Radius®

• Engine Specifications: See your Engine Owner’s Manual

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

• RPM:

  • X-Series: Full Speed: 3820 ±100 RPM (PTO not engaged) Idle: 1550 ±100 RPM

  • S-Series: Full Speed: 3800 ±100 RPM (PTO not engaged) Idle: 1550 ±150 RPM

  • E-Series with Exmark Engines: Full Speed: 3600 ±100 RPM (PTO not engaged) Idle: 1800 ±150 RPM

  • E-Series with Kohler Engines: Full Speed: 3600 ±75 RPM (PTO not engaged) Idle: 1750 ±100 RPM

• Capacity: 7.0 gal. (26.5 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:

  All Units: 1/4 turn (“ON”, “OFF”).

• Charging System: Flywheel Alternator

• Charging Capacity: 15 amps

• Battery Type: BCI Group U1

• Recommended Minimum Battery CCA: 260 CCA

• Battery Voltage: 12 Volt

• Polarity: Negative Ground

• Fuses:

  All units:

  • 20 amp charging system fuse

  • 15 amp main fuse

• LCD indicators appear for the PTO, park brake, drive levers, and operator presence in the message display on the RH control panel.

• PTO must be disengaged, brake engaged, and motion control levers out (neutral lock) to start engine. (It is not necessary for the operator to be in the seat to start the engine.)

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

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

• Steering and Motion Control:

  Note: Motion control levers are adjustable to three heights.

  • Separate levers, on each side of the console, control speed and direction of travel of the respective drive wheels.

  • Steering is controlled by varying the position of the levers relative to each other.

  • Moving motion control levers outward (in slots) locks the drive system in neutral.

• PTO Engagement Switch: Engages electric clutch (to drive belt) which engages mower blades.

• Parking Brake Lever: Engages parking brake.

• Deck Height Adjustment Lever: Sets cutting height to desired position.

• Deck Lift Pedal: Foot pedal that lifts deck.

• Transport Lock:

  • Latching position: Automatically latches at the transport position.

  • Unlatching position: Deck does not latch at the transport position.

• Seat Type:

  • X-Series:

    Deluxe suspension (adjustable spring suspension) seat with high back, molded foam flip-up armrests, and integral safety switch.

  • S-Series:

    Deluxe suspension (adjustable spring suspension) seat with high back, molded foam flip-up armrests, and integral safety switch.

  • E-Series:

    Standard seat with foam padded seat cushion with armrests and integral safety switch.

• Mounting:

  • X-Series: Hinged seat frame to tilt up seat. Adjustable fore and aft on seat tracks.

  • S- and E-Series: Adjustable fore and aft on seat tracks.

• Armrests: Molded flip-up armrests.

• Seat Safety Switch: Integrated seat switch. Time delay seat switch eliminates rough ground cut-outs.

• Two unitized hydrostatic transmissions:

  • X-Series:

    Hydro Gear ZT3400

  • S-Series:

    Hydro Gear ZT3100

  • E-Series:

    • Models with 48 or 52 inch decks:

      Hydro Gear ZT2800

    • Models with 60 inch deck:

      Hydro Gear ZT3100

• Hydraulic Oil Type: Exmark Premium Hydro Oil.

• Hydraulic Oil Capacity: 77 oz (2.3 L) per side

• Hydraulic Filter: P/N 109-3321

• Speeds:

  • X-Series:

    • Forward: 0-10 mph (16.1 km/hr) forward.

    • Reverse: 0-7 mph (11.3 km/hr) reverse.

  • S-Series:

    • Forward: 0-9 mph (14.5 km/hr) forward.

    • Reverse: 0-6 mph (9.7 km/hr) reverse.

  • E-Series:

    • Forward: 0-8 mph (12.9 km/hr) forward.

    • Reverse: 0-5 mph (8.0 km/hr) reverse.

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

X-Series:

S-Series:

E-Series:

E and S-Series

X-Series

• Cutting Width:

  • 48 inch Deck: (121.9 cm)

  • 52 inch Deck: (132.1 cm)

  • 60 inch Deck: (152.4 cm)

• Discharge: Side

• Blade Size:

  • 48 inch Deck: 24.50 inches (62.2 cm) – (2 ea.)

  • 52 inch Deck: 18.00 inches (45.7 cm) – (3 ea.)

  • 60 inch Deck: 20.50 inches (52.1 cm) – (3 ea.)

• Blade Spindles:

  • X-Series: Solid steel spindles with .98 inch (25 mm) I.D. bearings.

  • S- and E-Series: Solid steel spindles with .67 inch (17 mm) I.D. bearings.

• Deck Drive: “B” Section belt with self-tensioning idler.

• Electric clutch:

  • 48 Inch Deck: 125 ft-lb Neo Mag Stop

  • 52 Inch E- and S-Series Deck: 125 ft-lb Mag Stop

  • 52 Inch X-Series Deck: 200 ft-lb Neo-Mag Stop

  • 60 Inch E- and S-Series Decks: 125 ft-lb Neo-Mag Stop

  • 60 Inch X-Series Deck: 225 ft-lb Neo-Mag Stop

• Deck:

  • 48 inch Deck: 3 anti-scalp rollers

  • 52 inch Deck: 5 anti-scalp rollers

  • 60 inch Deck: 5 anti-scalp rollers

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

• Deck Depth:

  • S- and E-Series: 5.0 inches (12.7 cm)

  • X-Series: 5.5 inches (14.0 cm)

• Cutting Height Adjustment:

  Foot activated lever is used to adjust the cutting height from 1 1/2 inch (3.8 cm) to 5 inches (12.7 cm) in 1/4 inch (6.4 mm) increments.

• Mulching Kit: Optional.

X-Series:

S-Series:

E-Series:

X-Series

S-Series

E-Series

X-Series

S-Series

E-Series

Side Discharge Units:

The motion control levers are located on each side of the console and control the forward and reverse motion of the machine.

Moving the levers forward or backward turns the wheel on the same side forward or reverse respectively. Wheel speed is proportional to the amount the lever is moved.

Moving the levers outward from the center position into the T-slot locks them in the neutral position (Figure 4).

Figure 4

1. Neutral lock position (handles out)
2. Neutral operate position (handles in)
3. Front of unit
4. Forward
5. Neutral (operate)
6. Reverse

Located on right console (black lever) (see Figure 5).

The choke is used to aid in starting a cold engine. Moving the choke lever forward will put the choke in the “ON” position and moving the choke lever to the rear, to the detent, will put the choke in the “OFF” position. Do Not run a warm engine with choke in the “ON” position.

Figure 5

1. Throttle lever
2. Choke lever
3. Blade control switch (power take-off)
4. Ignition switch
5. Hour meter

Located on right console (red lever) (see Figure 5).

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

Located on left side of unit, just to the front of the LH motion control lever.

The brake lever engages a parking brake on the drive wheels.

Pull the lever up and rearward to engage the brake.

Push the lever forward and down to disengage the brake.

The unit must be tied down and brake engaged when transporting.

Located on right console (see Figure 5).

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 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). Allow the key to return to the “ON” position immediately after the engine starts.

Figure 6

1. Off
2. On
3. Start

Note: Brake must be engaged, motion control levers out (neutral lock position) and PTO switch disengaged to start engine. (It is not necessary for the operator to be in the seat to start the engine.)

Located on the control panel (see Figure 5 and Figure 7).

The hour meter records the number of hours that the engine has run.

Figure 7

1. LCD indicators
2. Low voltage indicator light
3. Hour/Voltage display

Located by the lower LH ROPS tube mounting.

The fuel shut-off valve is used to shut off the fuel when the machine will not be used for a few days, during transport to and from the jobsite, and when parked inside a building.

Align valve handle with the fuel line to open. Rotate 90° to close.

Located on the left and right sides underneath the engine deck.

During normal operating conditions, the drive wheel release valves are positioned in front of the slots. If the machine has to be pushed by hand, the valves must be in the “released” position (see Figure 8).

Figure 8

1. Front of the machine
2. Rotate bypass release knob counterclockwise to loosen
3. Lever position for operating the machine
4. Pull lever in this direction to push the machine
5. Lever position for pushing the machine
6. Rotate bypass release knob clockwise to tighten
7. Engine
8. Release lever

To release the drive system (see item 5 in Figure 8), loosen the knob by turning counterclockwise. Then pull the release lever on the underside of machine towards the back of the machine and retighten the knob to hold the release lever back in the released state. Repeat this on each side of the machine.

Release the parking brake. The machine is now able to be pushed by hand.

To reset the drive system (see item 3 in Figure 8), loosen the knob by turning counterclockwise. Then push the release lever on the underside of machine towards the front of the machine and retighten the knob to hold the release lever in the operating state. Repeat this on each side of the machine.

Do Not tow machine.

Located on right console (see Figure 5).

Pushing down on the front of the switch will put the PTO in the “ON” (engage) position. Pushing down on the back of the switch will put the PTO in the “OFF” (disengage) position.

Figure 9

1. “ON” (engage)
2. “OFF” (disengage)

Located on right console.

Switch must be pulled out (up) to engage the blades. Switch is pushed in to disengage the blades.

Located at the right front corner of the floor pan.

Push the pedal forward with your foot to raise the cutting deck. Allow the pedal to move rearward to lower the cutting deck to the cut height that has been set.

Figure 10

1. Transport lock knob
2. Height adjustment pin
3. Height of cut decal
4. Deck foot pedal

Located on RH console in front of the motion control lever (see Figure 10 and Figure 11).

Position the knob in latching position (rearward hole) to automatically latch the cutting deck when it is raised to the transport position. To lower the deck, take the pressure off of the latching mechanism by lifting the deck with the foot control, then raise the transport lock knob to release the latch, and the deck may be lowered. Position the knob in the non-latching position (front hole). The deck will not catch on the latching mechanism when the deck is raised.

Figure 11

1. Transport lock control
2. Latching position–rearward hole position
3. Non-latching position–front hole position

Important: The roll bar is an integral and effective safety device. Keep the roll bar in the fully raised and locked position when operating the mower. Lower the roll bar temporarily only when absolutely necessary.

1. The knob must be completely latched with the tabs interlocking as shown in Figure 13 to lock the roll bar in the raised, operate position.

2. Apply forward pressure to the upper hoop of the roll bar.

3. Pull the knob and rotate 90° to hold in the unlatched position to lower the roll bar.

4. To return to the operate position, raise the roll bar, and then rotate knobs 90° so that the tabs interlock partially. Apply forward pressure to the roll bar upper hoop and observe that the knobs return to the completely latched position.

   

   Figure 13

   1. Roll bar upper hoop
   2. Knob in “latched” position
   3. Pull knob to unlatch
   4. Rotate 90° to hold unlatched
   5. Knob in “unlatched” position

5. Make sure the knobs are fully engaged with the roll bar in the raised position. The upper hoop of the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged (see Figure 14).

Figure 14

1. Engaged
2. Partially engaged — Do Not operate with ROPS in this condition.

Important: Always use the seat belt with the roll bar in the operate (raised) position. Ensure that the rear part of the seat is secured with the seat latch.

Rotate the valve and align with the fuel line to open.

1. Move the motion control levers out to the neutral lock position.

2. Pull up and back on the parking brake lever to engage the parking brake.

3. Push down on the PTO switch to the “disengage” position.

   Note: It is not necessary for the operator to be in the seat to start the engine.

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

5. On a cold engine, push the choke lever forward into the “ON” position.

   On a warm engine, leave the choke in the “OFF” position.

6. Turn ignition switch to the “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 cool-down period between starting attempts. Failure to follow these guidelines can burn out the starter motor.

7. If the choke is in the “ON” position, gradually return choke to the “OFF” position as the engine warms up.

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

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

1. Set the throttle midway between the “SLOW” and “FAST” positions.

2. Engage the blades.

   • Models with rocker switch:

     Push down on the front of the switch.

   • Models with push/pull switch:

     Pull the switch out (up).

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

1. Set the throttle midway between the “SLOW” and “FAST” positions.

2. Disengage the blades.

   • Models with rocker switch:

     Push down on the back of the switch.

   • Models with push/pull switch:

     Push the switch in (down).

1. Bring the unit to a full stop.

2. Move the motion control levers out to the neutral lock position.

3. Engage the parking brake.

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

5. Disengage the PTO.

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

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

8. 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.

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

When the motion control levers are positioned fully outward (apart) in the T-slot, the drive system is in the neutral lock position (Figure 15).

When the motion control levers are moved directly inward (together) the drive system is in the neutral operate position.

Figure 15

1. Neutral lock position (handles out)
2. Neutral operate position (handles in)
3. Front of Unit
4. Forward
5. Neutral (operate)
6. Reverse

Driving Forward

1. Release the parking brake.

2. Move the motion control levers inward to the center to the neutral position.

3. To move forward in a straight line, move both levers forward with equal pressure.

   

   Figure 16

   To turn left or right, pull the motion control lever back toward neutral in the desired turn direction.

   The machine will move faster the farther the motion control levers are moved from the neutral position.

4. To stop, position both motion control levers in the neutral operate position.

Driving in Reverse

1. Move the motion control levers inward to the neutral operate position.

2. To move rearward in a straight line, move both levers rearward with equal pressure.

   

   Figure 17

   To turn right, release pressure on the RH motion control lever and the rear of the machine will move towards the rear and to the right.

   To turn left, release pressure on the LH motion control lever and the rear of the machine will move towards the rear and to the left.

3. To stop, position both motion control levers in the neutral operate position.

The cutting height of the mower deck is adjusted from 1 1/2 to 5 inches (3.8 cm to 12.7 cm) in 1/4 inch (6.4 mm) increments.

1. Stop the machine and move the motion control levers outward to the neutral locked position.

2. Disengage the PTO.

3. Raise and lock the deck to the transport position (Figure 18).

   The deck is raised by pushing the foot operated deck lift pedal forward. The pedal is located at the front right corner of the floor pan. Position the knob in latching position (rearward hole) to automatically latch the cutting deck when it is raised to the transport position.

   Note: When changing the cutting height positions, always come to a complete stop and disengage the PTO.

   

   Figure 18

   1. Transport lock knob
   2. Height adjustment pin
   3. Height of cut decal
   4. Deck foot pedal

4. Insert the height adjustment pin into the hole corresponding to the desired cutting height.

   See the decal on the top of the deck lift plate for cut heights.

5. Push the foot lever forward and pull up on the transport lock knob. Slowly decrease foot pressure on the pedal to allow the pedal to move rearward, lowering the cutting deck to the cut height that has been set.

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

1. Stop the machine and move the motion control levers outward to the neutral locked position.

2. Disengage the PTO.

3. Engage the park brake.

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

5. After adjusting the height of cut, adjust the anti-scalp rollers by removing the mounting hardware.

6. Place the rollers in one of the positions shown (Figure 19). Rollers will maintain 3/4 inch (19 mm) clearance to the ground to minimize gouging and roller wear or damage.

   

   Figure 19

   For cutting heights above 3.5 inches (90 mm) use the bottom hole. The rollers will still be effective against scalping.

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

   For Maximum Deck Flotation, place the rollers one hole position lower. Rollers should maintain 1/4 inch (6.4 mm) clearance to the ground. Do Not adjust the rollers to support the deck.

7. Reinstall the mounting hardware.

8. Be sure the roller bolts are installed with the spring disc washer between the head of the bolt and the mounting bracket (see Figure 20).

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

   

   Figure 20

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

Note: The foot operated deck lift assist lever can be used to momentarily lift the deck to clear objects. Be sure that PTO is disengaged.

Important: For Kawasaki and Kohler Engines, refer to the Engine Owner’s Manual for additional maintenance procedures.

Important: If you are using a machine with an Exmark engine above 5,000 ft (1500 m) for a continuous period, ensure that the High Altitude Kit has been installed so that the engine meets CARB/EPA emission regulations. The High Altitude Kit increases engine performance while preventing spark fouling, hard starting, and increased emissions. Once you have installed the kit, attach the high-altitude label next to the serial decal on the machine (reference Figure 24). Contact an Authorized Service Dealer to obtain the proper High Altitude Kit and high-altitude label for your machine. To locate a dealer convenient to you, access our web site at http://www.Exmark.com or contact our Exmark Customer Care Department at the number(s) listed in your Emission Control Warranty Statement. Remove the kit from the engine and restore the engine to its original factory configuration when running the engine under 5,000 ft (1500 m). Do Not operate an engine that has been converted for high-altitude use at a lower altitudes; otherwise, you could overheat and damage the engine. If you are unsure whether or not your machine has been converted for high altitude use, look for the following label:

Figure 24

High Altitude Label

1. Note: The engine on this product has been modified for use at above 5,000 feet elevation. If using below 5,000 feet, it must be revised back to original specifications.

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. 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 has an output of 16 volts and 7 amps or less to avoid damaging the battery (see chart for recommended charger settings).

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 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 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 58

   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. Engine block

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 ENGINE BLOCK OF THE STALLED VEHICLE (NOT TO THE NEGATIVE POST) AWAY FROM THE BATTERY. STAND BACK.

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 section.

3. Inspect blades and sharpen or replace as required.

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

   1. Install either the splined bushing or blade:

      • X-Series:

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

        

        Figure 59

        1. Spindle
        2. Blade
        3. Splined bushing
        4. Blade bolt washer assembly — Torque to 50-60 ft-lb (68-81 N-m) Apply lubricant to threads as needed to prevent seizing. Copper-based anti-seize preferable. Grease acceptable substitute.

      • S- and E-Series:

        Install the blade onto the spindle shaft.

        

        Figure 60

        1. Spindle
        2. Blade
        3. Blade drive washer
        4. Blade bolt washer assembly — Torque to 50-60 ft-lb (68-81 N-m) Apply lubricant to threads as needed to prevent seizing. Copper-based anti-seize preferable. Grease acceptable substitute.

   2. Apply lubricant to the threads of the blade bolt as needed to prevent seizing. Copper based anti-seize is preferable. Grease is an acceptable substitute.

   3. Install the splined bushing/blade assembly and blade bolt washer assembly into the spindle. Install blade bolt finger tight.

   4. Place wrench on the top spindle nut then torque the blade bolts to 50-60 ft-lb (68-81 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.

Note: To prevent engine cut-outs on rough terrain, the seat has a 1/2 second time delay before the engine begins to shutdown.

Check the Normal Engine Starting Chart

		System
		Parking Brake	PTO	Motion Control Levers	Operator	Outcome
	State of System	Engaged	Disengaged (Blades)	Both levers out (neutral lock)	In seat or out of the seat	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
	Parking Brake	PTO (Blades)	Motion Control Levers	Operator	Outcome
State of System	Engaged	Disengaged	Both levers moved in, or either right or left lever moved in	Operator in seat	Starter must not crank
	Disengaged	Disengaged	Both levers out (neutral lock)	Operator in seat	Starter must not crank
	Engaged	Engaged	Both levers out (neutral lock)	Operator in seat	Starter must not crank

Check Shutdown Circuit Chart

Note: The state of system item(s) that is bold is being checked in each scenario.

	System
	Engine	Parking Brake	PTO (Blades)	Motion Control Levers	Operator	Outcome
State of System	Running idle (1/3 throttle)	Disengaged	Disengaged	Both levers moved out (neutral lock), both levers moved in, or either right or left lever moved in	Raise off of seat (but don’t get off)	Engine must begin shutdown within 1 second
	Running idle (1/3 throttle)	Disengaged	Engaged	Both levers moved in	Raise off of seat (but don’t get off)	Engine must begin shutdown within 1 second
	Running idle (1/3 throttle)	Engaged	Disengaged	Both levers moved in, or either right or left lever moved in	Operator in seat	Engine must begin shutdown within 1 second

Check that both the mounting hardware and the knobs are in good working condition. Make sure the knobs are fully engaged with the ROPS in the raised position. The upper hoop of the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged.

Figure 61

1. Engaged
2. Partially engaged — Do Not operate with ROPS in this condition.

Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle. Replace before operating if damaged.

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. Check tire pressure in drive tires.

3. Inflate drive tires to 13 psi (90 kPa).

4. Check tire pressure in caster tires.

5. Inflate caster tires to 13 psi (90 kPa).

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

2. Remove left and right belt shields on deck and lower the deck to inspect deck drive belt.

3. Check under machine to inspect the pump drive belt.

   Note: No adjustments are required for belt tension.

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 Axles (S- and E-Series Only)	1	2	25 hours
   1. Front Caster Axles (X-Series)	1	2	Yearly
   2. Front Caster Pivots (X-Series)	0*	2	Yearly

   

   Figure 62

   * See step 3 for special lubrication instructions on the caster pivots.

3. Lubricate 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 63

   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.

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

Figure 64

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.

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

2. Squeeze the ends of the hose clamps together and slide them away from the filter.

3. Remove the filter from the fuel lines.

4. Install a new filter with the flow direction arrow coming from the fuel tank and pointing to the engine. Move the hose clamps close to the filter to secure it in place.

1. Park the machine on level ground. Stop engine, wait for all moving parts to stop, and allow engine to cool. Remove key and engage parking brake.

   Important: Transaxles must be cool (less than 100°F (38°C)) before changing oil. Failure to allow the transaxles to cool prior to changing the oil, could result in overfilling the unit and damaging the breather assembly.

2. Locate the two filters under the transmissions. Remove filter guard screws and filter guard.

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

4. Unscrew filters to remove and allow oil to drain from drive system.

   Important: Before reinstalling new filters, apply a thin coat of Exmark Premium Hydro Oil on the surface of the filters rubber seal.

5. Install the new filter by hand; turn the filter clockwise until rubber seal contacts the filter base then tighten the filter an additional 3/4 to 1 full turn.

6. Reinstall the filter guard with the filter guard screws. Torque the screws to 65 in-lb (7 N-m).

7. Remove the top port plug. Fill the oil through the top port plug using a hand pump or through the fill port plug. Fill until it flows out of the top port opening.

   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 75 hours*Every 500 hours thereafter
   Mobil 1 15W50	After first 75 hours *Every 250 hours thereafter

   *May need more often under severe conditions.

   

   Figure 65

   Right side shown

   1. Top port plug
   2. Breather vent
   3. Fill port plug
   4. Filter guard and oil filter

8. Torque the top port plug to 120 in-lb (14 N-m).

9. Torque the fill port plug to 210 in-lb (24 N-m), if it was removed to fill the transmission.

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

11. Start engine and move throttle control ahead to 1/2 throttle position. Disengage parking brake.

    1. With the bypass valve open and the engine running, slowly move the directional control in both forward and reverse (5 or 6 times).

    2. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 to 6 times). Check the oil level, and add oil as required after stopping the engine.

    3. It may be necessary to repeat steps 1 and 2 until all the air is completely purged from the system. When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds, then the transaxle is considered purged.

12. Remove the jack stands.

Note: Do Not change the 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 contaminants into the system.

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

2. Wait for muffler to cool.

3. If any breaks in the screen or welds are observed, replace arrester.

4. If plugging of the screen is observed, remove arrester and shake loose particles out of the arrester and clean screen with a wire brush (soak in solvent if necessary). Reinstall arrester on exhaust outlet.

Thread locking adhesives such as “Loctite 242”, “Loctite 243”, or “Fel-Pro, Pro-Lock Nut Type” are used on the following fasteners:

• ROPS spring pin housing.

• Sheave and clutch retaining bolt in the end of engine crankshaft.

• Hydro cross member mounting bolts

Thread locking adhesives are required for some hardware on engines — see the Engine manual.

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

On threads of Blade Bolts. See Check Mower Blades section.

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.

1. Position the mower on a flat surface.

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

3. Check the tire pressure in the drive tires. Proper inflation pressure for tires is 13 psi (90 kPa). Adjust if necessary.

4. Position the transport lock in the latching position.

5. Carefully rotate the blades from side to side.

6. Measure between the outside cutting edges and the flat surface (Figure 66). If both measurements are not within 3/16 inch (5 mm), an adjustment is required; continue with this procedure.

   

   Figure 66

   1. Blades side to side
   2. Measure here

7. Set anti-scalp rollers to top holes or remove completely for this adjustment.

8. For 60 Inch Decks Only:

   1. Raise the deck to the transport (5 inch (12.7 cm) cutting height) position.

   2. Slowly loosen the adjusting screw on the lift assist spring until the screw can be removed (see Figure 67). Save the screw for reinstallation.

   

   Figure 67

   1. Adjusting screw
   2. Bracket
   3. Set gap to 1.02-1.28 inch (26-33 mm)

9. Set the height-of-cut lever to the 3 inch (76 mm) position. Place two “B” thick blocks (see Block Height and Rake Table) under the rear edge of the cutting deck skirt; one on each side of the cutting deck. Place two “A” thick blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets.

   S and E-Series—Block Height and Rake Table

   Front Block Height “A”	Rear Block Height “B”	Rake “R”
   2.56 inches (6.5 cm)	2.81 inches (7.1 cm)	1/16–5/16 inch (1.6–7.9 mm)

   X-Series—Block Height and Rake Table

   Front Block Height “A”	Rear Block Height “B”	Rake “R”
   2.63 inches (6.7 cm)	2.88 inches (7.3 cm)	1/16–5/16 inch (1.6–7.9 mm)

10. Carefully rotate the blades side to side (Figure 66).

11. Loosen the leveling adjust locking nuts (item 1 Figure 68) on all four corners so that the deck is sitting securely on all four blocks. Make sure that the slack is removed from the deck hangers and the deck lift foot lever is pushed back against the stop, then tighten the four leveling adjust locking nuts.

    

    Figure 68

    1. Leveling adjust locking nuts
    2. Deck lift arm
    3. Deck hanger
    4. Chain

12. Recheck that blocks fit just snugly under the deck skirt. Make sure all attachment bolts are tight

13. Continue leveling the deck by checking the front-to-rear blade slope; refer to Adjusting the Blade Slope.

14. Recheck blades for levelness and repeat deck leveling procedure if necessary.

15. For 60 Inch Decks Only:

    1. Raise the deck to the transport (5 inch (12.7 cm) cutting height) position.

    2. Reinstall the lift assist spring adjusting screw that was removed in step 8.

    3. Set the gap between the spring and bracket to 1.02-1.28 inch (26-33 mm).

1. Check the front-to-rear blade level. If the front blade tip is not “R” (see Block Height and Rake Table in Deck Leveling) lower than the rear blade tip, adjust the blade level using the following instructions:

2. Park the machine on a level surface and disengage the blade control switch.

3. Move the motion control levers outward to the neutral position, engage the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

4. Check the air pressure of all four tires. If needed, adjust to the recommended inflation; refer to Checking the Tire Pressure in Drive System Maintenance section.

5. Check and adjust the side-to-side blade level if you have not checked the setting; refer to Deck Leveling.

6. Set the height-of-cut lever to the 3 inch (76 mm) position. Place two “B” thick blocks (see Block Height and Rake Table in Deck Leveling) under the rear edge of the cutting deck skirt; one on each side of the cutting deck. Place two “A” thick blocks (see Block Height and Rake Table in Deck Leveling) under each side of the front edge of the deck, but not under the anti-scalp roller brackets.

7. Loosen the leveling adjust locking nuts (item 1 Figure 68) on all four corners so that the deck is sitting securely on all four blocks. Make sure that the slack is removed from the deck hangers and the deck lift foot lever is pushed back against the stop, then tighten the four leveling adjust locking nuts.

8. Carefully rotate the blades so they are facing front to rear (Figure 69).

9. For 60 Inch Decks Only:

   1. Raise the deck to the transport (5 inch (12.7 cm) cutting height) position.

   2. Slowly loosen the adjusting screw on the lift assist spring until the screw can be removed (see Figure 67). Save the screw for reinstallation.

10. Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat surface (Figure 69). If the front blade tip is not “R” (see Block Height and Rake Table in Deck Leveling) lower than the rear blade tip, adjust the front deck hanger.

    

    Figure 69

    1. Blades front to rear
    2. Measure here

11. When the front-to-rear blade slope is correct check the side-to-side level of the mower again; refer to Deck Leveling.

12. For 60 Inch Decks Only:

    1. Raise the deck to the transport (5 inch (12.7 cm) cutting height) position.

    2. Reinstall the lift assist spring adjusting screw that was removed in step 9.

    3. Set the gap between the spring and bracket to 1.02-1.28 inch (26-33 mm) (see Figure 67).

Self-tensioning - No adjustment necessary.

Self-tensioning - No adjustment necessary.

Check to make sure brake is adjusted properly. This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced.

1. Drive the machine onto a level surface.

2. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake.

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

4. Setup the machine to be pushed by hand (see Drive Wheel Release Valves in the Operation section).

5. Raise the back of the machine up and support the machine with jack stands.

6. Engage/disengage the brake and check each drive tire to make sure each brake engages/disengages.

7. If adjustment is necessary, disengage the park brake. Remove cotter pin from the brake linkage shaft (see Figure 70).

   

   Figure 70

   1. Cotter pin
   2. Parking brake
   3. Brake linkage shaft

8. Check both spring lengths as shown in Figure 71. If adjustment is necessary, turn the top nut clockwise to shorten and counterclockwise to lengthen.

   

   Figure 71

   1. Top nut
   2. Spring
   3. 1.75 inches (44 mm)

9. Push the parking brake lever all the way forward and down. Rotate the brake linkage shaft until the end aligns with hole in lever.

   • Shorten the linkage by turning it clockwise.

   • Lengthen the linkage by turning it counterclockwise.

   Insert the brake linkage shaft into parking brake hole and secure with the cotter pin. Repeat step 6 and readjust if necessary.

10. When adjustment is complete, remove the jack stands or equivalent support and lower the machine.

11. Place the machine into the “operating” position. Refer to the Drive Wheel Release Valves section in Operation.

Adjusting the height:

The motion control levers can be adjusted higher or lower for maximum operator comfort.

1. Remove the hardware holding the control lever to the control arm shaft.

   

   Figure 72

   1. Bolts
   2. Slotted hole
   3. Control lever
   4. Control arm shaft

2. Move the control lever to the next set of holes. Secure the lever with the hardware.

3. Repeat the adjustment for the opposite control lever.

Adjusting the Tilt

The motion control levers can be tilted fore or aft for maximum operator comfort.

1. Loosen the upper bolt holding the control lever to the control arm shaft.

2. Loosen the lower bolt just enough to pivot the control lever fore or aft. Tighten both bolts to secure the control in the new position.

3. Repeat the adjustment for the opposite control lever.

If the machine travels or pulls to one side, when the motion control levers are in the full forward position, adjust the tracking screw.

1. Insert a 3/16 inch hex wrench through the access hole on the front cover panel, rotate the tracking screw clockwise or counterclockwise to adjust the travel of the lever.

   

   Figure 73

   1. Access hole on front cover panel
   2. Tracking screw

2. Drive the machine and check the full forward tracking.

3. Repeat steps 1 and 2 until desired tracking is obtained.

Located on either side of the machine, below the seat are the pump control linkages. Rotating the end nut with a 1/2 inch deep socket wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only.

1. Prior to starting the engine, push the deck lift pedal and remove the height of cut pin. Lower deck to the ground.

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

3. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat. The switch is a part of the seat assembly.

4. Temporarily install a jumper wire across the terminals in the connector of the main wiring harness.

5. Start engine. Brake must be engaged and motion control levers out to start engine. Operator does not have to be in the seat. Run engine at full throttle and release brake.

6. Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic oil up to operating temperature.

   Note: The motion control lever needs to be in neutral while making any necessary adjustments.

7. Bring the motion control levers into the neutral position. The control plate tabs should touch the return to neutral plates on the hydros. Adjust pump control rod lengths by turning the nut in the appropriate direction until the wheels slightly creep in reverse (see Figure 74). Move the motion control levers to the reverse position and while applying slight pressure to the lever allow the reverse indicator springs to bring the levers back to neutral. The wheels must stop turning or slightly creep in reverse.

   The motion control cover may need to be removed to gain access.

   

   Figure 74

   1. Nut
   2. Stationary plate
   3. Control plate
   4. Return to neutral plate
   5. Tabs touching return to neutral plate

8. Shut off unit. Remove jumper wire from wire harness and plug connector into seat switch.

9. Remove the jack stands.

10. Raise the deck and re-install the height of cut pin.

11. Check that the machine does not creep in neutral with the park brake disengaged.

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, under the seat, 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 inadequate cooling.

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

1. Park the machine on a level surface and disengage the blade control switch.

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

3. Raise deck to the transport (5 inch (12.7 cm) cutting height) position. Lift the front of unit and support unit using jack stands or equivalent support.

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