Maintenance
Maintenance Safety
- If you leave the key in the switch,
someone could accidently start the engine and seriously injure you
or other bystanders. Remove the key from
the switch before you perform any maintenance.
- Before you leave the operator’s position, do the following:
- Park the machine on a level surface.
- Disengage the drives.
- Engage the parking brake.
- Shut off the engine and remove
the key.
- Wait for the machine to cool before
performing maintenance.
- Do not allow untrained personnel
to service the machine.
- Keep your hands and feet away
from moving parts or hot surfaces. If possible, do not make adjustments
with the engine running.
- Keep all guards, shields, switches,
and all safety devices in place and in proper working condition. Frequently
check for worn or deteriorating components
and replace them with genuine Exmark parts when necessary.
- Carefully release pressure from
components with stored energy.
 |
Warning |
|
Removing or modifying original
equipment, parts, and/or accessories may alter the warranty, controllability,
and safety of the machine. Making unauthorized
modifications to the original equipment or failing to use original Exmark parts could lead
to serious injury or death.
- Check the parking brake operation
frequently. Adjust and service it as required.
- Never tamper with safety devices.
Check their proper operation regularly.
- Clean grass, leaves, excessive
grease and oil, and other debris from the cutting unit, muffler, drives,
grass catcher, and engine compartment to
prevent fires.
- Clean up oil or fuel spills and
remove fuel-soaked debris.
- Do not rely solely on mechanical
or hydraulic jacks to support the machine. Use adequate jack stands.
- Keep all parts in good working
condition and all hardware tightened, especially the blade-attachment
hardware.
- To ensure optimum performance,
use only genuine Exmark replacement parts and accessories.
Replacement parts and accessories made by other manufacturers could
be dangerous.
Recommended Maintenance Schedule
| Before each use or daily |
Check the safety-interlock system.
|
| Check the engine-oil level.
|
| Clean the cooling system (more often in dusty, dirty conditions). |
| Inspect the blades. |
| Inspect the grass deflector for damage.
|
| After each use |
Clean grass and debris from the cutting unit, muffler, drives, grass
catcher, and engine. |
| Clean the mower-deck housing.
|
| Every 25 hours |
Grease the caster wheel bearings (more often in sandy soil conditions). |
| Clean the air-cleaner foam element (more often in dusty, dirty conditions). |
| Check the tire pressure.
|
| Check the belts for wear or cracks.
|
| Every 100 hours or yearly, whichever
comes first |
Replace the paper air-cleaner element (more often in dirty or dusty
conditions). |
| Change the engine oil and oil
filter (more often in dirty or dusty conditions). |
| |
| Before storage |
Charge the battery and disconnect the battery cables. |
| Perform all maintenance procedures listed above before storage. |
| Paint any chipped surfaces. |
| |
| Yearly |
Replace the air-cleaner paper and foam elements (more often in dusty,
dirty conditions). |
| Change the spark plug(s).
|
| Replace the in-line fuel filter.
|
| Clean the cooling system; contact an Authorized Service Dealer. |
Refer to your engine owner's manual
for additional maintenance procedures.
Pre-Maintenance Procedures
Moving a Non-Functioning Machine
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine and wait for all moving parts to stop before leaving the
operating position.
-
Locate the
bypass levers 
on the frame on both sides of
the engine.
-
Move both
bypass levers forward through the slotted hole and over to lock them
in place 
.
|
Warning |
|
Contact
with hot surfaces may cause personal injury.
Keep your hands,
feet, face, clothing and other body parts away the engine, muffler
and other hot surfaces.
|
Warning |
|
The
machine could unintentionally move while the bypass levers are locked
forward in the slot and injure you or bystanders.
Lock the bypass
levers rearward after moving the machine.
-
Disengage
the parking brake by moving both motion-control levers down to the
center, unlocked position.
Note: Do not start the machine.
-
Move the
machine as required.
Always
push the machine by hand. Do not tow the machine, because towing may
damage it.
-
Move the
motion-control levers outward to the Park position.
-
Move both
bypass levers rearward and over through the slotted hole to lock them
in place 
.
Raising the Machine
-
Use jackstands
to support the machine when you raise it.
|
Warning |
|
Supporting
the machine on the lower muffler shield may damage the shield and
cause the machine to fall, injuring you or bystanders.
Do
not use the lower muffler shield to lift or support the machine.
Lubrication
Greasing the Bearings
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine and wait for all moving parts to stop before leaving the
operating position.
-
Clean the
grease fittings with a rag.
Note: Scrape any paint off the front of the fittings.
-
Connect a
grease gun to each fitting.
-
Pump grease
into the fittings until grease begins to ooze out of the bearings.
-
Wipe up any
excess grease.
Engine Maintenance
Engine Safety
- Keep your hands, feet, face, other
body parts, and clothing away from the muffler and other hot surfaces.
Wait for the engine to cool before performing
maintenance.
- Do not change the engine governor
speed or overspeed the engine.
Air Cleaner Service
Removing the Air-Cleaner Elements
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine and wait for all moving parts to stop before leaving the
operating position.
-
Clean around
the air-cleaner cover to prevent dirt from getting
into the engine and causing damage.
-
Loosen the
fasteners and remove the cover.
-
Remove the
air-cleaner elements .
-
Separate
the foam and paper elements.
Servicing the Foam Element
-
Wash the
foam element in liquid soap and warm water. When the element is clean,
rinse it thoroughly.
-
Dry the element
by squeezing it in a clean cloth.
Replace
the foam element if it is torn of worn.
-
Lightly oil
the foam element using new engine oil and squeeze out any excess oil.
Servicing the Paper Air-Cleaner Element
-
Clean the
paper element by tapping it gently to remove dust.
Note: If it is very dirty, replace the paper element with a new one.
-
Inspect the
element for tears, an oily film, or damage to the rubber seal.
-
Replace the
paper element if it is damaged.
Do
not clean the paper filter.
Installing the Air-Cleaner Elements
-
Install the
foam pre-cleaner element over the paper element.
Note: Ensure that you do not damage the elements.
-
Install the
air-cleaner elements onto the air-cleaner base.
-
Install the
cover and tighten the fasteners.
Engine-Oil Service
Engine-Oil Specifications
| Oil Type
|
Detergent oil (including synthetic)
of API service SJ or higher
|
| Crankcase Capacity |
1.9 L (64 fl oz)
with oil filter; 1.8 L (60 fl oz) without oil filter |
| Viscosity
|
See the table below |
 |
Checking the Engine-Oil Level
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Wait for
the engine to cool so that the oil has had time to drain into the
sump.
-
To keep dirt,
grass clippings, etc., out of the engine, clean the area around the
oil-fill cap and dipstick before removing
it.
-
Check the
engine-oil level as shown.
If
you overfill or underfill the engine crankcase with oil and run the
engine, you may damage the engine.
Changing the Engine Oil and Oil Filter
-
Park the
machine on a level surface to ensure that the oil drains completely.
-
Disengage
the blade-control switch, and move the motion-control levers outward
to the Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Drain the
oil from the engine.
-
Change the
engine-oil filter.
Note: Ensure that the oil-filter gasket touches the engine and then turn
the filter an extra 3/4 turn.
-
Slowly pour
approximately 80% of the specified oil into the filler tube and slowly
add the additional oil to bring it to the
Full mark.
-
Dispose of
the used oil per local regulations.
Servicing the Spark Plug
Ensure that
the air gap between the center and side electrodes is correct before
installing the spark plug. Use a spark plug
wrench for removing and installing the spark plug and a gapping
tool or feeler gauge to check and adjust the air gap. Install
a new spark plug if necessary.
Type: Champion® XC92YC
Air gap: 0.76 mm (0.03 inch)
Removing the Spark Plug
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Clean the
area around the base of the plug to keep dirt and debris out of the
engine.
-
Remove the
spark plug.
Checking the Spark Plug
Do not clean the spark plug(s).
Always replace the spark plug(s) when it has a black coating, worn
electrodes, an oily film, or cracks.
If
you see light brown or gray on the insulator, the engine is operating
properly. A black coating on the insulator usually
means the air cleaner is dirty.
-
Set the gap
to 0.75 mm (0.03 inch).
Installing the Spark Plug
Fuel Maintenance
|
Danger |
|
In certain conditions, fuel is
extremely flammable and highly explosive. A fire or explosion from
fuel can burn you and others and can damage
property.
Refer to Fuel Safety for a complete list of fuel related
precautions.
Replacing the Fuel Filter
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Clamp the
fuel lines on both sides of the fuel filter.
-
Replace the
filter.
Note: Ensure that the flow-direction arrow on the replacement filter points
toward the engine.
Never
install a dirty filter after removing it from the fuel line.
-
Remove the
clamps blocking the fuel flow.
Electrical System Maintenance
Electrical System Safety
- Disconnect the cable from the
negative terminal of the battery before repairing the machine.
- Charge the battery in an open,
well-ventilated area, away from sparks and flames. Unplug the charger
before connecting or disconnecting the
battery. Wear protective clothing and use insulated tools.
Battery Service
Removing the Battery
|
Warning |
|
Battery terminals or metal tools
could short against metal machine components, causing sparks. Sparks
can cause the battery gasses to explode,
resulting in personal injury.
- When removing or installing the
battery, do not allow the battery terminals to touch any metal parts
of the machine.
- Do not allow metal tools to short
between the battery terminals and metal parts of the machine.
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Raise the
seat to access the battery.
-
Disconnect
the negative (black) ground cable from the battery post.
Note: Retain all fasteners.
|
Warning |
|
Incorrectly
removing the cables from battery could damage the machine and cables,
causing sparks. Sparks can cause the battery
gasses to explode, resulting in personal injury.
- Always disconnect the negative
(black) battery cable before disconnecting the positive (red) cable.
- Always connect the positive (red)
battery cable before connecting the negative (black) cable.
-
Slide the
rubber cover off the positive (red) cable.
-
Disconnect
the positive (red) cable from the battery post (+).
Note: Retain all fasteners.
-
Remove the
battery hold-down and lift the battery from the battery tray.
G293472s
-
Battery
-
Terminal boot
-
Negative (–) battery post
-
Wing nut, washer, and bolt
-
Battery hold-down
-
Bolt, washer, and nut
-
Positive (+) battery post
Charging the Battery
|
Warning |
|
Charging the battery produces
gasses that can explode.
Never smoke near the battery and
keep sparks and flames away from battery.
Always keep the battery fully
charged. This is especially important to prevent battery damage when
the temperature is below 0°C (32°F).
-
Remove the
battery from the machine.
-
Charge the
battery per the battery charger manufacturer’s instructions.
Do
not overcharge the battery; otherwise, you could damage it.
G003792S
- Positive
battery post
- Negative
battery post
- Red (+)
charger lead
- Black
(-) charger lead
-
When the
battery is fully charged, unplug the charger from the electrical outlet
(if applicable), then disconnect the charger
leads from the battery posts.
Cleaning the Battery
Note: Keep the terminals and the entire battery case clean, because a dirty
battery discharges slowly.
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine and wait for all moving parts to stop before leaving the
operating position.
-
Remove the
battery from the machine.
-
Wash the
entire case with a solution of baking soda and water.
-
Rinse the
battery with clear water.
-
Coat the
battery posts and cable connectors with Grafo 112X (skin-over) grease
or petroleum jelly to prevent corrosion.
-
Install the
battery.
Installing the Battery
-
Position
the battery in the tray.
-
Using the
fasteners previously removed, install the positive (red) battery cable
to the positive (+) battery terminal.
-
Using the
fasteners previously removed, install the negative battery cable to
the negative (-) battery terminal.
-
Slide the
red terminal boot onto the positive (red) battery post.
-
Secure the
battery with the hold-down.
G440221
-
Battery
-
Terminal boot
-
Negative (–) battery post
-
Wing nut, washer, and bolt
-
Battery hold-down
-
Bolt, washer, and nut
-
Positive (+) battery post
-
Lower the
seat.
Jump-Starting the Machine
|
Warning |
|
Jump-starting the battery can
produce gasses that can explode.
Do not smoke near the battery,
and keep sparks and flames away from battery.
|
Danger |
|
Jump-starting a weak battery that
is cracked or frozen or has a 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.
-
Check and
clean corrosion from the battery terminals before jump-starting. Ensure
that the connections are tight.
|
Caution |
|
Corrosion
or loose connections can cause unwanted electrical voltage spikes
at any time during the jump-starting procedure.
Do not attempt
to jump-start the machine with loose or corroded battery terminals,
or damage to the engine may occur.
-
Make sure
that the booster battery is a good and fully charged lead-acid battery
at 12.6 V or greater.
Note: Use properly sized jumper cables with short lengths to reduce voltage
drop between systems. Make sure that the cables are
color coded or labeled for the correct polarity.
|
Warning |
|
Batteries
contain acid and produce explosive gases.
- Shield your eyes and face from
the batteries at all times.
- Do not lean over the batteries.
Note: Ensure that the vent caps are tight and level. Place a damp cloth,
if available, over any vent caps on both batteries. Also
ensure that the machines 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.
-
Connect the
positive (+) cable to the positive (+) terminal of the discharged
battery that is wired to the starter or solenoid
as shown:
g012785
- Positive
(+) cable on discharged battery
- Positive
(+) cable on booster battery
- Negative
(–) cable on the booster battery
- Negative
(–) cable on the engine block
- Booster
battery
- Discharged
battery
- Engine
block
-
Connect the
other end of the positive (+) jumper cable to the positive terminal
of the battery in the other machine.
-
Connect an
end of the negative (-) jumper cable to the negative post of the battery
in the other machine.
-
Connect the
other end of the negative (-) jumper cable to a ground point, such
as an unpainted bolt or chassis member.
-
Start the
engine in the other machine. Let it run a few minutes, then start
your engine.
-
Remove the
cables in the reverse order of connection.
-
Install the
cover to the jump post.
Servicing the Fuses
The electrical
system is protected by fuses. It requires no maintenance; however,
if a fuse blows, check the component/circuit
for a malfunction or short.
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Raise the
seat.
-
Replace the
blown fuse with a new fuse.
G293931s
- Charge
circuit (15 A)
- Main
(25 A)
-
Lower the
seat.
Drive System Maintenance
Checking the Tire Pressure
Maintain the air pressure in the
front and rear tires as specified. Uneven tire pressure can cause
an uneven cut. Check the pressure at the valve
stem when the tires are cold to get the most accurate pressure reading.
-
Inflate the
front caster wheel tires to 90 kPa (13 psi) or the pressure indicated
on the sidewall, whichever is lower.
-
Inflate the
rear drive-wheel tires to 90 kPa (13 psi).
Checking the Wheel Lug Nuts
-
Check and
torque the wheel lug nuts to 95
to 122 N∙m (70 to 90 ft-lb).
Adjusting the Tracking
If the machine
pulls to one side while driving forward at full speed across a flat,
level surface, adjust the tracking.
If the machine pulls to
the left, adjust the right motion-control lever; if the machine pulls
to the right, adjust the left motion-control
lever.
Note: You can adjust the tracking only for driving forward.
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Locate the
tracking-adjustment bolt near the motion-control lever on the particular
side that needs adjusting.
-
Rotate the
bolt to decrease the speed for that particular wheel.
Note: Rotate the bolt a small amount to make minor adjustments.
-
Start the
machine and drive forward across a flat, level surface with the motion-control
levers fully forward to check if the machine
tracks straight. Repeat the procedure as needed.
Belt Maintenance
Inspecting the Belts
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine and wait for all moving parts to stop before leaving the
operating position.
-
Set the height
of cut at the lowest cutting position.
-
Inspect the
belt for wear. Replace the belt if it is worn.
The signs of
a worn belt include squealing while the belt is rotating; the blades
slipping while cutting grass; and frayed
edges, burn marks, and cracks on the belt.
Replacing the Mower Belt
The signs of a worn belt include
squealing while the belt is rotating, blades slipping while cutting
grass, and frayed edges, burn marks, and cracks
on the belt. Replace the mower belt if any of these conditions are
evident.
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Set the height
of cut at the lowest cutting position.
-
Remove the
hairpin cotter and push in the tab on
the cover to remove the pulley covers.
-
For 50-inch
or 54-inch decks, loosen the nut securing the wire form to the idler
pulley.
G336421s
- Wire
form
- Nut
- Idler
pulley
-
Using a spring-removal
too (Exmark Part
No. 92-5771), remove the idler spring from the deck hook to remove
tension on the idler pulley.
|
Warning |
|
The
spring is under tension when installed and can cause personal injury.
Be careful when removing the belt.
G454314
- Deck
pulley
- Mower
belt
- Engine
pulley
- Idler
pulley
- Spring
- Spring-removal
tool
-
Roll the
belt off the pulleys.
-
Route the
new belt around the engine pulley and mower pulleys.
-
Use the spring-removal
tool to install the idler spring over the deck hook and place tension
on the idler pulley and the mower belt.
-
Tighten the
nut securing the wire form to the idler pulley (if applicable).
Note: Position the wire form against the idler arm.
-
Install the
pulley covers.
Mower-Deck Maintenance
Blade Safety
- Inspect the blades periodically
for wear or damage.
- Use care when checking the blades.
Wrap the blade(s) or wear gloves and use caution when servicing them.
Only replace damaged blades; never straighten
or weld them.
- On multi-bladed machines, take
care as rotating one blade can cause other blades to rotate.
- Replace worn or damaged blades
and bolts in sets to preserve balance.
Blade Service
To ensure a superior quality of
cut, keep the blades sharp. For convenient sharpening and replacement,
keep extra blades on hand.
Replace the
blades if they hit a solid object, or if the blade is out of balance
or bent.
Before Inspecting or Servicing the Blades
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Disconnect
the spark-plug wires from the spark plugs.
Checking for Bent Blades
The machine must be on a level
surface for this procedure.
-
Raise the
mower deck to the highest height-of-cut position.
-
While wearing
thickly padded gloves, or other adequate hand protection, slowly rotate
the blade into a position that allows
you to measure the distance between the cutting edge and the level
surface.
-
Measure from
the tip of the blade to the level surface.
G451422
- Blade
(in position for measuring)
- Level
surface
- Measured
distance between blade and the surface (A)
-
Rotate the
same blade 180 degrees so that the opposite blade edge is now in the
same position.
G451423
- Blade
edge previous measured
- Opposite
blade edge
-
Measure from
the tip of the blade to the level surface.
G451422
- Blade
(in position for measuring)
- Level
surface
- Measured
distance between blade and the surface (B)
-
If the difference
between A and B is greater than 3 mm (1/8 inch), replace the blade.
Note: If you replace the blade and the difference continues to exceed 3
mm (1/8 inch), the blade spindle could be bent. Contact
an Authorized Service Dealer for service.
-
Repeat this
procedure each blade.
Removing the Blades
-
Hold the
blade end using a rag or thickly padded glove.
-
Remove the
blade as shown.
Sharpening the Blades
-
Use a file
to sharpen the cutting edge at both ends of the blade. Ensure to maintain
the original angle .
Note: Remove the same amount of material from both cutting edges so that
the blade retains its balance.
-
Check the
balance of the blade by putting it on a blade
balancer .
Note: If the blade stays in a horizontal position, the blade is balanced
and can be used.
If the blade
is not balanced, file some metal off the end of the sail area only.
-
Repeat this
procedure until the blade is balanced.
Installing the Blades
|
Warning |
|
Operating a machine after incorrectly
installing the blade assembly and/or not using genuine Exmark blade and blade hardware
could allow a blade or blade component to be thrown out from under
the deck, resulting in serious injury
or death.
Always install genuine Exmark blades and blade
hardware according to the instructions.
-
Install the
blade as shown.
Note: The curved part of the blade must point upward toward the inside
of the mower to ensure proper cutting.
-
Torque the
blade bolt to 81
to 108 N·m (60 to 80 ft-lb).
Leveling the Mower Deck
Ensure that
the mower deck is level any time you install the mower deck or when
you see an uneven cut on your lawn.
Preparing to Level the Mower Deck
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Ensure that
the tires are inflated to the correct specifications and the caster
wheels are facing straight forward.
-
Check the
mower deck for bent blades; remove and replace any bent blades.
-
Raise the
mower deck to the 76 mm (3 inch) height-of-cut setting.
Checking the Mower-Deck Level
-
Position
the blades side-to-side.
-
Measure at
locations 
and 
from a level surface to the cutting
edge of the blade tips .
The difference between the measurements
should be no more than 5 mm (3/16 inch). If the measurement is larger,
adjust the side-to-side level.
-
Position
1 blade front-to-rear.
-
Measure at
locations and from a level surface to the cutting
edge of the blade tips .
The front blade tip should be
1.6 to 7.9 mm (1/16 to 5/16 inch) lower than the rear blade tip. If
the measurement is not correct, adjust
the front-to-rear level.
Leveling the Mower Deck for E-Series Machines
-
Set the anti-scalp
rollers to the top holes or remove them completely for this procedure.
-
Set the height-of-cut
lever to the 76 mm (3 inch) position.
-
Place 2 blocks,
each having a thickness of 6.6 cm (2-5/8 inches), under each side
of the front edge of the deck.
Do
not place the blocks under the anti-scalp roller brackets.
G567733
- Wood
block—6.6 cm (2-5/8 inches) thick
- Wood
block—7.3 cm (2-7/8 inches) thick
-
Place 2 blocks,
each having a thickness of 7.3 cm (2-7/8 inches), under each side
of the rear edge of the deck.
-
Adjust the
side-to-side level as necessary:
-
Remove the hairpin cotter and washer from the left lower lift-arm
pin.
-
Rotate the height-of-cut plate to a different hole so that it supports
the weight of the mower deck after you install the
plate.
-
Install the washer and hairpin cotter.
-
Repeat the adjustment for the other side of the machine.
-
Check the side-to-side level and adjust it again until the measurements
are correct.
-
Adjust the
front-to-rear level as necessary:
-
Rotate the adjustment nut in the front of the mower deck.
To raise the
front of the deck, tighten the adjustment nut; lower the front of
the deck, loosen the adjustment nut.
-
Check the front-to-rear level and adjust it again until the measurements
are correct.
-
Verify that
the deck is level and make further adjustments as needed.
Leveling the Mower Deck for S-Series Machines
-
Set the anti-scalp
rollers to the top holes or remove them completely for this procedure.
-
Set the height-of-cut
lever to the 76 mm (3 inch) position.
-
Place 2 blocks , each having a thickness of 6.6
cm (2-5/8 inches), under each side of the front edge of the deck.
Do
not place the blocks under the anti-scalp roller brackets.
G567733
-
Wood block—6.6 cm (2-5/8 inches) thick
-
Wood block—7.3 cm (2-7/8 inches) thick
-
Place 2 blocks , each having a thickness of 7.3
cm (2-7/8 inches), under each side of the rear edge of the deck.
-
Loosen the
lower fasteners securing the brackets to all 4 corners of the deck
and ensure that the mower deck sits securely
on all 4 blocks.
-
Remove any
slack from the deck brackets and ensure that the deck-lift foot lever
is pushed back against the stop.
-
Tighten the
fasteners.
-
Ensure that
the blocks fit snugly under the deck edge and that all attachment
bolts are tight.
-
Check the
side-to-side level and front-to-rear level; repeat the procedure until
the measurements are correct.
Removing the Mower Deck
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Lower the
height-of-cut lever to the lowest position.
-
Detach the
mower deck from the machine.
For
E-Series Machines:
-
Remove the
hairpin cotter from the front support rod and remove the rod from the deck
bracket .
-
Carefully
lower the front of the mower deck to the ground.
-
On each side
of the machine, remove the washer and hairpin cotter from the deck pin.
-
Remove the
lift arm from the deck pin.
For S-Series Machines:
-
At the rear
of the mower deck, remove the 2 shoulder bolts and nuts securing the deck to the pivot
pan .
-
At all 4
corners of the deck, remove the hairpin cotter and washer from the deck pin .
-
Raise the
height of cut to the highest position.
-
Slide the
mower deck rearward to remove the mower belt from the engine pulley.
-
Slide the
mower deck out from underneath the machine.
Note: Retain all parts for future installation.
Installing the Mower Deck
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Slide the
mower deck under the machine.
-
Lower the
height-of-cut lever to the lowest position.
-
Connect the
mower deck to the machine.
For E-Series Machines:
-
On each side
of the machine, lift the rear of the mower deck and install the lift
arm to the deck pin.
-
Use the previously
removed washer and hairpin cotter to secure the arm on the pin.
-
Use the previously
removed hairpin cotter to secure the deck bracket to the front support rod.
For S-Series Machines:
-
Lift the
rear of the mower deck and attach the rear deck hangers to the rear
deck pins .
-
Attach the
front deck hangers to the front deck pins.
-
Use the previously
removed hairpin cotters and washers to secure the hangers on the
deck pins.
-
Use the previously
removed shoulder bolts and nuts to secure the rear of the deck
to the pivot pan.
-
Install the
mower belt onto the engine pulley.
-
Check the
level of the mower deck.
Replacing the Grass Deflector
|
Danger |
|
An uncovered discharge opening
allows objects to be thrown toward you or bystanders. Also, contact
with the blade could occur. Thrown objects
or blade contact will cause serious injury or death.
Do not operate
the mower with the discharge deflector raised, removed, or altered
unless a grass collection system or mulch
kit is in place and working properly.
-
Park the
machine on a level surface, disengage the blade-control switch, and
move the motion-control levers outward to the
Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Remove the
nut from the rod under the mower deck.
G451625
- Mower
deck
- Grass-deflector
pivot
- Grass
deflector
- Rod
- Spring
- Nut
-
Slide the
rod out.
-
Remove the
damaged or worn grass deflector.
-
Install the
new grass deflector.
-
Slide the
straight end of the rod through the rear grass deflector pivot.
-
Place the
spring on the rod, with end wires down, and between the grass deflector
brackets.
-
Slide the
rod through the second grass-deflector pivot.
-
Insert the
rod at the front of the grass deflector into the bracket on the deck.
-
Secure the
rear end of the rod into the mower with the nut.
The
grass deflector must be spring-loaded in the down position. Lift the
deflector up to test that it snaps into the full-down
position.
Cleaning
Washing the Underside of the Mower
Deck
You can wash the machine with
a 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.
Wash the underside of the mower
deck after each use to prevent grass buildup for improved mulch action
and clipping dispersal.
-
Park the
machine on a level surface, disengage the blade-control switch (PTO),
and move the motion-control levers outward
to the Park position.
-
Shut off
the engine, remove the key, and wait for all moving parts to stop
before leaving the operating position.
-
Attach a
hose to the hose coupling 
, then attach the hose coupling
to the end of the mower washout fitting and turn the water on high.
Note: Spread petroleum jelly on the washout fitting O-ring to make the coupling slide on
easier and protect the O-ring.
-
Sit on the
seat, lower the mower to the lowest height-of-cut, and start the engine.
-
Engage the
blade-control switch and let the mower run for 1 to 3 minutes.
-
Disengage
the blade-control switch, shut off the engine, remove the key, and
wait for all moving parts to stop.
-
Turn the
water off and remove the coupling from the washout fitting.
Note: If the mower is not clean after 1 washing, soak it and let it stand
for 30 minutes. Then repeat the process.
-
Run the mower
again for 1 to 3 minutes to remove excess water.
|
Warning |
|
A
broken or missing washout fitting could expose you and others to thrown
objects or blade contact. Contact with a blade or
thrown debris can cause injury or death.
- Replace broken or missing washout
fitting immediately, before using machine again.
- Never put your hands or feet under
the mower or through openings in the machine.
Disposing of Waste
Engine oil, batteries,
hydraulic fluid, and engine coolant are pollutants to the environment.
Dispose of these according to your state and
local regulations.
Troubleshooting
The fuel tank is showing signs
of collapsing or the machine is frequently showing signs of running
out of fuel.
| Possible Cause |
Corrective Action |
| The air-cleaner paper element
clogged. |
-
Clean the
paper element.
|
The engine overheats.
| Possible Cause |
Corrective Action |
| The engine load is excessive. |
-
Reduce the
ground speed.
|
| The oil level in the crankcase
is low. |
-
Add oil to
the crankcase.
|
| The cooling fins and air
passages under the engine-blower housing are plugged. |
-
Remove the
obstruction from the cooling fins and air passages.
|
| The air cleaner is dirty. |
-
Clean or
replace the air-cleaner element.
|
| Dirt, water, or stale fuel
is in the fuel system. |
-
Contact an
Authorized Service Dealer.
|
The starter does not crank.
| Possible Cause |
Corrective Action |
| The blade-control switch
is engaged. |
-
Disengage
the blade-control switch.
|
| The motion-control levers
are not in the park position. |
-
Move the
motion-control levers outward to the park position.
|
| The battery is dead. |
-
Charge the
battery.
|
| The electrical connections
are corroded or loose. |
-
Check the
electrical connections for good contact.
|
| A fuse is blown. |
-
Replace the
fuse.
|
| A relay or switch is damaged. |
-
Contact an
Authorized Service Dealer.
|
The engine does not start, starts
hard, or fails to keep running.
| Possible Cause |
Corrective Action |
| The fuel tank is empty. |
-
Fill the
fuel tank.
|
| The choke (if applicable)
is not on. |
-
Move the
choke lever to the on position.
|
| The air cleaner is dirty. |
-
Clean or
replace the air-cleaner element.
|
| The spark-plug wire(s)
is loose or disconnected. |
-
Install the
wire(s) on the spark plug.
|
| The spark plug(s) is pitted,
fouled, or the gap is incorrect.
|
-
Install a
new, correctly gapped spark plug(s).
|
| There is dirt in fuel filter. |
-
Replace the
fuel filter.
|
| Dirt, water, or stale fuel
is in fuel system. |
-
Contact an
Authorized Service Dealer.
|
| There is incorrect fuel
in the fuel tank. |
-
Drain the
tank and replace the fuel with the proper type.
|
| The oil level in the crankcase
is low. |
-
Add oil to
the crankcase.
|
The engine loses power.
| Possible Cause |
Corrective Action |
| The engine load is excessive. |
-
Reduce the
ground speed.
|
| The air cleaner is dirty. |
-
Clean the
air-cleaner element.
|
| The oil level in the crankcase
is low. |
-
Add oil to
the crankcase.
|
| The cooling fins and air
passages under the engine blower housing are plugged. |
-
Remove the
obstruction from the cooling fins and air passages.
|
| The spark plug(s) is pitted,
fouled, or the gap is incorrect.
|
-
Install a
new, correctly gapped spark plug(s).
|
| The fuel-tank vent is blocked. |
-
Contact an
Authorized Service Dealer.
|
| There is dirt in the fuel
filter. |
-
Replace the
fuel filter.
|
| Dirt, water, or stale fuel
is in the fuel system. |
-
Contact an
Authorized Service Dealer.
|
| There is incorrect fuel
in the fuel tank. |
-
Contact an
Authorized Service Dealer.
|
The machine does not drive.
| Possible Cause |
Corrective Action |
| The bypass valves are open. |
-
Close the
tow valves.
|
| The traction belts are
worn, loose, or broken. |
-
Contact an
Authorized Service Dealer.
|
| The traction belts are
off the pulleys. |
-
Contact an
Authorized Service Dealer.
|
| The transmission has failed. |
-
Contact an
Authorized Service Dealer.
|
The machine vibrates abnormally.
| Possible Cause |
Corrective Action |
| The cutting blade(s) is/are
bent or unbalanced. |
-
Install new
cutting blade(s).
|
| The blade mounting bolt
is loose. |
-
Tighten the
blade mounting bolt.
|
| The engine mounting bolts
are loose. |
-
Tighten the
engine mounting bolts.
|
| The engine pulley, idler
pulley, or blade pulley is loose.
|
-
Tighten the
appropriate pulley.
|
| The engine pulley is damaged. |
-
Contact an
Authorized Service Dealer.
|
| The blade spindle is bent. |
-
Contact an
Authorized Service Dealer.
|
| The motor mount is loose
or worn. |
-
Contact an
Authorized Service Dealer.
|
The cutting height is uneven.
| Possible Cause |
Corrective Action |
| The blade(s) is not sharp. |
-
Sharpen the
blade(s).
|
| A cutting blade(s) is/are
bent. |
-
Install a
new cutting blade(s).
|
| The mower is not level. |
-
Level the
mower from side-to-side and front-to-rear.
|
| An anti-scalp roller (if
applicable) is not set correctly.
|
-
Adjust the
anti-scalp wheel height.
|
| The underside of the mower
deck is dirty. |
-
Clean the
underside of the mower deck.
|
| The tire pressure is incorrect. |
-
Adjust the
tire pressure.
|
| A blade spindle is bent. |
-
Contact an
Authorized Service Dealer.
|
The blades do not rotate.
| Possible Cause |
Corrective Action |
| The drive belt is worn,
loose or broken. |
-
Install a
new drive belt.
|
| The drive belt is off of
the pulley. |
-
Install the
drive belt and check the adjusting shafts and belt guides for the
correct position.
|
| The power-takeoff (PTO)
switch or PTO clutch is faulty.
|
-
Contact an
Authorized Service Dealer.
|
| The mower belt is worn,
loose, or broken. |
-
Install a
new mower belt.
|
