Page 2 - IMPORTANT
WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in p...
Page 4 - CONGRATULATIONS; on the purchase of your Exmark Mower. This product has been; BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS
- ii - CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety in...
Page 5 - TABLE OF CONTENTS; ASSEMBLY INSTRUCTIONS
- iii - TABLE OF CONTENTS 1. SAFETY .............................................................................................PAGE 1.1 Safety Alert Symbol ...................................................................................... 1 1.2 Training ...........................................
Page 6 - CAUTION
- 1 - 1. SAFETY 1.1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents. This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol appears above ...
Page 7 - DO NOT
- 2 - 1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, ...
Page 10 - DANGER; EXTREME
- 5 - DANGER POTENTIAL HAZARD ♦ Mowing on wet grass or steep slopes can cause sliding and loss of control. WHAT CAN HAPPEN ♦ Loss of control and/or loss of operator’s footing could result in a fall with an arm or leg getting under the mower or engine deck, which may result in serious injury or death...
Page 11 - midway; Do NOT; MAINTENANCE AND STORAGE
- 6 - 1.4.13 Stop the engine and wait for all moving parts to stop: • Before removing grass catcher. • Before refueling. • Before making height adjustments. 1.4.14 Before stopping the engine, place the throttle control midway between the “slow” and “fast” positions. Allow the engine to run a minimum...
Page 12 - WARNING; RIDING ATTACHMENTS; Exmark
- 7 - 1.5.7 Gasoline powered equipment or fuel containers should not be stored in a basement or any enclosed area where open pilot lights or heat appliances are present. 1.5.8 Maximum mowing results and safety can only be achieved if the mower is properly maintainedand operated correctly. 1.5.9 Chec...
Page 14 - Front RH Side of Mower Deck
- 9 - PART NO. 1-403143 LOCATION: RH Rear Surface of Engine Deck PART NO. 1-513747 LOCATION: Top Rear of Battery Cover PART NO. 1-553049 LOCATION: On Top Front LH Surface of Mower Deck PART NO. 103-4935 LOCATION: Left Rear Top Corner of Engine Deck PART NO. 1-413214 LOCATION: Right Side of Hydro Con...
Page 15 - ENGINE; unleaded
- 10 - 2. SPECIFICATIONS 2.1 MODEL NUMBER: TT23KCC; TT23KAC; TT20KCC 2.2 ENGINE 2.2.1 Engine Specifications: See your Engine Owner's Manual. 2.2.2 3600 RPM (No Load). 2.3 FUEL SYSTEM 2.3.1 Capacity: 5.0 gal. (18.9 L.) 2.3.2 Type of Fuel: Regular unleaded gasoline, 87 octane or higher. In countries u...
Page 16 - TIRES; Discharge chute down; TORQUE REQUIREMENTS
- 11 - 2.8 TIRES Drive Front Caster Size .......................... 18 x 8.50-8 ..........................11 x 4.0-5 Quantity ............................ 2 ........................................ 2 Tread ........................ Turf Master ........................... Smooth Ply Rating ..............
Page 17 - ASSEMBLY INSTRUCTIONS; The machine is shipped with a filled lead-acid battery.; Wash
- 12 - 3. ASSEMBLY INSTRUCTIONS 3.1 UNCRATE UNIT 3.1.1 Remove tractor and mower deck from crates. 3.2 SERVICE BATTERY: The machine is shipped with a filled lead-acid battery. 3.2.1 Remove battery cover from machine. DANGER POTENTIAL HAZARD ♦ Charging the battery may produce explosive gasses WHAT CAN...
Page 18 - cable first; MOWER DECK INSTALLATION
- 13 - NOTE: If the positive cable is also disconnected, connect the positive (red) cable first , then the negative (black) cable. Slip insulator boot over the positive terminal. NOTE: If time does not permit charging the battery, or if charging equipment is not available, connect the negative batte...
Page 19 - Mower Deck Stationary Idler Installation:; FIGURE 2; Carefully; SERVICE HYDRAULIC OIL
- 14 - FIGURE 1 SUPPORT PIN LOCATION 3.5.5 Mower Deck Stationary Idler Installation: Locate the two holes along the back center section of the deck and install the stationary idler and related parts (from bolt bag) in the right hand hole. See Figure 2. Be sure the coned end of the disc spring washer...
Page 20 - NOTE: UNIT IS NOT GREASED AT THE FACTORY.; FAMILIARIZE YOURSELF WITH THE CONTROLS.; See Maintenance and Adjustment Section 5.; OPERATION INSTRUCTIONS; When these levers
- 15 - 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 tempe...
Page 22 - Do Not; OPERATING INSTRUCTIONS; PTO
- 17 - 4.1.11 Drive Wheel Release Valves: Located on the left rear corner of the hydrostatic pumps. Drive wheel release valves are used to release the hydro-static 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 counter-c...
Page 23 - FIGURE 4
- 18 - 4.3.2 Stopping Engine: Lock drive levers in neutral, disengage PTO, move speed control lever to neutral, and engage park brake. Move throttle to the “midway” position. Allow engine to run a minimum of 15 seconds. Rotate ignition switch to “Off” position. Remove key to prevent children or othe...
Page 24 - For straight ahead motion: S; pulled out
- 19 - 4.3.4 Drive Wheel Engagement/Turning: With drive levers locked in “neutral”, shift speed control lever to desired forward speed. 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. DO NO...
Page 26 - PERIODIC MAINTENANCE; See Engine Owner's Manual; operate the engine with oil level below the “LOW”; Service Interval: Daily
- 21 - 5.1 PERIODIC MAINTENANCE 5.1.1 Check engine oil level. Service Interval: See Engine Owner's Manual a) Stop engine, wait for all moving parts to stop and make sure unit is on a level surface. b) Check with engine cool. c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert t...
Page 27 - FIGURE 5
- 22 - 5.1.4 Check mower blades. Service Interval: Daily a) Stop engine, wait for all moving parts to stop, and remove key. b) Lift deck and secure in raised position as stated in Section 5.1.3. c) Inspect blades and sharpen or replace as required. For Serial Nos. 510,000 – 539,999: d) Re-install th...
Page 28 - Daily
- 23 - FIGURE 6 BLADE BOLT INSTALLATION IMPORTANT: DO NOT use components other than the original blade, blade bushing, spring disc washer, and blade bolt supplied with the unit. Failure to use all original components and assembled as shown will increase the risk of a blade bolt becoming loose or wea...
Page 29 - more often under severe conditions.
- 24 - c) If machine does not pass any of these tests, DO NOT operate. Contact your authorized EXMARK SERVICE DEALER. IMPORTANT: It is essential that all Operator Safety Mechanisms, be in place and in proper operating condition prior to mowing. 5.1.6 Check for loose hardware. Service Interval: Daily...
Page 30 - Do not overtighten; After First 250 hrs, then yearly thereafter.
- 25 - Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater. IMPORTANT: Make sure the negative battery cables a...
Page 31 - FIGURE 7; Make sure engine is not running.
- 26 - f) Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground. Run machine to allow any other air to be purged from the hydraulic system and recheck the oil level. g) If either drive wheel does not rotate, one or both of the charge pumps (located...
Page 32 - Note: Front caster tires have permanent tire sealant installed.; LUBRICATION CHART
- 27 - f) If either drive wheel still does not rotate, stop and repeat steps (d) and (e) above for the respective pump. If wheels rotate slowly, the system may prime after additional running. Check oil level as stated in Section 5.1.10. g) Allow unit to run several minutes after the charge pumps are...
Page 33 - Service Interval: Once Yearly; NOTE
- 28 - c) Lubricate front caster pivots once a year. Remove hex plug and cap. Thread grease zerk in hole and pump with grease until it oozes out around top bearing. Remove grease zerk and thread plug back in. Place cap back on. 5.1.16 Lubricate caster wheel hubs: Service Interval: Once Yearly a) Sto...
Page 34 - not; to bond the bearing, next to each OPC
- 29 - b) Remove cooling shroud cleanout covers (Kohler) or cooling shrouds (Kawasaki) from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine which can cause improper cooling. c) Make sure cooling shroud cleanout covers or cooling shrouds are properly rei...
Page 35 - FIGURE 9
- 30 - 5.2 ADJUSTMENTS IMPORTANT: Disengage PTO, shut off engine, wait for all moving parts to stop, and remove key before servicing, cleaning, or making adjustments to the unit. 5.2.1 Cutting height and anti-scalp roller adjustment. CAUTION POTENTIAL HAZARD ♦ When mower deck is not installed or the...
Page 37 - NEUTRAL SAFETY SWITCH ADJUSTMENT; b) Adjust Neutral Control Linkages; HYDRO DRIVE LINKAGE ADJUSTMENT
- 32 - FIGURE 11 NEUTRAL SAFETY SWITCH ADJUSTMENT b) 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 lat...
Page 38 - Note: The neutral lock latches should still be “unlocked” and in the; left; neutral
- 33 - 7. After adjustments are made and the wheels stop when the drive lever is in the neutral position, tighten the nut against the yokes. c) Adjust Hydro Control Linkage: 1. Place the speed control lever in the “neutral” position. This adjustment is again made with rear of machine on jack stands ...
Page 40 - THROTTLE TENSION; MOTOR OIL DISPOSAL
- 35 - FIGURE 16 THROTTLE TENSION 5.2.8 Electric Clutch Adjustment No adjustment necessary. 5.2.9 Park Brake Adjustment: a) Shut off engine and wait for all moving parts to stop. b) Disengage the park brake. c) Remove the hairpin in the park brake linkage. Turn the linkage in the yoke until there is...
Page 41 - ENGINE TROUBLESHOOTING
- 36 - 7.2 MOWER CUTS UNEVENLY. a) Check the drive tire pressures and tire circumferences. See 5.1.13. A more uniform cutting height may be obtained with higher tire pressure on rough terrain. A lower tire pressure provides more flotation. b) Check deck support pins. Hairpin clips must be in the sam...
Page 42 - ENGINE TROUBLESHOOTING TABLE
- 37 - ENGINE TROUBLESHOOTING TABLE PROBLEM NO FUEL IMPROPER FUEL DIRT IN FUEL LINE DIRTY AIR FILTER FAULTY SPARK PLUG ENGINE OVERLOADED BLOCKED FUEL FILTER INCORRECT OIL LEVEL DIRTY AIR SCREEN Will not start X X X X X X Hard starting X X X X X X X Stops suddenly X X X X X X X Lacks power X X X X X ...
Page 43 - HYDRAULIC SCHEMATIC
Page 46 - SERVICE RECORD; Date
- 40 - SERVICE RECORD Date Description of Work Done Service Done By
Page 47 - IS
- 41 - T H IS IS A 1 5 ° S L O P E T H IS IS A 1 0 ° S L O P E T H IS IS A 5 ° S L O P E ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) EXAMPL E : CO MP A R E SLOPE W ITH FOLDED EDGE. FOLD AL ONG APP R OPRI A T E L INE T HI S IS A 2 0 ° S L O P E
Page 48 - RIDING ACCESSORIES; INDUSTRIAL PARK BOX 808; Check us out on the Web:
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