Exmark TURF TRACER X SERIES LP User manual

TURFTRACER®
X-SERIESLP
ForSerialNos.
400,000,000&Higher
PartNo.4503-100Rev.A

WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemical
orchemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:ItisaviolationofCaliforniaPublic
ResourceCodeSection4442or4443touse
oroperatetheengineonanyforest-covered,
brush-covered,orgrass-coveredlandunlessthe
engineisequippedwithasparkarrester,as
denedinSection4442,maintainedineffective
workingorderortheengineisconstructed,
equipped,andmaintainedforthepreventionof
re.
Toacquireasparkarresterforyourunit,seeyour
EngineServiceDealer.
Thissparkignitionsystemcomplieswiththe
CanadianstandardICES-002.Cesystèmed’allumage
parètincelledevèhiculeestconformeàlanorme
NMB-002duCanada.
Pleaserefertotheenginemanufacturer’s
informationincludedwiththemachine.
Labeledpowerratingsaresuppliedbytheengine
manufacturerinaccordancewithSAEtesting
andgross/netpowerratingstandards(J1940,
J1995,J1349).
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2016ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE683102
Contactusatwww.Exmark.com.
PrintedintheUSA
AllRightsReserved

Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Important:Tomaximizesafety,performance,
andproperoperationofthismachine,itis
essentialthatalloperatorscarefullyreadand
fullyunderstandthecontentsoftheOperator’s
manualprovidedwiththeproduct.Safe
operationofExmarkequipmentisessential.
Failuretocomplywiththeoperatinginstructions
orreceivepropertrainingmayresultininjury.
Gotohttp://www.Exmark.comforadditional
safeoperationinformation,suchassafetytips,
trainingmaterials,andOperator’smanuals.
Ifadditionalinformationisneeded,orshould
yourequiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
g026566
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3

Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals......................11
Specications........................................................17
Systems..........................................................17
Dimensions....................................................18
TorqueRequirements.....................................18
ProductOverview.................................................19
Operation..............................................................20
Controls.........................................................20
Pre-Start.........................................................22
OperatingInstructions...................................22
Transporting..................................................26
Maintenance..........................................................27
RecommendedMaintenanceSchedule(s)............27
PeriodicMaintenance........................................28
CheckEngineOilLevel..................................28
CheckBatteryCharge.....................................28
CheckMowerBlades......................................30
CheckSafetyInterlockSystem........................31
CheckforLooseHardware.............................31
ServiceAirCleaner.........................................31
ChangeEngineOil.........................................31
CheckHydraulicOilLevel..............................32
CheckTirePressures......................................32
CheckConditionOfBelts...............................32
LubricateGreaseFittings................................32
LubricateCasterWheelHubs.........................33
RemoveEngineShroudsandClean
CoolingFins...............................................34
CheckSparkPlugs..........................................34
CheckLPGTank............................................34
CheckLPGFuelDeliverySystem...................34
CheckHighPressureLinesand
Fittings.......................................................34
DrainVaporizer/Regulator.............................34
CleanVaporizer/Regulator.............................34
RemoveCombustionDeposits.......................34
CheckFuelLockOffAssembly.......................34
ChangeEngineLPGFuelFilters.....................35
ChangeHydraulicSystemFilterand
Fluid..........................................................36
WheelHub-SlottedNutTorque
Specication...............................................37
ThreadLockingAdhesives..............................37
MobilHTSGrease(OrFood-Grade
Anti-seize)..................................................38
Copper-BasedAnti-seize...............................38
DielectricGrease............................................38
Adjustments......................................................38
DeckLeveling................................................38
PumpDriveBeltTension................................38
DeckBeltTension..........................................38
BladeDriveBeltTension...............................38
ParkBrakeAdjustment...................................38
HydroDriveLinkageAdjustment...................38
TrackingAdjustment......................................41
HydroPumpSpringTensionSetting...............41
ElectricClutchAdjustment.............................41
LPGRegulator..............................................41
Cleaning............................................................42
CleanEngineandExhaustSystem
Area...........................................................42
CleanDebrisFromMachine...........................42
CleanGrassBuild-UpUnderDeck.................42
WasteDisposal...............................................42
Troubleshooting....................................................43
Schematics............................................................46
4

Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents.
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
g000502
Figure2
SafetyAlertSymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Indicatesanimminentlyhazardous
situationwhich,ifnotavoided,Willresultindeathor
seriousinjury.
WARNING:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Couldresultindeath
orseriousinjury.
CAUTION:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Mayresultinminor
ormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
WhatisLPG?LPGstandsforliqueedpetroleum
gasandismorecommonlycalledpropane.LPGis
aliquidfuelthatisstoredinatankunderpressure.
Beforetheliquidleavesthetank,itisconvertedinto
avapor.SinceLPGisstoredasbothliquidandgas,
itmayleakfromjointsorconnectionsthatarenot
sealedproperly.LPGbecomesammablewhenitis
mixedwithair.
TheLPGinformationinthisOperator'smanual
isprovidedonlyasaguide.ConsulttheNFPA
58:LiqueedPetroleumGasCodeforadditional
safetyinformation.ThisNationalFireProtection
Association(NFPA)codepertainstothehandling,
storing,transporting,andusageofLPG.
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readthismanualitistheowner’sresponsibilityto
explainthismaterialtothem;otherlanguagesmay
beavailableonourwebsite.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
•Onlyadultsandmatureteenagersshouldoperate
amower,andevenmatureteenagersshouldhave
adultsupervision.Besureateenager:
1.hasreadandunderstandstheOperator's
Manualandrecognizestherisksinvolved;
2.issufcientlymaturetousecaution;and
3.isofsufcientsizeandweighttooperate
thecontrolscomfortablyandtomanagethe
mowerwithouttakingrisks.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
•Wearappropriateclothingincludingsafetyglasses,
substantialslip-resistantfootwear,andhearing
protection.Longhair,looseclothingorjewelry
maygettangledinmovingparts.
5

Safety
CAUTION
Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.
Wearhearingprotectionwhenoperatingthis
machine.
•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
DANGER
LPGfuelisextremelyammableandvapors
areexplosive.
AreorexplosionfromLPGfuelcanburn
you,others,andcausepropertydamage.
•Neversmokearoundtank(s)andstay
awayfromanopenameorwherefumes
maybeignitedbyaspark.
•Extinguishallsourcesofsparkorame
whenapproachingLPGtanksormowers.
Thehazardincreasesforenclosedtrailers
orstoragelocationswherevaporleakage
mayoccurandcollect.
•LPGisheavierthanairandmay
accumulateinlowlyingareas,suchas
ditches,drains,orpits.
•LPGtank(s)shouldbelledbytrained
andqualiedpersonnelONLY.
•Nevertamperwithorrepairthetank(s);
contacttrainedandqualiedpersonnel.
•DoNotchangethetank(s)whenthe
engineisrunning.
•Beforedisconnectingthehose(s),purge
allLPGvaporsfromthesystem,by
closingthefuelvalve(s)onALLtanksand
allowingtheenginetorununtilitstops.
•Storethetank(s)awayfromheat,sparks,
oropenames.
•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
DANGER
LPGfuelisextremelyammableandvapors
areexplosive.
•Incaseofretakethefollowingsteps:
1.Ifyoucansafelydoso,stoptheowof
gasasquicklyaspossible.Neverput
outameunlessgascanbeshutoff.
2.NotifytheFireDepartmentandclear
immediateareaofallpeople.
3.Whengasowisstopped,putoutthe
re.Usuallywhenowofgasiscutoff,
rewillautomaticallystop.
4.Ifgasowcannotbeimmediately
stopped,directwaterontankstokeep
themcool,butDoNotputoutre.
•Storagelocationsandtrailersshouldbe
equippedwithatleastoneapproved
portablereextinguisherhavinga
minimumcapacityof18lb(8.2kg)dry
chemicalwithaB:Crating.DoNot
useCarbonTetrachlorideextinguishers
(Pyreneetc.).
DANGER
LPGvaporsandliquidescapingfromthetank
maycauseseriousinjuryordeath.Vapors
orliquidmaycausesuffocation,freezingof
tissue,orfrostbite.
•Storeandservicethemowerinawell
ventilatedarea.
•AnapprovedLPGdetectorinstalledin
trailersandstorageareasisrecommended.
•LPGisheavierthanairandmay
accumulateinlowlyingareas,suchas
ditches,drains,orpits.
•Avoidbreathingofvapors.
•Keepawayfromventvalve.
•Keepawayfromeyesandskin.
•Contacttrainedandqualiedpersonnelif
tankshowssignsoffrostedareas,makesa
hissingsound,oremitsafoulodor.
•Obtainimmediatemedicalattentionif
contactoccurswithvaporsorliquid.
•Checkthattheoperatorpresencecontrols,
safetyswitches,andshieldsareattachedand
6

Safety
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
Inspection
ItisveryimportanttochecktheLPGtankand
componentsforwearorleaks.
Important:Nevercheckforleaksusinganopen
ame.
Important:Neverusebarehandswhen
checkingthettingorvalve.EscapingLPG
vaporandliquidfreezesskinoncontact.
Important:Onlyhandtightentankconnection
tting.Overtighteningbytheuseoftoolsmay
causedamage.Ifhandtighteningdoesnotstop
aleak,contacttrainedandqualiedpersonnel
immediately.
•Beforeeachuse:
–Visuallyinspectthetank,hose,andttingand
bealerttoafoulodorcomingfromthetank.
–TheLPGtankshouldbefreeofdentsor
damage.Ifthetankshowsignsofdentsor
damage,replaceitimmediately.
–Checkthevalveandttingopeningsfordirt
anddebris.
–Slowlyopenthevalveallthewayandlisten
foracontinuoushissfromtheregulator,it
mayindicatealeak.
–LPGhasarotteneggorskunksmelladded
toittohelpdetectagasleak.Ifyoudetect
agasleak:
◊TurnofftheLPGvalveifyoucansafely
doso.
◊Leavethearea.
◊Contacttrainedandqualiedpersonnel
immediately.
–DoNotuseifthehosesareabraded,damaged,
kinked,orattened.
–Makesurethetankissecurelymountedto
themower.Ifthetankisloose,thehoseor
ttingsmayleak.
•Witheachtankchange:
–Checkallgauges,ttings,andvalvesfor
damage.
–Lookfordeterioration,damagedormissing
o-ringsontankconnectiontting.
–InspecttheLPGtankandthefuelconnection
jointforleaks.Usethefollowingprocedure
belowtodetectleaks:
◊Applyanapprovedleakdetectorsolution,
obtainedfromatrainedandqualiedLPG
distributor,orathicknon-ammoniasoapy
watersolution(50%non-ammoniasoap
and50%water).(Aleakdetectorsolution
thatcontainsammoniawillcausethe
ttingstocorrodeandleak.)
◊Usingasmallbrushorspraybottle,apply
thesolutionaroundallthettingsofthe
LPGtankandthefuelconnectionjoint.
◊Slowlyopenthegasvalveahalf-turn.
◊Ifbubblesaredetected,thejointortting
hasaleak.Shutoffthevalve,tighten
theleakingconnection,andslowlyopen
thevalveagain.Ifbubblesstillappear,
DoNotusethetank.Ifitissafetodo
so,removethetankfromyourmower;
otherwise,contacttrainedandqualied
personnelimmediately.
◊Ifnobubblesaredetected,theLPGtank
maybeused.
•Weekly:
–ChecktheentireLPGfueldeliverysystemfor
damageordeterioration.
–ChecktheentireLPGfueldeliverysystemfor
leaksatalljointsusingthesamemethodas
describedintheprevioussection.
–Followalltheinspectionchecksasspeciedin
thetwopreviousinspectionsections.
•TankRequalication:
–USDOT(UnitedStatesDepartmentof
Transportation)regulationsrequireLPGtanks
tobeinspected,requalied,andmarkedwithin
12yearsofthemanufacturedateandona
regularbasisthereafter.Typicallythisoccurs
whenthetankisrelled;contactatrainedand
qualiedLPGtankproviderformoredetails.
–DoNotlltheLPGtankifitisbeyondthe
requalicationperiod.
–DoNotlldamagedorrustedLPGtanks.
7

Safety
Operation
WARNING
Operatingengineparts,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,to
coolbeforetouching.
•Removeaccumulateddebrisfrommuferand
enginearea.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcankill
you.
DoNotrunengineindoorsorinasmallconned
areawheredangerouscarbonmonoxidefumes
cancollect.
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,
DoNotoperatethemachine;seekshelter.
•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.
•Neverraisedeckwithbladesrunning.
•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.
•DoNotchangetheenginegovernorsettingor
overspeedtheengine.
•Parkmachineonlevelground.Stopengine,wait
forallmovingpartstostop,removekeyand
engageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:
–Beforechangingtanks.
–Beforedumpingthegrasscatcher.
–Beforemakingheightadjustments.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesinplace
andworkingproperly.
•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
•DONOToperatethemowerwhenpeople,
especiallychildren,orpetsareinthearea.
•Bealert,slowdownandusecautionwhen
makingturns.Lookbehindandtothesidebefore
changingdirections.
•Stoptheblades,slowdown,andusecaution
whencrossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
8

Safety
DANGER
Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Lossofcontrol
and/orlossofoperator'sfootingcouldresultina
fallwithanarmorleggettingunderthemachine
orenginedeckwhichmayresultinseriousinjury,
deathordrowning.
•Operateacrossslopes,neverupanddown.
•DoNotoperateonslopeswhengrassiswet.
•Useextremecautionwhenoperatingnear
drop-offsornearwater.
•DoNotoperateonslopesgreaterthan20
degrees.
•Reducespeedanduseextremecautionon
slopes.
•Avoidsuddenturnsorrapidspeedchanges.
•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.
•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.
•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.
MaintenanceandStorage
•Disengagedrives,setparkingbrake,stopengine
andremovekeyordisconnectsparkplugwire.
Waitforallmovementtostopbeforeadjusting,
cleaningorrepairing.
•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.
•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
•Storemowerinawellventilatedoutdoorshelter,
building,ortrailer.
•Closefuelvalvewhenmowerisnotinuse,
includingwhilestoringortransporting.
•Theemptytank(s)shouldbetreatedasifitwas
full.
•Storethetank(s)outsideofbuildingsinanopen
wellventilatedarea,awayfromsparkandames.
•DoNotstorethetank(s)ormachinewith
tank(s)inanareawherethetemperaturecanrise
above120°F(49°C).Ifthetemperatureexceeds
approximately160°F(71°C),thetankwillrelease
highlyammablepropanevapor.SeePreparation
intheSafetySection.
•Storethetank(s)inuprightpositionorwith
pressurereliefvalvetowardsthetop.
•DoNotdrag,drop,orabusethetank(s).
•Storageoftheemptytank(s)shouldfollowlocal
andstateregulations.
•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.
•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
9

Safety
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
DANGER
Chargingorjumpstartingthebatterymay
produceexplosivegases.Batterygasescan
explodecausingseriousinjury.
•Keepsparks,ames,orcigarettesaway
frombattery.
•Ventilatewhenchargingorusingbattery
inanenclosedspace.
•Makesureventingpathofbatteryis
alwaysopenoncebatteryislledwith
acid.
•Alwaysshieldeyesandfacefrombattery.
DANGER
Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.
•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.
•DoNotswallowelectrolyte.
•Intheeventofanaccident,ushwith
waterandcalladoctorimmediately.
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagementof
components.Sparkscouldcauseanexplosion
ormovingpartscouldaccidentallyengage
causingpersonalinjury.
Besureignitionswitchisinthe“OFF”
positionbeforechargingthebattery.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
WARNING
Removalormodicationoforiginalequipment,
partsand/oraccessoriesmayalterthewarranty,
controllability,andsafetyofthemachine.
Unauthorizedmodicationstotheoriginal
equipmentorfailuretouseoriginalExmark
partscouldleadtoseriousinjuryordeath.
Unauthorizedchangestothemachine,engine,
fuelorventingsystem,mayviolateapplicable
safetystandardssuchas:ANSI,OSHAand
NFPAand/orgovernmentregulationssuchas
EPAandCARB.
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbyadoctor
familiarwiththisformofinjuryorgangrenemay
result.
•Ifequipped,makesureallhydraulicuid
hosesandlinesareingoodconditionandall
hydraulicconnectionsandttingsaretight
beforeapplyingpressuretohydraulicsystem.
•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpaper,notyourhands,to
ndhydraulicleaks.
•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrollevers
inneutralandshuttingofftheenginebefore
performinganyworkonthehydraulicsystem.
WARNING
Fuelsystemcomponentsareunderhigh
pressure.Theuseofimpropercomponentscan
resultinsystemfailure,fuelleakageandpossible
explosion.
Useonlyapprovedfuellinesandfuelltersfor
highpressuresystems.
10

Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
decal98-1977
98-1977
1.Entanglementhazard,belt—stayawayfrommoving
parts.
decal103-2242
103–2242
decal103-2243
103–2243
decal106-5517
106-5517
1.Warning—donottouchthehotsurface.
11

Safety
decal112-8760
112-8760
1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.
2.Cutting/dismembermentofhandorfoot—stayaway
frommovingparts.
decal112-9028
112-9028
1.Warning—stayawayfrommovingparts;keepallguards
inplace.
decal114-3489
114-3489
1.Thrownobjecthazard;cutting/dismemberment
hazard—donotoperatethemachinewiththedischarge
openinguncovered;alwaysoperatethemachinewith
thereardischargedeector,dischargecoverorgrass
collectorinstalled.
decal115-4212
115-4212
1.Hydraulicoillevel3.Warning—donottouch
thehotsurface.
2.ReadtheOperator's
Manual.
decal116-5988
116-5988
1.Parkingbrake—engaged2.Parking
brake—disengaged
decal116-7912
116-7912
1.Interval4.Neutral
2.PowerT ake-off(PTO)5.Operatorpresence
control
3.Parkingbrake6.Battery
12

Safety
decal116-7918
116-7918
1.Readtheinstructions
beforeservicingor
performingmaintenance.
2.Turnknobtoadjust
tracking.
decal116-8253
116-8253
1.Rotatecounterclockwise
torelease.
3.Unlocktopushmachine.
2.Rotateclockwisetolock.4.Readtheinstructions
beforeservicingor
performingmaintenance.
decal116-8278
116-8278
1.ReadtheOperator'sManual.
2.Removetheignitionkeyandreadtheinstructionsbefore
servicingorperformingmaintenance.
3.Heightofcut
decal116-8283
116-8283
1.Warning—readtheOperator'sManualforinstructions
ontorquingthebladebolt/nutto55-60ft-lb(75-81N-m).
decal116-8727
116-8727
decal117-2718
117–2718
13

Safety
decal126-0898
126-0898
1.ReadtheOperator’smanual
2.3/8-16x33/4inchbolt.BoltmustbeGrade8.Boltand
springdiscwashermustbeinstalledasshown.
3.Nylocnut-torqueto50-55ft-lb(68-75N-m)
4.Roller
5.Bushing
6.Mountbracket
7.Springdiscwasher
decal126-1400
126-1400
1.Warning-ReadtheOperator’smanual.UseonlyExmark
ridingattachments.Useofotherridingattachmentsmay
createahazardousconditionresultingininjury.
decal126-2056
126-2056
1.Wheellugnuttorque95ft-lb(129N-m)(4x)
2.Wheelhubnuttorque125ft-lb(169N-m)
3.ReadandunderstandtheOperator’smanualbefore
performinganymaintenance,checktorqueafterrst
100hoursthenevery500hoursthereafter.
decal126-3275
126-3275
1.Danger-LPGfuelisextremelyammableandvapors
areexplosive.
2.ReadtheOperator’smanual.ConsultNFPA58:
LiqueedPetroleumGasCodeforadditionalsafety
information.
3.DoNOTsmokeorreplacetank(s)aroundsourcesof
fuelignition.
4.DoNOTattempttorepairormodifythetankorits
components.Contacttrainedandqualiedperson.
ONLYuseLPGSystemManufacturerapprovedLPG
tank(s),ttings,andhosesthatweredesignedforthe
unit.
5.Closefuelvalvewhenmowerisnotinuse,instorage,
ortransporting.
6.AvoidcontactwithLPGfuel.Escapingvaporsand
liquidsfreezesskinoncontact.
decalptosymbols
PTOSwitchSymbols
1.PTO–disengage2.PTO–engage
14

Safety
decal126-3276
126-3276
decal126-3277
126-3277
1.IMPORTANT :Onlyusereplacementtank(s)thatarefree
ofdentsordamage.Matchsizeandtyperequiredontank
specicationdecal.
7.Removeemptytank(s).Checkvalveandttingsfordebris
ordamagedo-rings.
2.Stopthemachineonalevelsurface,disengagePTO,and
engageparkingbrake.
8.Installfullreplacementtank(s)byaligningcenterholeon
tankcollarovermountingtab.
3.Closethefuelvalve(s)onALLtanksbyrotatingclockwise,
continuetorunengine.
9.Latchbracket(s)andensuretank(s)issecurelyfastened
tomower.
4.Whentheenginestops,removekey.10.Re-connectfuelhose(s).
5.DisconnectLPGfuelhose(s).11.Slowlyopenfuelvalve(s)counterclockwisetoequalize
pressure.Checkforleaks.
6.Unlatchcylinderbracket(s).
15

Safety
decal126-3315
126-3315
1.Engine–off7.Thrownobjecthazard-Pickupobjectsthatcouldbethrown
bymower.DoNotoperatewhenpeopleandpetsarein
thearea.Keepdeectorinplace.
2.Engine–on8.Warning-DisengagePTO,shiftspeedcontroltoneutral,
andengageparkingbrakebeforeleavingtheoperator’s
position.
3.Engine–start9.Cutting/dismembermenthazard-DoNotoperateonslopes
greaterthan20degrees.DoNotmowwetslopes–use
extremecautionwhenoperatingonslopes;mowacross
slopesnotupanddown.
4.Warning-ReadtheOperator’sManual.DoNotoperatethis
machineunlessyouaretrained.Wearhearingprotection.
10.Throttle-slow
5.Warning-Stayawayfrommovingparts;keepallguards
inplace.Stopengineandremovekeybeforeadjusting,
servicing,orcleaning.
11.Throttle-fast
6.Neutral12.Enginefailure/malfunction
16

Specications
Specications
Systems
Engine
•EngineSpecications:SeeyourEngineOwner’s
Manual
•EngineOilType:Exmark4–CyclePremium
EngineOil
•RPM:FullSpeed:3600(NoLoad)
Idle:1550RPM
TankTypeandRelling
Important:TheLPGtankusedonthismower
isaspecialtankwithinternalbafesdesigned
forthisapplication.
•HorizontalTankSpecications:
–TankMaterial:Aluminum
–Capacity:33.5lb
–DisconnectCoupling:LHACMEThreaded
–FuelWithdrawal:Vapor
–FuelShut-OffValve:Rotateclockwiseto
close.
•TypeofFuel:HD5gradepropane
•Newtanksmustbeproperlylledbytrainedand
qualiedpersonnel.
•OnlyusetanksrecommendedbyExmark.Failure
todosowillresultinimproperoperationofthe
fuelsystem.
CAUTION
Undernocircumstancesshouldpropane
tankslledbeyond80%capacitybeusedin
service.
Theuseofoverlledtanksmayresultinthe
releaseofhighlyconcentratedandextremely
ammableliquidpropane.RefertotheSafety
section.
Note:Useofa“forklift”typeliquidwithdrawaltank
willresultinicingorfreezingoftheLPGregulator
andpreventtheenginefromoperating.Thismay
alsoresultinpermanentfuelsystemdamageandthe
releaseofhighlyammablepropaneliquidorvapor.
ElectricalSystem
•ChargingSystem:FlywheelAlternator
•ChargingCapacity:20amps
•BatteryType:BCIGroupU1235amps0°F
•BatteryVoltage:12Volt
•Polarity:NegativeGround
•Fuses:Twobladetype,20amptochargingcircuit;
20amptoelectricclutch
SafetyInterlockSystem:
•OperatormusthaveOPC(OperatorPresence
Control)leversheldincontactwithhandle
grips,speedcontrolleverinneutral,andPTO
disengagedtostartengine.ReleaseofOPClevers
willcausetheenginetostopifspeedcontrollever
isnotinneutraland/orPTOisengaged.
•Parkbrakemustbedisengagedtomovespeed
controloutofneutralorenginewillkill.
OperatorControls
SteeringControl:Fingertipdrivecontrollevers
provideindependentspeedcontrol,brakingand
neutraltoeachdrivewheelformovingforwardor
reverse,stopping,andpowerturning.
Transmission
•TwoHydroGearvariabledisplacementpiston
pumpsindependentlycoupledtotwohigh
efciencyParkerwheeldrivemotors.
•HydraulicOil:UseExmarkPremiumHydroOil.
•HydraulicOilCapacity:2.4qt.(2.2L)
•HydraulicFilterisreplaceablecartridgetype.
P/N109–4180:25microns,10psibypass
(Summeruseabove32°F(0°C))
P/N1–523541:40microns,18psibypass(Winter
usebelow32°F(0°C))
•Speeds:
–0-6.75mph(10.9km/hr)forward.
–0-2.25mph(3.6km/hr)reverse.
•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
WheelDriveSystem
DrivewheelsaredirectcoupledtoParkerwheeldrive
motorswith1inch(25.4mm)taperedshaft.
17

Specications
Tires&Wheels
DriveFrontCaster
Pneumatic
(Air-Filled)
Semi-
Pneumatic
Quantity22
TreadTurfMasterSmooth
Size18x8.50-811x4.00-5
PlyRating4
Pressure14psi(96kPa)
CuttingDeck
•ModelNumbers:
–FMD524
–FMD604
•CuttingWidth:
–52inch(132.1cm)
–60inch(152.4cm)
•Discharge:Side
•BladeSize:(3ea.)
–52inchDeck:18.00inches(45.7cm)
–60inchDeck:20.50inches(52.1cm)
•BladeSpindles:Solidsteelspindleswith1inch
(25.4mm)I.D.bearings.
•DeckDrive:
–Electricclutchmountedonengineshaft.
–Bladesdrivenbytwobelts(w/self-tensioning
idlers).
•Deck:
Fulloatingdeckisattachedtoout-frontsupport
frame,removableforservice.Anti-scalprollers
providemaximumturfprotection.Deckdesign
allowsforbagging,mulchingorsidedischarge.
•DeckDepth:
–52inchDeck:5.5inches(14.0cm)
–60inchDeck:5.5inches(14.0cm)
•CuttingHeightAdjustment:
Adjustsfrom11/2inches(3.8cm)to41/2
inches(11.4cm)in1/2inch(1.3cm)increments.
•MulchingKit:Optional
•Bagger:Optional
Dimensions
OverallWidth:
52inchDeck60inchDeck
DeectorUp53.4inches
(135.6cm)
61.4inches
(156.0cm)
DeectorDown64.0inches
(162.6cm)
72.0inches
(183.0cm)
OverallLength:
52inchDeck60inchDeck
85.4inches(217.0cm)85.4inches(217.0cm)
OverallHeight:
52inchDeck60inchDeck
45inches(114.3cm)45inches(114.3cm)
TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)
52inchDeck60inchDeck
45.8inches(116.3cm)45.8inches(116.3cm)
WheelBase:(CenterofCasterTireto
CenterofDriveTire)
52inchDeck60inchDeck
43.3inches(110.0cm)43.3inches(110.0cm)
CurbWeight:
52inchDeck60inchDeck
740lb(336kg)780lb(354kg)
TorqueRequirements
BoltLocationTorque
CutterHousingSpindle
Nut
140–145ft-lb(190–197
N-m)
BladeMountingBolt
(lubricatewithanti-seize)
55-60ft-lb(75-81N-m)
EngineDeck/Mower
DeckSupportMount
Bolts
30-35ft-lb(41-47N-m)
18

ProductOverview
BoltLocationTorque
Anti-ScalpRollerNyloc
Nut(SeeFigure9)
50-55ft-lb(68-75N-m
EngineMountingBolts15-20ft-lb(20-27N-m)
WheelLugNuts85-105ft-lb(115-142
N-m)
WheelHubSlottedNuts140-155ft-lb(190-210
N-m)
ClutchRetaining
Bolt(securedwith
threadlocker)
55-60ft-lb(75-81N-m)
WheelMotorMounting
Bolts
30-35ft-lb(41-47N-m)
MuferGuardMounting
Bolts
30-35ft-lb(41-47N-m)
ProductOverview
g031252
Figure3
1.Controls3.ParkBrakeLever
2.LPGFuelT ank4.Height-of-CutPins
19

Operation
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
OperatorPresenceControl(OPC)
Levers
Locatedontheupperhandleassemblydirectlyabove
thehandlegrips.
Whentheseleversaredepressed,theOPCsystem
sensesthattheoperatorisinthenormaloperator's
position.Whentheleversarereleased,theOPC
systemsensesthattheoperatorhasmovedfromthe
normaloperatingpositionandwillkilltheengineif
eitherthespeedcontrolleverisnotintheneutral
positionorthePTOisengaged(seeFigure4).
g006189
Figure4
1.OPCLever3.NeutralLockLatch
2.Rotateneutrallocklatch
downwardforneutral
lockposition
4.DriveLeverinneutral
position
DriveLevers
Locatedoneachsideoftheupperhandleassembly
aheadofandbelowthehandlegrips.
Theseleversindividuallycontrolthespeedand
directionofeachdrivewheel.Whenthespeedcontrol
leverismovedoutoftheneutralpositionandthe
neutrallocklatchesaremovedintothedriveposition,
asshowninFigure4,andthedriveleversarereleased,
thedrivewheelsareengagedintheforwarddirection.
Squeezingthelefthandand/orrighthandlever
causesthelefthandand/orrighthanddrivewheel
respectivelytoslowdown,stop,orreverse,depending
onhowfareachdriveleveris“squeezed”.Squeezing
thedriveleversbeyondtheneutralpositioncauses
thedrivewheelstoengageinthereversedirection
regardlessofthepositionoftheneutrallocklatches
andthespeedcontrollever.
NeutralLockLatches
Locatedontheupperhandleassemblyontheends
ofthehandlegrips.
Theselatchesallowtheoperatortolockthedrive
leversina“neutral”positionwherethedrivewheels
arenotengagedineitheraforwardorreverse
direction.
ThrottleControl
Locatedonthecontrolconsole’srightside.
Thethrottleisusedtocontrolenginespeed.Moving
thethrottlecontrolforwardwillincreaseenginespeed
andmovingittotherearwilldecreaseenginespeed.
Movingthethrottleforwardintothedetentisfull
position.
SpeedControlLever
Locatedinmiddleofcontrolconsole.
Thespeedcontrollevercontrolsthemaximum
forwardspeedandisinnitelyvariablefromneutral
0–6.75mph(10.9km/hr).
Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.
BrakeLever
Locatedontheleftsideoftheunit.
Thebrakeleverengagestheparkbrakeonthedrive
wheels.
Pulltheleverupandrearwardtoengagethebrake.
Pushtheleverforwardanddowntodisengagethe
brake.
Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
20