recheck oil level.  
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6.1.9 Check hydraulic oil level:  
Service Interval: 40 hrs.  
a)  
b)  
c)  
Make sure mower is on a level surface.  
Stop engine, wait for all moving parts to stop.  
Visually inspect the sight gauge on hydraulic tank. Oil level should be  
visible to top of sight gauge. If not, clean area around hydraulic reservoir  
cap, remove cap, and add oil as specified in Section 2.7 (Specifications).  
Replace cap.  
6.1.10 Check tire pressures:  
Service Interval: 40 hrs.  
a)  
b)  
c)  
Stop engine, wait for all moving parts to stop, and remove key.  
Inflate tires to pressures specified in Section 2.8 (Specifications).  
See Section 8.1 for further information.  
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.  
6.1.11 Check battery charge:  
Service Interval: Monthly  
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, 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 battery in the table below and charge the battery for the  
recommended time interval to bring the charge up to a full charge of 12.6  
volts or greater.  
IMPORTANT: Make sure the negative battery cables are disconnected  
and the battery charger used for charging the battery has an output of 16  
volts and 7 amps or less to avoid damaging the battery (see chart below for  
recommended charger settings).  
Voltage  
Reading  
Percent  
Charge  
Maximum  
Charger Settings  
Charging Interval  
12.6 or greater 100%  
16 volts/7 amps  
No Charging Required  
30 Minutes  
1 Hour  
2 Hours  
3 Hours  
12.4 – 12.6  
12.2 – 12.4  
12.0 – 12.2  
11.7 – 12.0  
11.7 or less  
75 – 100% 16 volts/7 amps  
50 – 75%  
25 – 50%  
0 – 25%  
0%  
16 volts/7 amps  
14.4 volts/4 amps  
14.4 volts/4 amps  
14.4 volts/2 amps  
6 Hours or More  
6.1.12 Inspect Belt Wear:  
Service Interval: 40 hrs.  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
Remove the three mower deck belt shields to check mower primary and  
secondary belt condition.  
c)  
d)  
Look under engine deck to check the transmission drive belt condition.  
Check all idler arms to be sure they pivot freely.  
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Note: Be sure to check idler on transmission drive belt. Disassemble, clean and  
grease pivot bushing if necessary.  
6.1.13 Lubricate grease fittings.  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
Lubricate fittings with one to two pumps NGLI grade #2 multi-purpose gun  
grease. Refer to the following chart for fitting locations and lubrication schedule.  
LUBRICATION CHART  
INITIAL  
PUMPS  
NO of  
PLACES INTERVAL  
SERVICE  
FITTING LOCATIONS  
1. Front Caster Wheel hubs w/o zerk  
2. Front Caster Pivots  
3. Drive Wheel Bearings  
4. Engine Deck Pivots  
5. Steering Column  
6. Idler Pivots, Mower Deck  
7. Rear Steering Wheel Bearings  
*0  
*0  
1
1
1
2
2
2
2
1
2
1
Yearly  
Yearly  
200 hours  
40 hours  
40 hours  
40 hours  
200 hours  
1
1
* See 6.1.13 Section c) for special lubrication instructions on the front caster pivots  
and Section 6.1.14 for special lubrication instructions on the front caster wheel hubs.  
No. 3 (Drive Wheel Bearings)  
Located Under Engine Deck  
No. 6(IdlerPivots,MowerDeck)  
Monthly disassemble belt and  
spring and grease under a  
“No Load” condition.  
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 thread plug back in Place cap back on.  
6.1.14 Lubricate caster wheel hubs:  
Service Interval: Once Yearly  
a)  
Stop engine, wait for all moving parts to  
stop, and remove key.  
b)  
c)  
d)  
Remove caster wheel from caster forks.  
Remove seal guards from the wheel hub.  
Remove one of the spacer nuts from the  
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) from the wheel assembly.  
FIGURE 8  
CASTER WHEEL ASSEMBLY  
e)  
Pry out seals, and inspect bearings for wear or damage and replace if  
necessary.  
f)  
Pack the bearings with a NGLI grade #1 multi-purpose grease.  
Insert (1) bearing, (1) new seal into the wheel.  
g)  
NOTE: Seals (Exmark PN 103-0063) must be replaced.  
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h)  
If the axle assembly has had both spacer nuts removed (or broken loose),  
apply a thread locking adhesive to (1) spacer nut and thread onto the axle  
with the wrench flats facing outward. Do not thread spacer nut all of the way  
onto the end of the axle. Leave approximately 1/8” (3 mm) from the outer  
surface of the spacer nut to the end of the axle inside the nut.  
i)  
Insert the assembled nut and axle into the wheel on the side of the wheel  
with the new seal and bearing.  
h)  
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.  
i)  
j)  
Insert the second bearing and new seal into the wheel.  
Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle  
with the wrench flats facing outward.  
k)  
l)  
Torque 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.  
Re-install the seal guards over the wheel hub and insert wheel into caster  
fork. Re-install caster bolt and tighten nut fully.  
IMPORTANT: To prevent seal and bearing damage, check the bearing  
adjustment often. Spin the 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 until there is a slight amount of drag.  
Re-apply threadlocking adhesive.  
6.1.15 Remove engine shrouds and clean cooling fins:  
Service Interval: See Engine Owner's Manual  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
Remove cooling shroud cleanout covers from engine and clean cooling fins.  
Also clean dust, dirt, and oil from external surfaces of engine, which can  
cause improper cooling.  
c)  
Make sure cooling shroud cleanout covers are properly reinstalled.  
Operating the engine without cooling shroud cleanout covers will cause  
engine damage due to overheating.  
6.1.16 Change fuel filter:  
Service Interval: As Required  
a)  
A fuel filter is installed in the fuel line between the fuel tank and the engine.  
Replace with Kohler P/N 2405002 when necessary.  
6.1.17 Lubrication of steering yoke pivot:  
Service Interval: Monthly  
a)  
The steering yoke pivot is permanently sealed and should require no additional  
lubrication. If there is evidence of seal leakage, replace the seals or bearings  
and fill with NGLI grade #2 multi-purpose grease or wheel bearing grease.  
6.1.18 Check spark plugs.  
Service Interval: 160 hrs.  
a)  
Remove spark plugs, check condition and adjust plug gap, or replace with  
new plugs. See Engine Owners Manual.  
6.1.19 Change hydraulic system oil or filter:  
6.1.19.1 Change hydraulic filter:  
Service Interval: After first 250 hrs, then yearly thereafter.  
a) Stop engine, wait for all moving parts to stop, and remove key.  
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b) Carefully clean area around filter. It is important that no dirt or  
contamination enters the hydraulic system.  
c) Unscrew filter and remove.  
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 filter clockwise until rubber seal contacts the filter adapter, and  
then tighten the filter an additional 2/3 to 3/4 turn. Use only Exmark  
(Part No. 1-513211) or Eaton (Part No. 103144) filter elements.  
d) Start engine and run several minutes.  
g) Check hydraulic oil level as outlined in 6.1.9.  
6.1.19.2 Change hydraulic oil:  
Service Interval: Yearly  
a) Stop engine, wait for all moving parts to stop, and remove key.  
b) Carefully clean area around small fitting under oil reservoir. Loosen  
clamp, remove hose, and allow oil to drain from reservoir. It is  
important that no dirt or contamination enters the hydraulic system.  
Reinstall hose and tighten clamp.  
c) Clean around reservoir cap and Refill reservoir to center of sight  
gauge with Mobil “1” 15W-50.  
d) Start engine and run several minutes.  
e) Recheck hydraulic oil level as outlined in 6.1.9. Do not attempt to  
drain all oil in hydraulic system (except what drains out of the filter or  
reservoir when changing filter or hydraulic oil); unless it is felt that  
the oil has been contaminated or becomes extremely hot. Changing  
oil unnecessarily, could damage the hydraulic system by  
introducing contaminates into the system.  
6.1.20 Inspect Electric clutch gap:  
Service Interval: 250 hrs.  
Refer to Section 6.2.12 for inspection and adjustment procedures.  
6.1.21 Refer to the Engine Owner’s Manual for detailed maintenance required for  
servicing the engine.  
6.1.22 Wheel hub, slotted nut torque specification.  
a)  
b)  
Tighten the slotted nut on the transaxle tapered shaft and torque to 100 ft. lbs.  
After proper torque has been applied, turn the nut until the next set of slots  
lines up with the cross hole in the shaft.  
c)  
Replace cotter pin.  
NOTE: Do not use anti-seize compound on the wheel hub.  
6.1.23 Thread locking adhesives such as "Loctite 242" or "Fel-Pro Pro-Lock, Nut-Type"  
are used on the following fasteners:  
a)  
b)  
c)  
d)  
Bolt which mounts blade drive clutch to engine crankshaft.  
Transaxle drive shaft pillow block bearing setscrews.  
Bolts which attach transaxle to lower stabilizer bracket.  
Caster wheel spacer nuts (Reference Section 6.1.14).  
6.1.24 An anti-seize compound on the following locations:  
a)  
Between the pillow block bearings and the transaxle shafts.  
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6.1.25 Mobil HTS grease (or food-grade antisieze) is used in the following locations:  
a)  
b)  
c)  
Between the cutter housing spindle and bearings.  
Between the cutter housing spindle and sheave.  
Under top cutter housing bearing guard.  
6.1.26 Dielectric grease is used on all blade type electrical connections to prevent  
corrosion and loss of contact.  
6.2 ADJUSTMENTS  
IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop,  
and remove key before servicing, cleaning or making any adjustments to the unit.  
6.2.1 Cutting height and anti-scalp roller adjustment.  
CAUTION  
POTENTIAL HAZARD  
¨
When mower deck is not installed or the two front  
support rod hairpins are removed, the unbalanced  
weight of the tractor or tractor with mounted mower  
deck support frame may cause the front of the unit to  
rise suddenly.  
WHAT CAN HAPPEN  
If the unit rises suddenly, injury may occur.  
HOW TO AVOID THE HAZARD  
¨
¨
Securely hold down the front end of the unit when the  
mower deck is not installed or front support rod  
hairpins are removed.  
a)  
b)  
Stop engine and wait for all moving parts to stop.  
Install hairpin clips in the holes for the desired cutting height (See Figure 9).  
IMPORTANT: To maintain correct cutting height and rake, check the  
following for proper adjustment.  
1. The front and rear hairpins are in the same holes with the proper spacers  
under the hair pins (See Figure 6).  
2. The tire pressures are set as directed in Section 6.1.10.  
3. The length of the rear deck support link assemblies should average  
6.89” (approximately 6 7/8” (17.5 cm)) from the center of the balljoint to  
the center of the farthest hole (See Figure 6).  
NOTE: All (4) pins must equally support the weight of the deck.  
Adjustment in the length of the rear deck support assemblies may be  
necessary. If one side is longer than 6.89” (17.5 cm), than the opposite  
side must be shorter by the same amount.  
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LEFT HAND  
SIDE SHOWN  
FIGURE 6  
CUTTING HEIGHT ADJUSTMENT  
FOR CUTTING HEIGHTS ABOVE  
3.5” (8.89 CM) USE THE BOTTOM HOLE  
THE ROLLERS WILL STILL BE  
EFFECTIVE AGAINST SCALPING  
FIGURE 7  
ANTI-SCALP ROLLER BOLT INSTALLATION  
ANTI-SCALP ROLLER AND  
CUTTING HEIGHT ADJUSTMENT  
c)  
Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in  
one of the positions shown in Figure 7. Rollers will maintain 3/4 in. (19 mm)  
clearance to the ground to minimize gouging and roller wear or damage.  
For Maximum Deck Flotation, place rollers one hole position lower.  
Rollers should maintain 1/4 in. (6.4 mm) clearance to ground. Do Not  
adjust rollers to support the deck. Be sure roller bolts and nuts are  
installed with the spring disc washer between head of the bolt and  
mounting bracket.  
Torque to 40-45 ft-lbs. (54-61 N-m), or loss of roller may result.  
d)  
When operating in extremely rough conditions it may be necessary to  
position the anti-scalp rollers one or two holes higher than described in  
"c" to prevent damage to the rollers and/or bolt failure (See Figure 7).  
NOTE: When anti-scalp rollers are placed in these positions, reduced  
deck flotation will result.  
6.2.2 Transmission drive belt tension adjustment: No adjustment necessary.  
6.2.3 Mower deck drive belt: No adjustment necessary.  
6.2.4 Blade drive belt tension. No adjustment necessary.  
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6.2.5 Neutral Centering Adjustment  
a) The Neutral Centering Device adjustment should be made with the engine  
running at full throttle. First raise and securely block up the frame so that  
the drive wheels can rotate freely without contacting the ground.  
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 surfaces.  
CAUTION  
POTENTIAL HAZARD  
¨
Raising the tractor frame 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 jack stands or equivalent  
support.  
b)  
Remove the electrical connection from the parking brake safety switch  
located on the right- hand underside at the front of the engine deck.  
Temporarily install a jumper wire across the terminals in the connector of  
the wiring harness.  
c)  
d)  
Release brake lever.  
The Neutral Centering Device is located on the right-hand underside of the  
engine deck. Loosen jam nut (d) from the ball joint which connects the  
override assembly (f), to the engine deck anchor mounting (See Figure 8).  
e)  
f)  
Start engine. Operator must be in seat to crank engine. Open to full throttle.  
Adjust neutral centering device length by rotating the neutral centering  
device barrel clockwise or counterclockwise until wheels stop turning or no  
longer creep. Tighten jam nut.  
g)  
h)  
Remove jumper and reconnect electrical connection to parking brake  
safety switch.  
Check safety interlock system as outlined in Section 6.1.5.  
IMPORTANT: Keep clear of wheels and other moving parts when making  
these adjustments.  
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FIGURE 8  
NEUTRAL CENTERING DEVICE ADJUSTMENT  
6.2.6 Parking Brake Quadrant Adjustment  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
Loosen the two 5/16 x 18 screws (a), that clamp the brake quadrant to the  
engine deck.  
c)  
d)  
Pull parking brake lever towards the operator to the brake “on” position (b).  
Check linkage to ensure that they butt up against the over-centering stop  
bolt (c), and retighten the two 5/16-18 screws (See Figure 9).  
FIGURE 9  
PARKING BRAKE QUADRANT ADJUSTMENT  
6.2.7 Parking Brake Spring Adjustment  
a)  
b)  
c)  
Stop engine, wait for all moving parts to stop, and remove key.  
Check the pin to pin length and adjust to 11 5/8” as required.  
Check the compression spring length and adjust to 3 1/32” as required  
(See Figure 10).  
FIGURE 10  
BRAKE CONTROL LINK AND SPRING ADJUSTMENT  
6.2.8 Parking Brake Neutral Lockout Adjustment.  
a) Stop engine, wait for all moving parts to stop, and remove key.  
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b)  
c)  
Remove inlet screen and fan.  
Engage parking brake. Loosen the jam nuts securing the two 5/16 x 1-1/2”  
carriage bolts to the hydro control arm. Be sure the hydro control arm is in  
the neutral position as outlined in the previous adjustment (6.2.5) and the  
parking brake is adjusted as per previous adjustment (6.2.6).  
d)  
Adjust two 5/16 x 1-1/2” carriage bolts in the hydro control arm in or out until the  
head contacts the butterfly plate, and then tighten jam nuts (See Figure 11).  
NOTE: When the bolts are properly adjusted, there will be no rotational  
movement of the hydro control arm when brake is engaged.  
e)  
f)  
Restart engine and open to full throttle.  
Step down on the forward pedal, then the rear pedal of the motion control  
pedal. Listen for a "whine" from the hydro transaxle. If any "whine" is heard  
during any of the above conditions, repeat adjustment steps “c”, “d” and “e”.  
g)  
Replace fan and inlet screen.  
FIGURE 11  
PARKING BRAKE NEUTRAL LOCKOUT ADJUSTMENT  
6.2.9 Parking brake switch adjustment  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
Engage parking brake. Adjust the parking brake switch mounting bracket until  
jack-shaft engagement arm depresses brake safety switch by at least 1/4”.  
c)  
Check safety interlock system as outlined in 6.1.5.  
6.2.10 Motion Control Linkage Adjustment  
a)  
b)  
Step down on the forward pedal until it touches the footrest.  
Check the gap between the motion override tube and the spacer. This gap  
should measure 1/16” (See Figure 12).  
c)  
If adjustment is required, remove clevis pin at foot pedal end and turn yoke  
in or out as required to obtain the 1/16" gap.  
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FIGURE 12  
MOTION CONTROL LINKAGE ADJUSTMENT  
6.2.11 Seat Switch Adjustment  
a)  
b)  
Stop engine, wait for all moving parts to stop, and remove key.  
With operator out of seat, adjust the seat switch to provide a 1/16”  
clearance between the switch plunger and the seat frame (See Figure 13).  
c)  
To adjust, loosen the top nut securing the seat switch to the seat rail  
weldment. Adjust the bottom nut until the 1/16” between plunger and seat  
frame has been obtained. Tighten the top nut. Recheck the measurement  
and adjust again if necessary.  
d)  
Check safety interlock system as outlined in 6.1.5.  
FIGURE 13  
SEAT SWITCH ADJUSTMENT  
6.2.12 Electric Clutch Adjustment  
a)  
b)  
c)  
Stop engine, wait for all moving parts to stop, and remove key.  
Engage parking brake.  
Place .015-.021 inch feeler gauge through each of the three clutch gap  
holes. If gap exceeds this range, tighten the three adjusting nuts (c) until  
the proper gap is obtained (See Figure 14). The three clutch gap holes are  
located at the “nut side” of the adjusting bolts. The adjusting bolts can be  
identified by the springs surrounding each bolt.  
( c )  
FIGURE 14  
ELECTRIC CLUTCH ADJUSTMENT  
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6.2.13 Steering Chain Adjustment  
a) Stop engine, wait for all moving parts to stop, and remove key.  
b) Position the steering handle bar so that it points the unit straight forward (the  
rear steering wheel should be in line with the rider main frame channel).  
c) Check to see if the chains are loose.  
d) To take up slack in the chains, loosen the rear jam nuts connecting the  
eyebolts to cross link bars, then equally tighten each forward jam nut until  
slack is taken up. Retighten the forward jam nuts onto the links.  
e) If the unit tends to turn left when handle bar is positioned for straight forward  
travel, adjust by shortening the right hand link (threading jam nuts closer to  
“eye” end of the eyebolt) and lengthening the left hand link (threading jam  
nuts away from the “eye” end of the eyebolt) an equal amount. Re check  
chain tension.  
f) If the unit tends to turn right when handle bar is positioned for straight  
forward travel, reverse procedure as stated in paragraph “d” above.  
6.2.14 Throttle Control Adjustment  
a) Stop engine, wait for all moving parts to stop, and remove key.  
b) Loosen the cable clamp on the engine and position the throttle control at the  
control console within 1/4” (6mm) from the upper end of the slot. Pull on  
cable assembly at lower end, where it attached to the engine, until the  
throttle control arm contacts the stop screw. Secure cable with cable clamp.  
6.2.15 Throttle Cable Tension  
a) Stop engine, wait for all moving parts to stop, and remove key.  
b) Tension in throttle lever can be adjusted by adjusting the tightness of the  
lever pivot bolt, which is located under the console. See Figure 15.  
FIGURE 15  
THROTTLE TENSION  
6.2.16 Seat armrest adjustment.  
a) Lift armrest on seat. Locate square  
tab marked with the numbers 1  
through 4. Rotate square tab 1/4  
turn to raise or lower the armrest in  
approximately 1/4” increments. See  
Armrest Adjustment  
Tab Rotate ¼ Turn  
Figure 16.  
FIGURE 16  
ARMREST ADJUSTMENT  
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7. WASTE DISPOSAL  
7.1 MOTOR OIL DISPOSAL.  
Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil  
at a certified recycling center or according to your state and local regulations.  
7.2 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.  
¨
Do not swallow electrolyte.  
Federal law states that batteries should not be placed in the garbage. Management and  
disposal practices must be within relevant federal, state, or local laws.  
If a battery is being replaced or if the unit containing the battery is no longer operating  
and is being scrapped, take the battery to a local certified recycling center. If no local  
recycling is available return the battery to any certified battery reseller.  
8. TROUBLE SHOOTING  
8.1 MOWER CUTS UNEVENLY.  
a) Check air pressure in tires. See Section 2.8. A more uniform cutting height may be  
obtained with higher tire pressure on rough terrain. A lower tire pressure provides  
more flotation.  
b) Check deck support pins. Hairpin clips must be in the same hole on each support pin.  
c) Check blades tip to tip for straightness. Blades should be within 3/16” or one blade  
width from being in line.  
8.2 ENGINE WILL NOT START.  
a) Make sure battery has a full charge.  
b) Check that throttle control is midway between “slow” and “fast” positions, and choke  
is in “on” position for a cold engine or “off” position for a warm engine.  
c) Be sure there is fuel in the tank and that the fuel valve is open.  
d) Operator must be in the seat.  
e) Check that parking brake is set.  
f) Be sure that the PTO is disengaged.  
g) Check that the spark plug wires are properly connected.  
h) Look 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 thoroughly and reconnect.  
NOTE: When disconnecting electrical connectors, DO NOT pull on the wires to  
separate connectors.  
j) Check that the seat switch is properly adjusted. See Section 6.2.11.  
k) Check that the parking brake switch is properly adjusted. See Section 6.2.9.  
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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 conditions prior to the use of the mower.  
ENGINE TROUBLESHOOTING  
When a problem occurs, do not overlook the simple causes. For example, starting  
problems could be caused by an empty fuel tank.  
The following tables list some common causes of troubles. Do not attempt to service or  
replace major items or any items that call for special timing or adjustment procedures  
(governor, valves, etc.). Have this work done by your Engine Service Dealer.  
ENGINE TROUBLESHOOTING TABLE  
FAULTY  
SPARK  
PLUG  
BLOCKED INCORRECT  
DIRTY  
AIR  
SCREEN  
NO  
FUEL  
IMPROPER  
FUEL  
DIRT IN  
FUEL LINE  
DIRTY AIR  
FILTER  
ENGINE  
OVERLOADED  
FUEL  
OIL  
PROBLEM  
FILTER  
LEVEL  
Will not start  
Hard starting  
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
Stops suddenly  
Lacks power  
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Operates erratically  
Knocks or pings  
Skips or misfires  
Backfires  
X
X
X
X
X
X
X
X
X
X
X
X
Overheats  
X
High fuel consumption  
X
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9. WIRING DIAGRAMS  
Engine Deck Wiring Diagram  
Note: All connectors are viewed from the wire input side of the connector.  
N.O. = Normally Open  
Console Wiring Diagram  
Note: All connectors are viewed from the wire input side of the connector.  
N.O. = Normally Open  
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10.  
Limited Warranty  
Exmark Turf Equipment  
Exmark Customer Service Department  
Conditions and Products Covered  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
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.  
Owner’s Responsibilities  
This warranty applies to Exmark turf equipment 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.  
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.  
Products  
Warranty Period  
1 year  
· All Products (except as noted below)  
(90 days for rental use)  
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.  
· Peerless 5-speed transmission  
1 year  
(extended beyond manufacturer’s warranty of 90 days)  
· Frame, Hydrostatic Traction System,  
Electric Clutch and Exmark supplied Mufflers 2 years  
General Conditions  
· Blade Spindle Assy and Deck Jackshaft Assy  
3 years  
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.  
(1 year parts and labor, with additional 2 years parts only)  
· Belts and Tires  
· Battery  
90 days  
Refer to the battery manufacturer’s  
warranty in the literature packet  
· 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.  
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.  
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.  
·
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.  
All warranty work must be performed by an authorized Exmark  
Service Dealer using Exmark approved replacement parts.  
Instructions for Obtaining Warranty Service  
1. Contact any Exmark Service Dealer to arrange service at  
their dealership. To locate a dealer convenient to you,  
may also call 402-223-6375.  
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.  
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:  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
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SEE EXMARK’S COMPLETE  
LINE OF PRODUCTS FOR TURF CARE  
LAZER Z®  
LAZER Z® XP  
TURF RANGER®  
TURF TRACER®  
METRO®  
LAZER Z® HP  
LAZER Z® CT  
VIKING HYDRO  
TURF TRACER® HP  
METRO® HP  
ULTRA VAC™  
GRASS CATCHER  
ULTRA VACQDS  
SELF STEERING SULKY  
MICRO-MULCH ACCESSORY  
WARNING  
The engine exhaust from this product  
contains chemicals known to the State of  
California to cause cancer, birth defects, or  
other reproductive harm.  
©1997 – 2003  
PART NO. 103-4867  
(402) 223-6300  
FAX (402) 223-5489  
EXMARK MFG. CO. INC.  
INDUSTRIAL PARK BOX 808  
BEATRICE, NE 68310  
ALL RIGHTS RESERVED  
®
PRINTED IN U.S.A.  
MFG. CO. INC.  
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