Turf Tracer® X-Series

• Engine Specifications: See your Engine Owner’s Manual

• Engine Oil Type: Exmark 4–Cycle Premium Engine Oil

• RPM: Full Speed: 3600 (No Load)

  Idle: 1550 RPM

• Capacity: 5.0 gal. (18.9 L)

• Fuel Recommendations:

  • For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

  • Oxygenated fuel with up to 10% ethanol or 15% MTBE by volume is acceptable.

  • Do Not use ethanol blends of gasoline (such as E15 or E85) with more than 10% ethanol by volume. Performance problems and/or engine damage may result which may not be covered under warranty.

  • Do Not use gasoline containing methanol.

  • Do Not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.

  • Do Not add oil to gasoline.

• Fuel Filter: Replaceable In-line

• Fuel Shut-Off Valve: 1/4 turn

• Charging System: Flywheel Alternator

• Charging Capacity:

  • Kawasaki: 15 amps

  • Kohler EFI: 20 amps

• Battery Type: BCI Group U1 235 amps 0°F

• Battery Voltage: 12 Volt

• Polarity: Negative Ground

• Fuses:

  • Kawasaki: Two blade type, 20 amp to charging circuit; 20 amp to electric clutch-Quantity: 2

  • Kohler EFI: Two blade type, 20 amp to charging circuit; 20 amp to electric clutch-Quantity: 1

• Operator must have OPC (Operator Presence Control) levers held in contact with handle grips, speed control lever in neutral, and PTO disengaged to start engine. Release of OPC levers will cause the engine to stop if speed control lever is not in neutral and/or PTO is engaged.

• Park brake must be disengaged to move speed control out of neutral or engine will initiate shutdown.

Steering Control: Fingertip drive control levers provide independent speed control, braking and neutral to each drive wheel for moving forward or reverse, stopping, and power turning.

• Two Hydro Gear variable displacement piston pumps independently coupled to two high efficiency Parker wheel drive motors.

• Hydraulic Oil: Use Exmark Premium Hydro Oil.

• Hydraulic Oil Capacity: 2.4 qt. (2.2 L)

• Hydraulic Filter is replaceable cartridge type.

  P/N 109–4180: 25 microns, 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))

• Speeds:

  • 0-6.75 mph (10.9 km/hr) forward.

  • 0-2.25 mph (3.6 km/hr) reverse.

• Drive wheel release valves allow machine to be moved when engine is not running.

Drive wheels are direct coupled to Parker wheel drive motors with 1 inch (25.4 mm) tapered shaft.

All Models Except “N0”:

“N0” Models:

For operator’s over 250 lb (113 kg), it is recommended to use pneumatic tire assembly P/N 103-3798.

• Cutting Width:

  • 52 inch (132.1 cm)

  • 60 inch (152.4 cm)

• Discharge: Side

• Blade Size: (3 ea.)

  • 52 inch Deck: 18.00 inches (45.7 cm)

  • 60 inch Deck: 20.50 inches (52.1 cm)

• Blade Spindles: Solid steel spindles with 1 inch (25.4 mm) I.D. bearings.

• Deck Drive:

  • Electric clutch mounted on engine shaft.

  • Blades driven by two belts (w/self-tensioning idlers).

• Deck:

  Full floating deck is attached to out-front support frame, removable for service. Anti-scalp rollers provide maximum turf protection. Deck design allows for bagging, mulching or side discharge.

• Deck Depth:

  • 52 inch Deck: 5.5 inches (14.0 cm)

  • 60 inch Deck: 5.5 inches (14.0 cm)

• Cutting Height Adjustment:

  Adjusts from 1 1/2 inches (3.8 cm) to 4 1/2 inches (11.4 cm) in 1/2 inch (1.3 cm) increments.

• Mulching Kit: Optional

• Bagger: Optional

All Models:

All Models Except “N0”:

“N0” Models:

All Models:

All Models:

All Models:

All Models Except “N0”:

“N0” Models:

Located on the upper handle assembly directly above the handle grips.

When these levers are depressed, the OPC system senses that the operator is in the normal operator's position. When the levers are released, the OPC system senses that the operator has moved from the normal operating position and will shutdown the engine if either the speed control lever is not in the neutral position or the PTO is engaged (see Figure 4).

Figure 4

1. OPC Lever
2. Rotate neutral lock latch for neutral lock position
3. Neutral Lock Latch
4. Drive Lever in neutral position

Located on each side of the upper handle assembly ahead of and below the handle grips.

These levers individually control the speed and direction of each drive wheel. When the speed control lever is moved out of the neutral position and the neutral lock latches are moved into the drive position, as shown in Figure 4, and the drive levers are released, the drive wheels are engaged in the forward direction.

Squeezing the left hand and/or right hand lever causes the left hand and/or right hand drive wheel respectively to slow down, stop, or reverse, depending on how far each drive lever is “squeezed”. Squeezing the drive levers beyond the neutral position causes the drive wheels to engage in the reverse direction regardless of the position of the neutral lock latches and the speed control lever.

Located on the upper handle assembly on the ends of the handle grips.

These latches allow the operator to lock the drive levers in a “neutral” position where the drive wheels are not engaged in either a forward or reverse direction.

Located on the control console front right hand side.

Choke 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 choke in the “ON” position.

Located on the control console’s right side.

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

Located in middle of control console.

The speed control lever controls the maximum forward speed and is infinitely variable from neutral 0–6.75 mph (10.9 km/hr).

Park brake must be disengaged to move speed control out of neutral or engine will initiate shutdown.

Located on the left side of the unit.

The brake lever engages the park brake on the drive wheels.

Pull the lever up and rearward to engage the brake.

Push the lever forward and down to disengage the brake.

When parking on a steep slope, the wheels must be chocked or blocked in addition to the brake being engaged. The unit must be tied down and brake engaged when transporting.

The park brake must be disengaged to move speed control out of neutral or engine will initiate shutdown.

Located on the left side of the control console.

The ignition switch is used to start and stop the engine. The ignition switch has three positions, “Off”, “On” and “Start”. Insert 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). Operator must have speed control lever in neutral, OPC levers depressed and PTO disengaged to start engine. When engine starts, release key.

Located on the front left hand side of console just above the PTO switch.

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.

Located in the fuel line midway between the tank and 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 the job sites, and when the machine will not be used for a few days.

Rotate valve 1/4 turn clockwise to shut fuel off. Rotate valve 1/4 turn counterclockwise to turn fuel on.

Located on the left rear corner of the hydrostatic pumps.

Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be moved by hand without the engine running.

With a 5/8 wrench, turn both valves one turn counterclockwise to release the drive system.

Turn clockwise to reset the drive system. Do Not overtighten.

Located on the right-hand side of the rear of the fuel tank support.

The knob can be adjusted so that machine will “track” straight ahead with the drive levers released.

Switch is located on left 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 have operator presence control levers depressed when PTO is engaged or engine will stop.

Kohler EFI Units Only:

The electronic control unit (ECU) continuously monitors operation of the EFI system. If a problem or fault within the system is detected, the malfunction indicator light (MIL) is illuminated. The MIL is the light located in the right console panel to the right of the throttle control. Follow the troubleshooting steps outlined in the Kohler engine operator’s manual if the MIL is illuminated.

Fill fuel tank on level ground. See Fuel Recommendations in the Specifications section for additional gasoline information.

Do Not add oil to gasoline.

Do Not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system.

Make sure you understand the controls, their locations, their functions, and their safety requirements.

Refer to the Maintenance section and perform all the necessary inspection and maintenance steps.

Rotate the valve 1/4 turn counterclockwise to turn fuel on.

Note: It is helpful to have the left and right neutral lock latches locked in neutral when starting the engine. Refer to Neutral Lock Latches section in Controls.

Note: Operator must have PTO disengaged, speed control lever in neutral position, and OPC levers depressed when starting the engine.

1. On a cold engine, place the throttle midway between the “Slow” and “Fast” positions and place the choke in the “On” position (except on Kohler EFI units).

   On a warm engine, place the throttle lever midway between “Slow” and “Fast” positions and leave the choke in the “Off” position.

   Note: Kawasaki engines generally need to be “choked” even when warm.

2. Turn ignition switch to “Start” position. Release the switch as soon as the engine starts.

   Important: Do not crank the engine continuously for more than ten 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.

3. After engine warms up, gradually push in the choke control. Do Not run warm engine with the choke in the “ON” position.

The PTO switch engages the cutting blades. Be sure that all persons are clear of mower deck and discharge area before engaging the PTO.

1. Set throttle to “MIDWAY” position.

2. Pull the PTO switch outward to the “ROTATE” position to engage the blades.

3. Place the throttle in the “FAST” position to begin mowing.

1. Set the throttle to the “MIDWAY” position.

2. Push the PTO switch in to the “STOP” position to disengage the blades.

1. Disengage the PTO.

2. Bring the unit to a full stop.

3. Lock drive levers in neutral.

4. Move speed control lever to neutral.

5. Engage the parking brake.

6. Place the throttle midway between the “SLOW” and “FAST” positions.

7. Allow the engine to run for a minimum of 15 seconds, then turn the ignition switch to the “OFF” position to stop the engine.

8. Remove the key to prevent children or other unauthorized persons from starting engine.

9. Close the fuel shut-off valve when the machine will not be in use for a few days, when transporting, or when the unit is parked inside a building.

Drive Lever/Neutral Lock Latch Operation

To lock the drive levers in “neutral lock”, squeeze the drive levers to the “neutral” position (Do Not squeeze the drive levers all the way back as this will cause the drive wheels to go into full reverse direction). SeeFigure 5 position 1. Place thumbs on the inner lobe of the neutral lock latches and rotate them under the drive levers into the “neutral lock” position. SeeFigure 5 position 2. Release the drive levers.

To place the drive levers in the “forward” position, slightly squeeze the drive levers while placing thumbs on the outer thumb lobe of the neutral lock latches (or the index finger on the front lobe) and rotate them from under the drive levers. Slowly and carefully release the drive levers. See Figure 5 position 3.

To place the drive levers in the “reverse” position, squeeze the drive levers past the neutral position. See Figure 5 position 4.

Figure 5

Left Hand Control Shown

1. Drive Lever in neutral position
2. Drive Lever locked in neutral position
3. Drive Lever in forward position
4. Drive Lever in reverse position

Driving Forward

1. Release the parking brake.

2. With drive levers locked in “neutral”, shift speed control lever to desired forward speed.

3. Slowly squeeze and hold both drive levers in the neutral position and rotate both neutral lock latches from the neutral lock position to the forward position.

   Note: Do Not squeeze both drive levers all the way back. This will cause the drive wheels to engage in the reverse direction.

4. To move forward in a straight line, smoothly release both drive levers to engage drive wheels.

   To turn left or right, squeeze the right hand drive lever to turn right and the left hand drive lever to turn left.

   To make a “zero turn”, squeeze either the left hand or the right hand drive lever back into the reverse position while the opposite drive lever is in a forward position at an equal but opposite speed.

   Note: For smooth operation of this machine, avoid quick, jerky movements of the drive levers. Move the drive levers smoothly and deliberately.

   To stop, squeeze drive levers back to the “neutral” position. Move the neutral lock latches into the “neutral lock” position and release drive levers. Move the speed control lever to the neutral position.

Driving in Reverse

To move rearward in a straight line, squeeze drive levers into the reverse position.

To turn left or right, squeeze the right hand drive lever to turn left and the left hand drive lever to turn right.

To make a “zero turn”, squeeze either the left hand or the right hand drive lever back into the reverse position while the opposite drive lever is in a forward position at an equal but opposite speed.

Note: For smooth operation of this machine, avoid quick, jerky movements of the drive levers. Move the drive levers smoothly and deliberately.

To stop, squeeze drive levers back to the “neutral” position. Move the neutral lock latches into the “neutral lock” position and release drive levers. Move the speed control lever to the neutral position.

The cutting height of the mower deck is adjusted from 1 1/2 to 4 1/2 inches (3.81 cm to 11.4 cm) in 1/2 inch increments.

1. Disengage the PTO.

2. Bring the unit to a full stop.

3. Lock drive levers in neutral.

4. Move speed control lever to neutral.

5. Engage the parking brake.

6. Stop the engine, remove the key and wait for all moving parts to stop.

7. Lift the cutting deck using the handle as shown in Figure 6 (handle position varies with deck size) to the highest position possible. Engage deck height change assist lever by shifting forward until contact with the deck support rod is felt (see Figure 7). While the lever is manually engaged, lower the deck to rest on the lever.

   

   Figure 6

   1. Deck height change assist lever
   2. Deck handle
   

   Figure 7

   1. Deck height change assist lever-engaged
   2. Deck raised

8. On lifted deck side, install hairpin clips in the holes for the desired cutting height (see Figure 8).

   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 8.

      

      Figure 8

      1. Deck support pin
      2. Cutting Height

   2. The tire pressures are set as directed in Check Tire Pressures in the Maintenance section.

   3. The length of the rear deck support link assemblies average 6.89 inches (approximately 6 7/8 inches) (175.01 mm) from the center of the balljoint to the center of the farthest hole. See Figure 9.

      Note: All four 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 inches (approximately 6 7/8 inches) (175.01 mm), than the opposite side must be shorter by the same amount.

      

      Figure 9

      Left Hand Side Shown

9. Repeat steps 7 and 8 for opposite side.

10. Lift deck to de-latch.

    Note: Deck height change assist levers are not intended to be used during transport or as cut height positions. During operation, vibration and jerky movements will lift the cutting deck enough to allow spring return disengagment of levers. This will result in sudden drop of the cutting deck, causing possible damage. Levers are also not intended to be used as tiedown locations during transport.

It is recommended to change the anti-scalp roller position when the height of cut has changed.

1. Disengage the PTO.

2. Bring the unit to a full stop.

3. Lock drive levers in neutral.

4. Move speed control lever to neutral.

5. Engage the parking brake.

6. Stop the engine, remove the key and wait for all moving parts to stop.

7. After adjusting the height of cut, adjust the anti-scalp rollers by removing the nyloc nut, spring disc washer, and bolt.

8. Adjust anti-scalp rollers for Normal Operating Conditions. Place rollers in one of the positions shown in Figure 10. Rollers will maintain 3/4 inches (19 mm) clearance to the ground to minimize gouging and roller wear or damage.

   Note: For Maximum Deck Flotation, place rollers one hole position lower. Rollers should maintain 1/4 inch (6.35 mm) clearance to ground. Do Not adjust rollers to support the deck.

   

   Figure 10

   For cutting heights above 3.5 inches (38 mm) use the bottom hole. The rollers will still be effective against scalping.

   1. Anti-scalp roller mounting bracket
   2. Cutting height

9. Be sure roller bolts are installed with the spring disc washer between head of the bolt and mounting bracket.

10. Torque the 3/8-16 nyloc nut to 50–55 ft-lb (68-75 N-m) (Figure 11).

    

    Figure 11

    1. 3/8-16 x 3 3/4 Grade 8 bolt
    2. Spring disc washer (cone towards bolt )
    3. Front right anti-scalp bracket shown
    4. 3/8 nyloc-torque to 50–55 ft-lb (68-75 N-m)

1. Stop engine and wait for all moving parts to stop. Make sure unit is on a level surface.

2. Check with engine cold.

3. Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick according to the engine manufacturer's recommendations. Remove the dipstick and read the oil level.

4. If the oil level is low, wipe off the area around the oil fill cap, remove cap and fill to the “FULL” mark on the dipstick. Exmark 4-Cycle Premium Engine Oil is recommended; refer to the Engine Owner's manual for an appropriate API rating and viscosity. 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.

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.

Charge batteries in an open well ventilated area, away from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

Check the voltage of the battery with a digital voltmeter or with the message display. If the ignition key is turned to the “on” position for a few seconds, the battery voltage will be displayed in the area where the hours are normally displayed. Locate the voltage reading of the battery in the table 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 cable is disconnected and the battery charger used for charging the battery should have an output of 16 volts and 7 amps or less to avoid damaging the battery (see chart for recommended charger settings). This is especially important on Kohler EFI (Electronic Fuel Injection) units. Failure to do so may damage the ECU (Electronic Control Unit).

Important: For Kohler EFI units: Unplug the harness from the ECU before performing any welding on the equipment.

1. Check the weak battery for terminal corrosion (white, green, or blue “snow”), it must be cleaned off prior to jump starting. Clean and tighten connections as necessary.

   Caution

   Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure.

   Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine or EFI may occur.

   Danger

   Jump starting a weak battery that is cracked, frozen, has low electrolyte level, or an open/shorted battery cell, can cause an explosion resulting in serious personal injury.

   Do Not jump start a weak battery if these conditions exist.

2. Make sure the booster is a good and fully charged lead acid battery at 12.6 volts or greater. Use properly sized jumper cables (4 to 6 AWG) with short lengths to reduce voltage drop between systems. Make sure the cables are color coded or labeled for the correct polarity.

   Caution

   Connecting the jumper cables incorrectly (wrong polarity) can immediately damage the electrical and/or EFI system.

   Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries.

   Note: The following instructions are adapted from the SAE J1494 Rev. Dec. 2001 – Battery Booster Cables – Surface Vehicle Recommended Practice (SAE – Society of Automotive Engineers).

   Warning

   Batteries contain acid and produce explosive gases.

   • Shield the eyes and face from the batteries at all times.

   • Do Not lean over the batteries.

   Note: Be sure the vent caps are tight and level. Place a damp cloth, if available, over any vent caps on both batteries. Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only.

3. Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 12.

   

   Figure 12

   1. Positive (+) cable on discharged battery
   2. Positive (+) cable on booster battery
   3. Negative (–) cable on the booster battery
   4. Negative (–) cable on the engine block
   5. Booster battery
   6. Discharged battery
   7. Ground stud

4. Connect the other end of the positive cable to the positive terminal of the booster battery.

5. Connect the black negative (–) cable to the other terminal (negative) of the booster battery.

6. MAKE THE FINAL CONNECTION ON THE GROUND STUD, LOCATED ON THE RIGHT SIDE REAR BRACKET OF THE ENGINE DECK, OF THE STALLED VEHICLE (NOT TO THE NEGATIVE POST) AWAY FROM THE BATTERY. STAND BACK (see Figure 13).

   

   Figure 13

7. Start the vehicle and remove the cables in the reverse order of connection (the engine block (black) connection is the first to disconnect).

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lift deck and secure in raised position as stated in the Clean Grass Build-Up Under Deck procedure in the deck Operator’s manual.

3. Inspect blades and sharpen or replace as required.

4. Reinstall blades (if they were removed) in the following order:

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

      

      Figure 14

      1. Install bushing in blade prior to installing bushing in spindle.

   2. Install bushing/blade combo into spindle.

      

      Figure 15

      1. Use wrench here for blade installation. This nut has been torqued to 90–110 ft-lb (122–149 N-m)
      2. Torque to 55-60 ft-lb (75-81 N-m) Apply lubricant to threads as needed to prevent seizing. Copper-based anti-seize preferable. Grease acceptable substitute.

   3. Apply lubricant to threads of blade bolt as needed to prevent seizing. Copper-based anti-seize preferable. Grease acceptable substitute. Install blade bolt finger tight. Place wrench on the top spindle nut then torque the blade bolts to 55-60 ft-lb (75-81 N-m).

   Warning

   Incorrect installation of the blade or components used to retain the blade can be dangerous. 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.

   Always install the original Exmark blades, blade bushings, and blade bolts as shown.

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

Note: If machine does not pass any of these tests, Do Not operate. Contact an Authorized Service Dealer.

Check the Normal Engine Starting Chart

		System
		PTO	OPC Levers	Speed Control Levers	Outcome
	State of System	Disengaged (Blades)	Both levers depressed (engaged)	In Neutral	Starter should crank

Check Engine Starting Circuit Chart

Note: In the Check Engine Starting Circuit Chart, the state of system item that is bold is being checked in each scenario.

		System
		PTO	OPC Levers	Speed Control Levers	Outcome
	State of System	Disengaged (Blades)	Both levers depressed (engaged)	Any speed except neutral	Starter must not crank
		Engaged (Blades)	Both levers depressed (engaged)	In Neutral	Starter must not crank

Check Shutdown Circuit Chart

		System
		Engine	Parking Brake	PTO	OPC Levers	Speed Control Levers	Outcome
	State of System	Running idle (1/3 throttle)	Engaged	Disengaged (Blades)	Both levers depressed (engaged)	Any speed except neutral	Engine must begin shutdown within 1 second

		System
		Engine	PTO	OPC Levers	Speed Control Levers	Outcome
	State of System	Running idle (1/3 throttle)	Disengaged (Blades)	Both levers depressed (engaged) or released (disengaged)	Any speed except neutral	Engine must begin shutdown within 1 second
		Running idle (1/3 throttle)	Engaged (Blades)	Both levers released (disengaged)	In Neutral	Engine must begin shutdown within 1 second
		Running idle (1/3 throttle)	Engaged (Blades)	Both levers released (disengaged)	Any speed except neutral	PTO must begin shutdown within 1 second; engine stays running.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Visually inspect machine for any loose hardware or any other possible problem. Tighten hardware or correct the problem before operating.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. See the Engine Owner's Manual for maintenance instructions.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Drain oil while engine is warm from operation.

3. The oil drain hose is located on right hand side of engine for Kohler or left hand side for Kawasaki. Place pan under machine to catch oil. Remove plug from end of drain hose. Allow oil to drain and replace oil drain plug. Torque plug to 20-24 ft-lb.

4. Replace the oil filter every other oil change. Clean around oil filter and unscrew filter to remove. Before reinstalling new filter, apply a thin coating of Exmark 4–Cycle Premium Engine Oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1/2 to 3/4 turn.

5. Clean around oil fill cap and remove cap. Fill to specified capacity and replace cap.

6. Use oil recommended in the Check Engine Oil Level section. Do Not overfill. Start the engine and check for leaks. Stop engine and recheck oil level.

1. Stop engine and wait for all moving parts to stop, and remove key. Engage parking brake.

2. Clean area around hydraulic reservoir cap and remove cap. Oil level should be to the top of the baffle inside the tank. If not, add oil. Use Exmark Premium Hydro Oil. Replace hydraulic reservoir cap and tighten until snug. Do Not overtighten.

   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 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 the 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.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Check tire pressure in drive tires.

3. Inflate drive tires to 12–14 psi (83–97 kPa).

4. Inflate tires to pressures stated above. Measure the circumference of each drive tire. Adjust tire pressures within the above range to try to make tire circumferences match as closely as possible.

   Semi-pneumatic caster tires do not need to be inflated.

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.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Remove the three mower deck belt shields to check mower primary and secondary belt condition.

3. Look under engine deck to check the pump drive belt condition.

4. Check all idler arms to be sure they pivot freely.

Note: See chart for service intervals.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lubricate fittings with one to two pumps of NLGI grade #2 multi-purpose gun grease.

   Refer to the following chart for fitting locations and lubrication schedule.

   Lubrication Chart
   Fitting Locations	Initial Pumps	Number of Places	Service Interval
   1. Front Caster Wheel Hubs	*0	2	*Yearly
   2. Front Caster Pivots	*0	2	*Yearly
   3. Idler Pivots (Mower Deck)	1	1	Yearly
   4. Hydro Control Arm Support Bushings	2	2	40 Hours

   * See step 3 for special lubrication instructions on the front caster pivots and the Lubricate Caster Wheel Hubs section for special lubrication instructions on the front casters wheel hubs.

3. 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.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

   

   Figure 16

   1. Seal guard
   2. Spacer nut with wrench flats

2. Remove caster wheel from caster forks.

3. Remove seal guards from the wheel hub.

4. 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.

5. Pry out seals, and inspect bearings for wear or damage and replace if necessary.

6. Pack the bearings with a NLGI grade #1 multi-purpose grease.

7. Insert one bearing, one new seal into the wheel.

   Note: Seals (Exmark P/N 103-0063) must be replaced.

8. If the axle assembly has had both spacer nuts removed (or broken loose), apply a thread locking adhesive to one 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 inch (3 mm) from the outer surface of the spacer nut to the end of the axle inside the nut.

9. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.

10. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of NLGI grade #1 multi-purpose grease.

11. Insert the second bearing and new seal into the wheel.

12. Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward.

13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen, then re-torque to 20-25 in-lb (2-3 N-m). Make sure axle does not extend beyond either nut.

14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall 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. Reapply thread locking adhesive.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Remove cooling shrouds from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine which can cause improper cooling.

3. Make sure cooling shrouds are properly reinstalled. Operating the engine without cooling shrouds will cause engine damage due to overheating.

Remove spark plugs, check condition and reset gaps, or replace with new plugs. See Engine Owner's Manual.

A fuel filter is installed between the fuel tank and the engine. Replace when necessary.

Note: It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage.

Note: Use only Exmark Part No. 109-4180 for Summer use above 32°F (0°C) or P/N 1-523541 for Winter use below 32°F (0°C) (Refer to Transmission section in Specifications for filter specifications).

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Carefully clean area around filter. It is important that no dirt or contamination enter hydraulic system.

3. Place a catch pan under the hydro.

4. Unscrew filter to remove and allow oil to drain from reservoir.

   Important: Before reinstalling new filter, fill it with Exmark Premium Hydro oil and apply a thin coat of oil on the surface of the rubber seal.

   Turn filter clockwise until rubber seal contacts the filter adapter, then tighten the filter an additional 2/3 to 3/4 turn.

5. Fill reservoir as stated in Check Hydraulic Oil Level.

   Exmark Premium Hydro Oil is recommended. Refer to the chart for an acceptable alternative:

   Hydro Oil	Service Interval
   Exmark Premium Hydro Oil (Preferred)	After first 250 hours*Every 500 hours/Yearly thereafter
   Mobil 1 15W50	After first 250 hours *Every 250 hours/Yearly thereafter

   *May need more often under sever conditions.

6. Loosen filter 1/2 turn and allow a small amount of oil to leak from the oil filter (this allows air to be purged from the oil filter and supply hose from the hydraulic reservoir). Turn filter clockwise until rubber seal contacts the filter adapter. Then tighten the filter an additional 2/3 to 3/4 turn.

7. Remove the catch pan and properly dispose of hydro oil and filter according to local codes.

8. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely.

9. Start engine and move throttle control ahead to full throttle position. Move the speed control levers to the full speed and run for one minute. Shut down the machine, allow the hydros to cool and recheck oil level.

   If either drive wheel does not rotate, one or both of the charge pumps (located on the top of the main pump as shown in Figure 17) may have lost their “prime”. Refer to Hydraulic System Air Purge section.

10. Remove the jack stands.

Note: Do Not change hydraulic system oil (except for what can be drained when changing filter), unless it is felt the oil has been contaminated or been extremely hot.Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system.

Air must be purged from the hydraulic system when any hydraulic components, including oil filter, are removed or any of the hydraulic lines are disconnected.

The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump (Figure 17). Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is “primed”.

Figure 17

1. Charge pump cap
2. Loosen 1 1/2 turns only

1. Stop engine and wait for all moving parts to stop. Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off the ground.

2. Check oil level as stated in Check Hydraulic Oil Level section.

3. Start engine and move throttle control ahead to full throttle position. Move the speed control lever to the middle speed position and place the drive levers in the “drive” position.

   If either drive wheel does not rotate, it is possible to assist the purging of the charge pump by carefully rotating the tire in the forward position.

   Note: It is necessary to lightly touch the charge pump cap with your hand to check the pump temperature. If the cap is too hot to touch, turn off engine. The pumps may be damaged if the pump becomes too hot.

   If either drive wheel still does not rotate continue with step 4.

4. Thoroughly clean the area around each of the charge pump housings.

5. Make sure engine is not running. To “prime” charge pump, loosen two hex socket head capscrews (shown in Figure 17) 1 1/2 turns only. Lift the charge pump housing upward and wait for a steady flow of oil to flow out from under the housing. Retighten the capscrews. Do this for both pumps.

   Note: Hydraulic reservoir can be pressurized up to 5 psi to speed this process.

6. If either drive wheel still does not rotate, stop and repeat steps 4 and 5 above for the respective pump. If wheels rotate slowly, the system may prime after additional running. Check oil level as stated in Check the Hydraulic Oil Level section.

7. Allow unit to run several minutes after the charge pumps are “primed” with drive system in the full speed position. Check oil level as stated in Check the Hydraulic Oil Level section.

8. Check hydro drive linkage adjustment as stated in Hydro Drive Linkage Adjustment section in Adjustments.

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

• Pump drive sheave set screws.

• Square head setscrews on Hydro pump control arms.

• Shoulder bolts in ends of speed control crank.

• OPC lever setscrews.

• Electric clutch retaining bolt.

• Pump drive idler pivot bolt.

• Thumb latch screw threads on handles.

• Caster wheel spacer nuts.

• Fuel tank bulkhead fitting nuts.

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

• OPC lever hubs and cross-shaft

  Note: Care must be used not to bond the bearing, next to each OPC hub, to the cross-shaft which could cause binding of the OPC levers and erratic operation.

• Fuel tank studs, where studs are inserted into tank.

Mobil HTS grease (or food-grade anti-seize) is used in the following locations:

• Between the cutter housing spindle and bearings.

• Between the cutter housing spindle and sheave.

• Under top cutter housing bearing guard.

Copper-based anti-seize is used in the following locations:

On threads of Blade Bolts Serial Nos. 540,000 and Higher. See Check Mower Blades section for instructions.

Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact. Dielectric grease should not be applied to sealed connectors.

See Adjusting the Cutting Height section in Operation.

Self-tensioning - No adjustment necessary.

Self-tensioning - No adjustment necessary.

1. Shut off engine and wait for all moving parts to stop.

2. Disengage the park brake.

3. Remove the clevis pin from the park brake yoke. Turn the yoke on the linkage until there is 3/16 inch (4.8 mm) to 1/4 inch (6.4 mm) clearance between the park brake tire bars and the tires with the park brake disengaged. Re-install the clevis pin.

• Adjust Speed Control Linkage and Neutral Safety Switch:

  1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s).

  2. Pull the speed control lever back to neutral. Check that the neutral safety switch actuating tab has depressed the plunger of the switch so that there is no more than 3/16–1/4 inch (4.8–6.4 mm) between the tab and the switch (see Figure 18).

     

     Figure 18

     1. Actuating Tab
     2. Neutral Safety Switch
     3. 3/16–1/4 inch (4.8–6.4 mm)

• Adjust Neutral Control Linkages:

  1. Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground.

  2. Start the engine and move the throttle ahead to the full throttle position. Place the neutral lock latches in the “forward” position as shown in Figure 5. Release the park brake and move the speed control lever to the “mid-speed” position.

     Note: The OPC levers must be held down and the park brake must be disengaged whenever the speed control lever is moved out of neutral or the engine will initiate shutdown.

  3. Squeeze the respective drive lever until an increased resistance is felt (pin is at the end of the slot), this is where neutral should be.

  4. Pull the drive lever(s) into reverse. Release the drive lever(s) until extra reverse spring resistance is gone (pin still at end of slot). If the wheel stops, then go to step 8. If the wheel turns while holding the drive lever in neutral, then neutral control linkages need to be adjusted; proceed with step 5.

  5. Loosen the nut against the neutral control linkage yoke as shown in Figure 19.

     

     Figure 19

     Viewed from Left Side of Unit

     1. Neutral Control Linkage
     2. Hydro Control Linkage
     3. Drive Lever Linkage
     4. Speed Control Crank
     5. Speed Control Linkage
     6. Adjust here-rotate at approximately 1/4 turn increments and re-check.
     7. Loosen nut
     8. Yoke
     9. Pin is at the end of slot

  6. Adjust the neutral control linkage until the respective drive wheel stops when the lever is pulled against the neutral spring (neutral position). Turn the adjusting bolt approximately 1/4 turn clockwise if the wheel is turning in reverse or turn the bolt approximately 1/4 turn counterclockwise if the wheel is turning forward. Release the drive lever to the forward drive position and squeeze back into the neutral position. Check to see if the wheel stops. If not, repeat the above adjustment procedure.

  7. Make this adjustment on both sides.

  8. After adjustments are made and the wheels stop when the drive levers are moved to the neutral position from both the forward and reverse positions, tighten the nuts against the yokes.

• Adjust Hydro Control Linkages:

  1. Place the speed control lever in the “neutral” position. This adjustment is again made with rear of machine on jack stands and engine running at full throttle. OPC levers will have to be held down and the park brake must be disengaged whenever speed control levers are moved out of the neutral position.

     Note: The neutral lock latches should be “unlocked” and in the forward position.

  2. Loosen the front nut on left hydro control linkage as shown in Figure 20. Turn the rear control linkage adjusting nut counterclockwise until wheel rotates forward. Turn the rear nut of left control linkage clockwise 1/4 of a turn at a time, stopping to move the speed control forward and back to neutral, until left wheel stops rotating forward.

     Turn the rear nut an additional 1/2 turn and tighten the front nut making sure not to put a bind on the linkage. Make sure flat part of linkage is perpendicular to pin part of swivel (see Figure 20).

     

     Figure 20

     1. Left Hydro Control Link (left side shown)
     2. Front nut
     3. Rear nut
     4. Linkage is perpendicular to pin (correct position)
     5. Linkage in incorrect position
     6. Swivel

     After adjusting the left hydro control linkage, move the speed control lever to the mid-speed position and then back to the neutral position. Recheck the left drive wheel rotation to see if further adjustment is necessary–be sure the speed control lever is in the neutral position.

     Important: If inconsistent neutral occurs, check to be sure both springs are properly tightened on the speed control lever under the console–especially the rear pivot spring. The gap between spring coils to be minimum 1/32 inch (.8 mm).

     Repeat above adjustments if necessary.

  3. Place the speed control lever in neutral. Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward. Begin to retighten the knob clockwise about 1/4 turn at a time, stopping to move the speed control forward and back to neutral. Recheck the drive wheel rotation to see if further adjustment is necessary.

  4. The spring that keeps tension on the knob should normally not need adjustment. However, if adjustment is needed, adjust to where length of spring is about 1 inch (2.5 cm) between the washers. Adjust spring length by turning nut at front of spring.

• Drive Lever Linkage Adjustment:

  1. With rear of machine still on jack stands and engine running at full throttle, disengage the park brake and move the speed control lever to the midway position. Move the respective drive lever upward/rearward until it reaches the neutral position and engage neutral lock latches (Figure 21). If the tire rotates in either direction, the length of the drive lever link will need to be adjusted.

     

     Figure 21

     1. OPC Lever
     2. Drive lever in neutral lock position
     3. Neutral lock latches

  2. Adjust the linkage length by loosening the jam nuts at the top end of the linkage and rotating the linkage in the ball joints. Lengthen the linkage if the tire is turning in reverse and shorten the linkage if the tire is creeping forward. Tighten the jam nuts. Release and re-engage the neutral lock latch checking that the tire stops. Continue this process until the tire is at a complete stop.

  3. Pull the drive lever(s) into reverse. Release the drive lever(s) until extra reverse spring resistance is gone (pin still at end of slot). If the wheel stops, then go to step 8 of Adjust Neutral Control Linkages procedure. If the wheel turns while holding the drive lever in neutral, then neutral control linkages need to be adjusted (see step 5 in Adjust Neutral Control Linkages procedure).

  4. Make this adjustment for both sides.

  5. Stop engine and wait for all moving parts to stop. Raise rear of machine, remove jack stands, and carefully lower machine to the ground.

1. Stop engine and wait for all moving parts to stop.

2. Check the drive tire pressures and tire circumferences as stated in Check the Tire Pressures section in Maintenance.

3. Run the unit and observe the tracking on a level, smooth, hard surface such as concrete or asphalt.

4. If the unit tracks to one side or the other, turn the quick track knob. Turn the knob right to “steer” right, turn the knob left to “steer” left.

1. For medium or heavy duty drive conditions such as operation with a sulky on steep slopes, a higher spring force may be required on the hydro pump control arms to prevent the drive system from stalling.

2. For a heavier drive setting, relocate the spring anchor link as shown in Figure 22. The spring anchor links are located under the engine deck on the left and right hand sides.

   Note: In “medium” or “heavy duty” positions, the drive lever forces at the upper handle will also be increased.

   

   Figure 22

   1. Heavy duty
   2. Medium duty
   3. Standard
   4. Retaining bolt

No adjustment necessary.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Clean off any oil, debris, or grass build-up on the machine and cutting deck, especially under deck belt shields, around the fuel tank, around engine and exhaust area.

   Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, around the engine, hydraulic pumps, and motors.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Clean all debris from rotating engine air intake screen, around engine shrouding, and exhaust system area.

3. Wipe up any excessive grease or oil around the engine and exhaust system area

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Remove cooling shrouds from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine which can cause improper cooling.

3. Make sure cooling shrouds are properly reinstalled. Operating the engine without cooling shrouds will cause engine damage due to overheating.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Raise deck to the transport (maximum cutting height) position. Lift the front of unit and support the machine using jack stands or equivalent support.

3. Clean out any grass build-up from underside of deck and in discharge deflector.