Exmark 0 Lawn Mower User Manual

NAVIGATOR
®
For Serial Nos.
850,000 & Higher
Part No. 4500-628 Rev. B
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
Important: The engine in this product is not
equipped with a spark arrester muffler. It is a
violation of California Public Resource Code
(CPRC) Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126.
Other states or federal areas may have similar
laws.
This spark ignition system complies with Canadian
ICES-002 Ce système d’allumage par ètincelle de
vèhicule est conforme à la norme NMB-002 du
Canada
The enclosed Engine Owner’s Manual is
supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and
the California Emission Control Regulation of
emission systems, maintenance and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become
damaged or illegible, replace immediately.
Replacements may be ordered through the
engine manufacturer.
Exmark reserves the right to make changes or
add improvements to its products at any time
without incurring any obligation to make such
changes to products manufactured previously.
Exmark, or its distributors and dealers, accept
no responsibility for variations which may be
evident in the actual specifications of its products
and the statements and descriptions contained
in this publication.
© 2010—Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
2
Contact us at www.Exmark.com.
Printed in the USA
All Rights Reserved
Introduction
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.
This manual contains operating, maintenance,
adjustment, and safety instructions for your Exmark
mower.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
Figure 1
1. Model and serial number location
If additional information is needed, or should you
require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
Exmark parts manuals are available online at
http://www.exmark.com/manuals.htm.
Model No.
Serial No.
All Exmark equipment dealers and distributors are
kept informed of the latest methods of servicing
and are equipped to provide prompt and efficient
service in the field or at their service stations. They
carry ample stock of service parts or can secure them
promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.
3
Contents
Speed Control Linkage Adjustment................ 33
Steering Control Lever Response
Adjustment ............................................... 34
Tracking Adjustment ..................................... 35
PTO Drive Pulley Alignment ......................... 35
Pump Drive Pulley Alignment........................ 35
Rear Caster Pivot Bearings Pre-Load
Adjustment ............................................... 36
Hopper Door Adjustment ............................. 36
PTO Brake Spring Adjustment ...................... 36
Cleaning ........................................................... 37
Clean Engine and Exhaust System
Area .......................................................... 37
Remove Engine Shrouds and Clean Cooling
Fins........................................................... 37
Clean Debris From Machine .......................... 37
Waste Disposal .............................................. 37
Troubleshooting ................................................... 38
Schematics ........................................................... 40
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ..................... 11
Specifications ....................................................... 14
Model Numbers ............................................ 14
Systems ......................................................... 14
Dimensions................................................... 15
Torque Requirements .................................... 16
Product Overview ................................................ 16
Operation ............................................................. 17
Controls ........................................................ 17
Pre-Start........................................................ 18
Operating Instructions .................................. 18
Transporting ................................................. 20
Maintenance ......................................................... 22
Recommended Maintenance Schedule(s) ........... 22
Periodic Maintenance ....................................... 23
Check Engine Oil Level ................................. 23
Check Battery Charge .................................... 23
Check Safety Interlock System ....................... 24
Check for Loose Hardware ............................ 25
Service Air Cleaner ........................................ 25
Change Engine Oil ........................................ 25
Check Hydraulic Oil Level ............................. 26
Check Tire Pressures ..................................... 26
Check Condition Of Belts.............................. 26
Lubricate Grease Fittings............................... 26
Lubricate Rear Caster Wheel Hubs................. 27
Lubricate Brake Handle Pivot ........................ 28
Lubricate Brake Rod Bushings ....................... 28
Lubricate Steering Linkage Rod Ends............. 28
Lubricate Hopper Actuator............................ 28
Check Spark Plugs ......................................... 28
Change Hydraulic System Filter ..................... 29
Check Wheel Hub Locknuts .......................... 29
Check Wheel Lug Nuts.................................. 29
Thread Locking Adhesives............................. 29
Dielectric Grease........................................... 30
Adjustments ..................................................... 30
PTO Drive Belt Tension ................................ 30
Pump Drive Belt Tension............................... 30
PTO Belt Replacement .................................. 30
Pump Drive Belt Replacement ...................... 31
Belt Guide Adjustment .................................. 31
Adjust Safety Switch ...................................... 32
Brake Adjustment.......................................... 32
Adjust Speed Control Lever Tension .............. 32
4
Safety
Safety
• Never let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.
Safety Alert Symbol
• Only adults and mature teenagers should operate
a mower, and even mature teenagers should have
adult supervision. Be sure a teenager:
This Safety Alert Symbol (Figure 2) is used both in
this manual and on the machine to identify important
safety messages which must be followed to avoid
accidents
1. has read and understands the Operator’s
Manual and recognizes the risks involved;
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
2. is sufficiently mature to use caution; and
3. is of sufficient size and weight to operate
the controls comfortably and to manage the
mower without taking risks.
Figure 2
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
1. Safety alert symbol
The safety alert symbol appears above information
which alerts you to unsafe actions or situations
and will be followed by the word DANGER,
WARNING, or CAUTION.
Preparation
• Evaluate the terrain to determine what accessories
and attachments are needed to properly and
safely perform the job. Only use accessories and
attachments approved by Exmark.
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
• Wear appropriate clothing including safety glasses,
substantial footwear, long trousers, and hearing
protection. Do Not operate when barefoot or
when wearing open sandals. Long hair, loose
clothing or jewelry may get tangled in moving
parts.
WARNING: Black lettering / Orange background.
Indicates a potentially hazardous situation which, if
not avoided, Could result in death or serious injury.
CAUTION: Black lettering / Yellow background.
Indicates a potentially hazardous situation which, if
not avoided, May result in minor or moderate injury.
CAUTION
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
This machine produces sound levels in
excess of 85 dBA at the operator’s ear and
can cause hearing loss through extended
periods of exposure.
Safe Operating Practices
Wear hearing protection when operating this
machine.
Training
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
• Read the Operator’s Manual and other training
material. If the operator(s) or mechanic(s) can
not read English it is the owner’s responsibility to
explain this material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
5
Safety
DANGER
DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.
A fire or explosion from gasoline can burn
you, others, and cause property damage.
In certain conditions during fueling, static
electricity can be released causing a spark
which can ignite gasoline vapors. A fire or
explosion from gasoline can burn you and
others and cause property damage.
• Fill the fuel tank outdoors on level
ground, in an open area, when the engine
is cold. Wipe up any gasoline that spills.
• Always place gasoline containers on the
ground away from your vehicle before
filling.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• Do Not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the
loss of any static charge.
• Do Not fill the fuel tank completely full.
Fill the fuel tank to the bottom of the filler
neck. The empty space in the tank allows
gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine
or emission system (if equipped).
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• Never smoke when handling gasoline,
and stay away from an open flame or
where gasoline fumes may be ignited by
spark.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• Store gasoline in an approved container
and keep it out of the reach of children.
• If a gasoline dispenser nozzle must be
used, keep the nozzle in contact with the
rim of the fuel tank or container opening
at all times until fueling is complete.
• Add fuel before starting the engine.
Never remove the cap of the fuel tank or
add fuel when engine is running or when
the engine is hot.
WARNING
• If fuel is spilled, Do Not attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors has caused
cancer in laboratory animals. Failure to use
caution may cause serious injury or illness.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Keep away from eyes and skin.
• Never siphon by mouth.
6
Safety
• Check that the operator’s presence controls,
safety switches, and shields are attached and
functioning properly. Do Not operate unless they
are functioning properly.
WARNING
Operating a Navigator tractor without an
approved Exmark front mount attachment
increases the possibility of operator
entanglement in drive wheels or forward tip
over. Entanglement or tip-over could cause
serious injury or death.
Operation
WARNING
When operating a Navigator tractor
without an approved Exmark front mount
attachment, observe the following:
Operating engine parts, especially the
muffler, become extremely hot. Severe burns
can occur on contact and debris, such as
leaves, grass, brush, etc. can catch fire.
• Keep feet and clothing away from tires.
• Allow engine parts, especially the muffler,
to cool before touching.
• Limit operation to minimum required to
install a different front mount attachment.
• Remove accumulated debris from muffler
and engine area.
• Minimize speed and use extreme caution.
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
• Do not operate up or down a trailer ramp.
• Only operate on a flat level surface.
• Avoid sudden acceleration or deceleration.
• Operate only in daylight or good artificial light,
keeping away from holes and hidden hazards.
WARNING
• Be sure all drives are in neutral and parking brake
is engaged before starting engine.
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can
kill you.
• Never raise deck with blades running.
• Never operate the mower with damaged guards,
shields, or covers. Always have safety shields,
guards, switches and other devices in place and in
proper working condition.
Do Not run engine indoors or in a small
confined area where dangerous carbon
monoxide fumes can collect.
• Never mow unless there is a grass collection
system or mulch kit in place and working properly.
• Do Not change the engine governor setting or
overspeed the engine.
• Stop engine, wait for all moving parts to stop,
remove key and engage parking brake:
– Before checking, cleaning or working on the
mower.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
damage and make repairs before restarting
and operating the mower).
– Before clearing blockages.
– Whenever you leave the mower.
7
Safety
• Stop engine, wait for all moving parts to stop, and
engage parking brake:
DANGER
Operating on wet grass or steep slopes can
cause sliding and loss of control. Wheels
dropping over edges, ditches, steep banks, or
water can cause rollovers, which may result
in serious injury, death or drowning.
– Before refueling.
– Before dumping the grass catcher.
WARNING
• Do Not mow slopes when grass is wet.
Hands, feet, hair, clothing, or accessories can
become entangled in rotating parts. Contact
with the rotating parts can cause traumatic
amputation or severe lacerations.
• Do Not mow near drop-offs or near water.
• Do Not mow slopes greater than 15
degrees.
• Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
• Reduce speed and use extreme caution
on slopes.
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
• Avoid sudden turns or rapid speed
changes.
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• NEVER carry passengers. DO NOT operate
the mower when people, especially children, or
pets are in the area.
• Use a walk behind mower and/or a hand trimmer
near drop-offs, ditches, steep banks or water.
(Figure 3).
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• Stop the blades, slow down, and use caution when
crossing surfaces other than grass and when
transporting the mower to and from the area to
be mowed.
• Be aware of the mower discharge path and direct
discharge away from others.
• Do Not operate the mower under the influence
of alcohol or drugs.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
Figure 3
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
1. Safe Zone-Use the mower here on slopes less than 15
degrees
2. Danger Zone-Use a walk behind mower and/or hand
trimmer on slopes greater than 15 degrees, near
drop-offs and water.
3. Water
Slope Operation
Use Extreme caution when mowing and/or turning
on slopes as loss of traction and/or tip-over could
occur. The operator is responsible for safe operation
on slopes.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
8
Safety
• Avoid sudden starts when mowing downhill.
Mower may tip forwards.
• Disconnect battery or remove spark plug wire
before making any repairs. Disconnect the
negative terminal first and the positive last.
Reconnect positive first and negative last.
• Be aware that operating on wet grass, across steep
slopes or downhill may cause the mower to lose
traction. Loss of traction to the drive wheels may
result in sliding and a loss of braking and steering.
• Use care when checking blades. Wrap the blade(s)
or wear gloves, and use caution when servicing
them. Only replace damaged blades. Never
straighten or weld them.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• Keep hands and feet away from moving parts.
If possible, do not make adjustments with the
engine running.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• 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.
• Use extreme care with attachments. These can
change the stability of the machine and cause loss
of control.
Note: A 2–post foldable ROPS (Rollover Protection
System) is available for the Navigator as an accessory.
A ROPS is recommended if you will be mowing
next to drop-offs, near water, or on steep banks
which could result in a rollover. The model number
for the ROPS attachment is FRPSNAV. Contact an
Authorized Exmark Service Dealer for more details.
Charging or jump starting the battery may
produce explosive gases. Battery gases can
explode causing serious injury.
Maintenance and Storage
• Ventilate when charging or using battery
in an enclosed space.
• Disengage drives, lower implement, set parking
brake, stop engine and remove key or disconnect
spark plug wire. Wait for all movement to stop
before adjusting, cleaning or repairing.
• Make sure venting path of battery is
always open once battery is filled with
acid.
DANGER
• Keep sparks, flames, or cigarettes away
from battery.
• Always shield eyes and face from battery.
• Keep engine, engine area, and pump drive belt
compartment free from accumulation of grass,
leaves, excessive grease or oil, and other debris
which can accumulate in these areas. These
materials can become combustible and may result
in a fire.
DANGER
Battery electrolyte contains sulfuric acid,
which is poisonous and can cause severe
burns. Swallowing electrolyte can be fatal or
if it touches skin can cause severe burns.
• Let engine cool before storing and do not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Wear safety glasses to shield eyes, and
rubber gloves to protect skin and clothing
when handling electrolyte.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Do Not swallow electrolyte.
• In the event of an accident, flush with
water and call a doctor immediately.
• Use jack stands to support components when
required.
• Carefully release pressure from components with
stored energy.
9
Safety
CAUTION
WARNING
If the ignition is in the “ON” position there
is potential for sparks and engagement
of components. Sparks could cause an
explosion or moving parts could accidentally
engage causing personal injury
Hydraulic fluid escaping under pressure
can penetrate skin and cause injury. Fluid
accidentally injected into the skin must be
surgically removed within a few hours by a
doctor familiar with this form of injury or
gangrene may result.
Be sure ignition switch is in the “OFF”
position before charging the battery.
• Make sure all hydraulic fluid hoses
and lines are in good condition and
all hydraulic connections and fittings
are tight before applying pressure to
hydraulic system.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Check all bolts frequently to maintain proper
tightness.
• Keep body and hands away from pinhole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Frequently check for worn or deteriorating
components that could create a hazard.
• Use cardboard or paper, not your hands,
to find hydraulic leaks.
WARNING
• Safely relieve all pressure in the hydraulic
system by placing the motion control
levers in neutral and shutting off the
engine before performing any work on
the hydraulic system.
Removing standard original equipment
parts, or using non-Exmark replacement
parts and accessories may alter the warranty,
traction, and safety of the machine. Failure
to use original Exmark parts could cause
serious injury or death.
Replace all parts including, but not limited
to, tires, belts, and blades with original
Exmark parts.
10
Safety
Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.
• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• Safety signs may be affixed by peeling off the
backing to expose the adhesive surface. Apply
only to a clean, dry surface. Smooth to remove
any air bubbles.
• Familiarize yourself with the following safety signs
and instruction labels. They are critical to the safe
operation of your Exmark commercial mower.
1-513747
103-8444
65-2690
98-4361
103-8451
98-5954
103-8495
103-8611
103-8425
11
Safety
103-9034
109-4638
103-9724
109-7318
109-4273
116-0404
12
Safety
116-1175
117–2718
Molded in LH Console
Molded into Front of Hopper
13
Specifications
Specifications
Model Numbers
Serial Nos: 850,000 and Higher
NAV20KC; NAV27KC
Systems
◊ If the PTO is engaged while the hopper
is tilted up.
Engine
Operator Controls
• Engine Specifications: See your Engine Owner’s
Manual
• RPM: Full Speed: 3600 ±50 RPM (No Load)
Idle: 1500 RPM
• Steering and Motion Control:
– Speed Control lever, located on RH console,
sets maximum forward speed.
– Steering levers, centered in front of the seat,
control the speed and direction of travel of
the respective drive wheels.
– Moving speed control lever rearward to the
neutral position places the drive system in
neutral.
Fuel System
• Capacity: 7.5 gal. (28 L)
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher; containing no more than 10%
methanol or ethanol.
• Fuel Filter: In-line 30 Micron Kohler P/N
2405010.
• Fuel Shut-Off Valve: 1/4 turn increments in-line
valve by fuel filter.
Note: The unit may be moved in reverse
while the speed control is in the neutral
position by pulling back on the steering levers.
• PTO Engagement Lever: Engages drive to PTO
(mower deck) and blower.
• Parking Brake Lever: Pull back to engage parking
brake.
Electrical System
•
•
•
•
•
•
•
Charging System: Flywheel Alternator
Charging Capacity: 15 amps
Battery Type: BCI Group U1
Battery Voltage: 12 Volt
Polarity: Negative Ground
Fuses: Two 20 amp and one 30 amp blade type
Safety Interlock System:
– PTO must be disengaged, brake engaged, and
speed control lever in neutral position 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 speed control
lever is moved out of neutral or engine will
stop.
– Engine will stop in the following conditions:
◊ If the speed control lever is moved from
neutral position while brake is engaged.
Seat
• Type: Standard seat with high back, foam padded
(internal suspension).
• Mounting: Seat is hinged to tilt up for access to
hydraulic pumps and other components. The seat
is held in the tilted position with a link.
• Armrests: None.
• Seat Safety Switch: Internal to the bottom seat
cushion, non serviceable. Time delay module
incorporated into the Safety Interlock System
eliminates rough ground cut-outs.
Hydrostatic Ground Drive System
• Hydrostatic Pumps: Two Hydro Gear variable
displacement piston pumps.
• Wheel Motors: Hydro Gear planetary reduction
motors.
14
Specifications
– Clutching belt on horizontal engine shaft.
Dual “A” section hexagon belt with spring
tensioned idler to jackshaft and blower.
• Hydraulic Oil Type: Use Exmark Premium Hydro
oil.
• Hydraulic Oil Capacity: 4.0 qt. (3.8 L)
• Hydraulic Filter: Replaceable cartridge type.
– Summer use above 32°F (0°C):
– Heavy-duty cast iron, spiral bevel gearbox is
final drive to blades.
• Deck:
P/N 109-0071: 25 microns, 10 psi bypass
Full floating deck is attached to out-front support
frame. Deck design allows for bagging or
mulching.
– Winter use below 32°F (0°C):
P/N 1-523541: 40 microns, 18 psi bypass
• Speeds:
– 0-7.0 mph (11.3 km/hr) forward.
– 0-5.5 mph (8.6 km/hr) reverse.
• Drive wheel release valves allow machine to be
moved when engine is not running.
• Deck Depth:
– 42 inch Deck: 4 5/8 inches (11.7 cm)
– 48 inch Deck: 4 5/8 inches (11.7 cm)
Dimensions
Tires & Wheels
Front
Caster
Rear Caster
Pneumatic
(Air-Filled)
SemiPneumatic
SemiPneumatic
Quantity
2
2
1
Tread
“Multi-Trac
C/S”
Smooth
Smooth
Size
18 x
10.50-10
8 x 3.00-4
13 x 8.00-6
Drive
Ply Rating
4
Pressure
15 psi (103
kPa)
Overall Width:
Without Deck
42 inch Deck
48 inch Deck
42.6 inches
(108.2 cm)
43.2 inches
(109.7 cm)
49.2 inches
(125.0 cm)
Overall Length:
Without Deck
42 inch Deck
48 inch Deck
67.3 inches
(170.9 cm)
91.8 inches
(233.2 cm)
94.5 inches
(240.0 cm)
Overall Height:
Cutting Deck
(Sold separately)
• Model Numbers:
– CD42CD
– CD48CD
• Cutting Width:
– 42 inch Deck: 42 inch (106.7 cm)
– 48 inch Deck: 48 inch (121.9 cm)
• Discharge: Center
• Blade Size: (2 ea.)
– w/42 inch Deck: 22.00 inches (55.9 cm)
– w/48 inch Deck: 25.00 inches (63.5 cm)
• Deck Drive:
Without Deck
42 inch Deck
48 inch Deck
51.2 inches
(130.0 cm)
51.2 inches
(130.0 cm)
51.2 inches
(130.0 cm)
Tread Width: (Center to Center of
Tires, Widthwise)
Drive Wheels
42 inch Deck
48 inch Deck
32.7 inches
(83.1 cm)
32.7 inches
(83.1 cm)
Wheel Base: (Center of Drive Wheel
to Center of Rear Caster Wheel)
15
42 inch Deck
48 inch Deck
44.2 inches (112.3 cm)
44.2 inches (112.3 cm)
Product Overview
Curb Weight:
Product Overview
42 inch Deck
48 inch Deck
850 lb (386 kg)
1145 lb (519 kg)
Torque Requirements
Bolt Location
Torque
Blade Mounting Bolt
85-110 ft-lb (115-149 N-m)
Engine Mounting Bolts
30-35 ft-lb (41-47 N-m)
Wheel Lug Nuts
90-95 ft-lb (122-129 N-m)
Wheel Motor Mounting
Bolts
72-77 ft-lb (98-104 N-m)
Wheel Hub Locknut
210-250 ft-lb
(285-339 N-m)
Figure 4
1. Speed Control Lever
2. Controls
3. Fuel Cap
16
4. Steering Levers
5. PTO Engagement Lever
6. Parking Brake Lever
Operation
Brake Lever
Operation
Located on left side of unit, between the seat and
console.
Note: Determine the left and right sides of the
machine from the normal operating position.
The brake lever engages a parking brake on the drive
wheels.
Controls
Pull the lever up and rearward to engage the brake.
Steering Levers
Push the lever forward and down to disengage the
brake.
Located in the center in front of the seat.
The unit must be tied down and brake engaged when
transporting.
Pulling back on the steering levers, progressively
slows, then reverses the direction of travel of the
respective drive wheels.
Ignition Switch
Located on the right hand console.
By moving both steering levers an equal amount back,
the machine can be slowed down or travel backward
in a straight line.
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).
Steering is controlled by varying the position of the
steering levers relative to each other.
Speed Control Lever
Note: Brake must be engaged, speed control lever
rearward (neutral position) and PTO disengaged to
start engine. (It is not necessary for the operator to
be in the seat to start the engine.)
Located on right hand console.
The speed control lever sets maximum forward speed.
Moving speed control lever rearward to the neutral
position places the drive system in neutral.
Hour Meter
Located on the right hand console.
Choke Control
The hour meter is connected to a pressure switch
installed in the engine block and it records the
number of hours that the engine has run. If the
ignition switch is left on without engine running,
hour meter will not run.
Located on right hand console.
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 will put the choke in the “OFF” position. DO
NOT run a warm engine with choke in the “ON”
position.
Note: This switch is not a low oil sensor and will not
alert the operator if the engine oil is low.
Fuel Shut-Off Valve
Throttle Control
Located on right hand console.
Located in fuel line by fuel tank and fuel filter
(accessible by raising the hopper).
The throttle is used to control engine speed. Moving
throttle lever forward will increase engine speed and
moving throttle lever to the rear will decrease engine
speed.
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.
Rotate the valve 1/4 turn clockwise to shut off the
fuel. rotate the valve 1/4 turn counterclockwise to
turn on the fuel.
17
Operation
Drive Wheel Release Valves
Pre-Start
Located on the top left front corner of hydrostatic
pumps.
Fill fuel tanks. For best results use only clean, fresh
regular grade unleaded gasoline with an octane rating
of 87 or higher.
Drive wheel release valves are used to release the
hydrostatic drive system to allow the machine to be
pushed without the engine running. Tilt seat up to
gain access to pumps.
Important: Never use methanol, gasoline
containing methanol, gasohol containing more
than 10% ethanol, premium gasoline, or white
gas because the fuel system could be damaged.
With a 7/16 wrench, turn both valves one turn
counterclockwise to release drive system. Turn
clockwise to reset system. Do Not overtighten. Do
Not tow machine.
Do Not add oil to gasoline.
Located under the seat on the left pump control link.
Do Not overfill fuel tank. Fill the fuel tank to the
bottom of the filler neck. The empty space in the
tank allows gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine or emission
system (if equipped).
Rotating this knob allows fine tuning adjustments so
that the machine tracks straight with the drive levers
in the full forward position.
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
Run unit at 3/4 speed for at least 5 minutes to
bring hydraulic oil up to operating temperature.
Stop machine and wait for all moving parts to stop.
Engage park brake. Tilt seat forward to gain access
to the tracking knob. Rotate the knob towards the
right to steer right and rotate towards the left to
steer left. Adjust in 1/8 turn increments until the
machine tracks straight. Check that the machine
does not creep when in neutral with the park brakes
disengaged.
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
Tracking Adjustment Knob
Operating Instructions
Open the Fuel Shut-Off Valve
The fuel shut-off valve is located on the right side of
unit in fuel line next to the fuel filter. Raise the hopper
to access. Rotate the valve 1/4 counterclockwise to
turn on fuel.
Important: Do Not rotate the knob too far, as
this may cause the machine to creep in neutral.
Refer to the Motion Control Linkage Adjustment
section in Maintenance.
Starting the Engine
1. Move the speed control lever to the neutral
position.
PTO Engagement Lever
2. Pull up and back on the parking brake lever to
engage the parking brake.
Located immediately left of the left console.
Lever must be moved up to the “ROTATE” position
to engage the PTO and blower drives. Lever is moved
down to the “STOP” position to stop the drives.
3. Push the PTO engagement lever down to the
“STOP” position.
Note: It is not necessary for the operator to be
in the seat to start the engine.
Engine Oil Temperature Light and
Buzzer
4. Place the throttle midway between the “SLOW”
and “FAST” positions.
Located on the right console.
5. On a cold engine, push the choke lever forward
into the “ON” position.
The engine oil temperature light monitors the
temperature of the engine oil. An illuminated engine
oil temperature light and intermittent buzzing sound
signals the engine is overheating.
On a warm engine, leave the choke in the “OFF”
position.
18
Operation
Disengaging the PTO
6. Turn ignition switch to the “START” position.
Release the switch as soon as the engine starts.
1. Set the throttle to the “MIDWAY” position.
2. Push PTO lever down to the “STOP” position
stopping the PTO and blower.
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.
Stopping the Engine
1.
2.
3.
4.
5.
Bring the unit to a full stop.
Disengage the PTO.
Move speed control lever to the neutral position.
Engage the parking brake.
Place the throttle midway between the “SLOW”
and “FAST” positions.
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.
7. If the choke is in the “ON” position, gradually
return choke to the “OFF” position as the engine
warms up.
Engaging the PTO
DANGER
The rotating blades under the mower deck
are dangerous. Blade contact can cause
serious injury or kill you.
Do Not put hands or feet under the mower
or mower deck when the blades are engaged.
DANGER
Driving the Machine
An uncovered discharge opening will allow
objects to be thrown in an operator’s or
bystander’s direction. Also, contact with the
blower blades could occur. Thrown objects
or blade contact can cause serious injury or
death.
CAUTION
Machine can spin very rapidly by positioning
one lever too much ahead of the other.
Operator may lose control of the machine,
which may cause damage to the machine
or injury.
Never operate the mower with the hopper
or hopper door raised, removed, or altered
unless there is a mulch kit in place and
working properly.
• Use caution when making turns.
• Slow the machine down before making
sharp turns.
The PTO lever engages the PTO and blower. Be sure
that the hopper is down, the hopper door is securely
closed, and all persons are clear of the mower deck
and discharge area before engaging PTO.
Important: To begin movement (forward or
backward) the operator must be in the seat, the
brake lever must be disengaged (pushed down)
before the speed control lever can be moved
forward or the engine will stop.
Important: Operator must be in seat before the
PTO can be engaged.
Driving Forward
1. Start the engine.
2. Release the parking brake.
3. To move forward in a straight line move the speed
control lever forward.
1. Set the throttle to the “MIDWAY” position.
2. Pull the PTO lever upward until locked over
center.
3. Place the throttle in the “FAST” position to begin
mowing.
19
Operation
To turn left or right, pull one of the steering levers
back toward neutral in the direction desired.
The machine will move faster the farther the
speed control lever is moved away from neutral.
4. To stop, pull the speed control lever back to the
neutral position.
Driving in Reverse
1. To move rearward in a straight line applying equal
pressure pull both steering levers rearward.
Figure 5
1. Front removable screen
can be rotated and
stored for wet condtions
2. Front removable screen
To turn left or right, release pressure on the
steering lever toward the direction desired.
3. Primary screen
4. Handles.
2. To stop, release the steering levers to the neutral
position.
Transporting
Emptying Hopper
Transporting a Unit
1. A full hopper is indicated by a buzzer located
behind the operator in the hopper. Empty hopper
when buzzer sounds to prevent clogging of the
blower or deck.
Use a heavy-duty trailer or truck to transport the
machine. Lock brake and block wheels. Securely
fasten the machine to the trailer or truck with straps,
chains, cable, or ropes. Be sure that the trailer or truck
has all necessary lighting and marking as required by
law. Secure a trailer with a safety chain.
2. Disengage PTO, move speed control to neutral,
set park brake and dismount unit to dump hopper.
3. Make sure unit is on a dry level surface.
4. Lift the rear door up and allow it to rest on top
of hopper.
CAUTION
This unit does not have proper turn
signals, lights, reflective markings, or a
slow moving vehicle emblem. Driving on a
street or roadway without such equipment
is dangerous and can lead to accidents
causing personal injury. Driving on a street
or roadway without such equipment may also
be a violation of State laws and the operator
may be subject to traffic tickets and/or fines.
5. Dump hopper by firmly grasping one of the
hopper handles on either side of the unit and
lifting the hopper.
Clearing Hopper Screen
Screen may be removed by firmly lifting screen
handles (see Figure 5).
Pull screen towards the back to remove. Gently tap
debris from the screen as needed.
Do Not drive a unit on a public street or
roadway.
Excessive build-up on the screen can cause the
blower to plug.
Note: In conditions where the screen clogs quickly,
the front removable screen panel can be turned and
reinstalled under the primary screen to allow free air
flow from the hopper.
20
Operation
WARNING
Loading a unit on a trailer or truck increases
the possibility of tip-over. Tip-over could
cause serious injury or death.
• Use extreme caution when operating a
unit on a ramp.
• Use only a single, full width ramp; Do
Not use individual ramps for each side
of the unit.
• If individual ramps must be used, use
enough ramps to create an unbroken
ramp surface wider than the unit.
• Do Not exceed a 15° angle between ramp
and ground or between ramp and trailer
or truck.
• Avoid sudden acceleration while driving
unit on a ramp.
Loading a Unit
Use extreme caution when loading units on trailers
or trucks. One full width ramp is required. If it is
not possible to use one full width ramp, use enough
individual ramps to simulate a full width continuous
ramp.
Ramp should be long enough so that the angles
between the ramp and the ground and the ramp and
the trailer or truck do not exceed 15°. A steeper angle
may cause mower deck components to get caught as
the unit moves from ramp to trailer or truck. Steeper
angles may also cause the unit to tip. If loading on or
near a slope, position the trailer or truck so it is on
the down side of the slope and the ramp extends up
the slope. This will minimize the ramp angle. The
trailer or truck should be as level as possible.
Important: Do Not attempt to turn the unit
while on the ramp, you may lose control and
drive off the side.
Avoid sudden acceleration when driving on a ramp.
21
Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could
seriously injure you or other bystanders.
The engine can become very hot. Touching
a hot engine can cause severe burns.
Allow the engine to cool completely before
service or making repairs around the engine
area.
Remove the key from the ignition switch,
engage parking brake, and pull the wire(s)
off the spark plug(s) before you do any
maintenance. Also push the wire(s) aside
so it does not accidentally contact the spark
plug(s).
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 5 hours
• Change the engine oil.
After the first 100 hours
• Check the wheel hub locknuts torque specification.
• Check the wheel lug nut torque specification.
After the first 250 hours
• Change the hydraulic filter.
Before each use or daily
•
•
•
•
•
Check the engine oil level.
Check the safety interlock system.
Check for loose hardware.
Remove accumulated debris from engine (see Cleaning section.)
Clean the grass and debris build-up from the machine.
Every 40 hours
• Check the hydraulic oil level.
• Check the tire pressures.
• Check the condition of the belts.
Every 50 hours
• Service the air cleaner. (May need more often under severe conditions. See the Engine
Owner’s Manual for additional information.)
Every 80 hours
• Remove engine shrouds and clean cooling fins (see Cleaning section.)
Every 100 hours
• Change the engine oil. (May need more often under severe conditions.)
Every 160 hours
•
•
•
•
•
Every 500 hours
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)
• Check the wheel hub locknuts torque specification.
• Check the wheel lug nut torque specification.
Lubricate the brake handle pivot.
Lubricate the brake rod bushings.
Lubricate the steering linkage rod ends.
Lubricate hopper actuator
Check the spark plugs.
22
Maintenance
Maintenance Service
Interval
Monthly
Yearly
Maintenance Procedure
• Check the battery charge.
• Lubricate grease fittings.
• Lubricate the caster wheel hubs.
Periodic Maintenance
Note: To prevent damage due to freezing, battery
should be fully charged before putting away for
winter storage.
Check Engine Oil Level
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.
Service Interval: Before each use or daily
1. Stop engine and wait for all moving parts to stop.
Make sure unit is on a level surface.
2. Check with engine cold.
3. Raise hopper.
4. Clean area around dipstick. Remove dipstick and
wipe oil off. Reinsert the dipstick and push it all
the way down into the tube. Remove the dipstick
and read the oil level.
5. If the oil level is low, wipe off the area around the
oil fill cap, remove cap and fill to the “FULL”
mark on the dipstick. Use oil as specified in
Engine Owner’s Manual. Do Not overfill.
Important: Make sure the negative battery
cables are 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).
Important: Do Not operate the engine with the
oil level below the “LOW” (or “ADD”) mark on
the dipstick, or over the “FULL” mark.
Check Battery Charge
Service Interval: Monthly
WARNING
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the State of
California to cause cancer and reproductive
harm. Wash hands after handling.
Voltage
Reading
Percent
Charge
Maximum
Charger
Settings
Charging
Interval
12.6 or
greater
100%
16 volts/7
amps
No
Charging
Required
12.4 – 12.6
75–100%
16 volts/7
amps
30 Minutes
12.2 – 12.4
50–75%
16 volts/7
amps
1 Hour
12.0–12.2
25–50%
14.4 volts/4 2 Hours
amps
11.7–12.0
0–25%
14.4 volts/4 3 Hours
amps
11.7 or less
0%
14.4 volts/2 6 Hours or
More
amps
Recommended Jump
Starting Procedure
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.
Service Interval: As required
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.
23
Maintenance
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 6.
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.
Figure 6
1.
2.
3.
4.
5.
6.
7.
CAUTION
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
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).
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).
Check Safety Interlock
System
WARNING
Batteries contain acid and produce explosive
gases.
Service Interval: Before each use or daily
Note: To prevent engine cut-outs on rough terrain
the seat kill switch has a 1/2 second delay.
1. Check starting circuit. Starter should crank with,
parking brake engaged, PTO disengaged and
• Shield the eyes and face from the batteries
at all times.
• Do Not lean over the batteries.
24
Maintenance
Manual for additional
information.)
speed control lever in the neutral position. The
operator does not need to be in the seat to start
the engine.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Try to start with operator in seat, parking
brake disengaged, PTO disengaged and speed
control lever in the neutral position - starter
must not crank.
2. Tilt hopper up to gain access to the air cleaner.
3. Loosen retaining clips and remove air cleaner
compartment cover.
Try to start with operator in seat, parking brake
engaged, PTO engaged and speed control lever
in the neutral position - starter must not crank.
4. Remove paper element. Check the condition
of the paper element. Replace if dirty, bent or
damaged.
Try to start with operator in seat, parking brake
engaged, PTO disengaged, and the speed
control lever forward (out of neutral), starter
must not crank.
5. Check the condition of the inner element. Replace
whenever it appears dirty, typically every other
time the paper element is replaced. Clean the base
around the inner element before removing, so
dirt does not get into the engine.
2. Check the kill circuits. Run engine at one-third
throttle, disengage parking brake and raise off
of seat (but do not get off of machine) engine
must initiate shutdown after approximately 1/2
second has elapsed (seat has time delay kill switch
to prevent cut-outs on rough terrain).
6. Do Not wash or use pressurized air to clean
paper element or inner element.
7. Reinstall elements. Position the cover so that the
rubber dust ejector is pointing downward and
secure with retaining clips.
Run engine at one-third throttle, engage PTO
and raise offof seat (but do not get off of
machine) engine must initiate shutdown after
1/2 second has elapsed.
Change Engine Oil
Service Interval: After the first 5 hours
Note: If machine does not pass any of these tests,
do not operate. Contact your authorized EXMARK
SERVICE DEALER.
Every 100 hours (May
need more often under
severe conditions.)
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Drain oil while engine is warm from operation.
Check for Loose Hardware
3. Tilt hopper up to gain access to the engine area.
Service Interval: Before each use or daily
4. The oil drain valve is located on right hand side
of engine at the back of the unit. Remove two
nuts near right hand drive tire and swing out the
fuel tank. Install oil drain hose, supplied in the
literature pack, onto oil drain valve. Place pan
under machine to catch oil. Open valve to allow
oil to drain and then close valve
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.
5. Replace the oil filter every other oil change. Clean
around oil filter and unscrew filter to remove.
Before reinstalling new filter, apply a thin coating
of oil on the surface of the rubber seal. Turn
filter clockwise until rubber seal contacts the filter
adapter then tighten filter an additional 1/2 to
3/4 turn.
Service Air Cleaner
Service Interval: Every 50 hours—Service
the air cleaner. (May
need more often under
severe conditions. See
the Engine Owner’s
25
Maintenance
6. Clean around oil fill cap and remove cap. Fill to
specified capacity and replace cap.
halfway between the “HOT” and “COLD” levels.
If the oil is at room temperature (about 75°F
(24°C)), fill only to the “COLD” level. Do Not
overfill.
7. Remove drain hose, close fuel tank, and lower
hopper.
8. Use oil recommended in engine owner’s manual.
Do Not overfill. Start the engine and check for
leaks.
Check Tire Pressures
Service Interval: Every 40 hours
9. Wipe up any spilled oil from engine deck
mounting surfaces.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Check tire pressure in drive tires.
Check Hydraulic Oil Level
3. Inflate drive tires to 15 psi (103 kPa).
Service Interval: Every 40 hours
4. The rear caster tire is semi-pneumatic and does
not need to be inflated.
WARNING
Note: Do Not add any type of tire liner or foam
fill material to the tires. Excessive loads created by
foam filled tires may cause failures to the hydro drive
system, frame, and other components. Foam filling
tires will void the warranty.
Oil spilled or vented from an overfilled
hydraulic reservoir onto the PTO brake band
will cause a longer stopping time for the deck
and blower rotating components. The deck
and blower rotating components can cause
serious injury.
Check Condition Of Belts
• Wait for all moving parts to come to a
complete stop before servicing.
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
• Do Not overfill the hydraulic reservoir.
Carefully fill only to the recommended
level.
2. Tilt hopper up and check pump and PTO drive
belts for wear, cracking, or contamination.
• Replace the brake band if it becomes
contaminated with oil.
3. Belts are spring tensioned and no adjustment is
necessary unless belts are replaced. See PTO
Belt Replacement and Pump Drive Belt
Replacement sections for belt replacement.
1. Stop engine and wait for all moving parts to stop.
Engage parking brake.
2. Tilt hopper up.
Lubricate Grease Fittings
3. Clean area around hydraulic reservoir cap and
remove cap. Oil level should be to the top of the
baffle inside the tank. If not, add oil. Use only
Exmark Premium Hydro oil. Replace hydraulic
reservoir cap and tighten until snug. Do Not
overtighten. Do Not overfill.
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
NGLI grade #2 multi-purpose gun grease.
Note: The baffle is labeled “HOT” and
“COLD”. The oil level varies with the
temperature of the oil. The “HOT” level shows
the level of oil when it is at 225°F (107°C). The
“COLD” level shows the level of the oil when
it is at 75°F (24°C). Fill to the appropriate level
depending upon the temperature of the oil. For
example: If the oil is about 150°F (65°C), fill to
Refer to the Lubrication Chart for fitting locations
and lubrication schedule.
26
Maintenance
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Lubrication Chart
Fitting
Locations
Initial
Pumps
Number of
Places
Service
Interval
1. Caster
Pivot
*0
3
*Yearly
2. PTO
Idler
1
1
Yearly
3. Pump
Idler
1
1
Yearly
4. Rear
Caster Hub
*0
1
*Yearly
Figure 7
* See step 3 for special lubrication instructions on
the front and rear caster pivots and the Lubricate
Rear Caster Wheel Hubs section for special
lubrication instructions on the rear caster wheel
hubs.
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 NGLI grade #1
multi-purpose grease.
7. Insert one bearing, one new seal into the wheel.
Note: Seals (Exmark PN 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.
Deck shown for reference only. See attachment
manual for lubrication schedule.
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.
9. Insert the assembled nut and axle into the wheel
on the side of the wheel with the new seal and
bearing.
Lubricate Rear Caster Wheel
Hubs
10. With the open end of the wheel facing up, fill
the area inside the wheel around the axle full of
NGLI grade #1 multi-purpose grease.
Service Interval: Yearly
27
Maintenance
Lubricate Brake Rod
Bushings
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.
Service Interval: Every 160 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Unhook seat latch and tilt seat up.
3. Lubricate bronze bushings on each end of brake
rod shaft with a spray type lubricant or a light oil
(bushings are located to the inside of the flange
bearings).
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.
Lubricate Steering Linkage
Rod Ends
Service Interval: Every 160 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Unhook seat latch and tilt seat up.
3. Lubricate each end of both steering linkage rods
with a spray lubricant or a light oil.
Lubricate Brake Handle Pivot
Service Interval: Every 160 hours
Lubricate Hopper Actuator
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Service Interval: Every 160 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Raise hopper and locate actuator on right hand
side of mainframe.
3. Lubricate switch actuator rod with a spray
lubricant or a light oil.
2. Lubricate bronze bushings on brake handle
pivot with a spray type lubricant or light oil (see
Figure 8).
Check Spark Plugs
Service Interval: Every 160 hours
Remove spark plugs, check condition and reset gaps,
or replace with new plugs. See Engine Owner’s
Manual.
Change Fuel Filter
Service Interval: As required
Figure 8
Left Side of Unit Shown
1. Brake Handle Pivot
2. PTO Handle Pivot
A fuel filter is installed between the fuel tank and the
engine. Replace when necessary.
3. Spring Arm Pivot
4. Toggle Pivot
Replacement Filters
Kohler
28
Kohler P/N 2405010
Maintenance
Change Hydraulic System
Filter
Note: Do Not change hydraulic system oil (except
for what can be drained when changing filter), unless
it is felt the oil has been contaminated or been
extremely hot.
Changing oil unnecessarily could damage hydraulic
system by introducing contaminates into the system.
Service Interval: After the first 250 hours
Every 500 hours/Yearly
(whichever comes
first) thereafter
(Every 250 hours/Yearly if
using Mobil 1 15W50)
Check Wheel Hub Locknuts
Service Interval: After the first 100 hours
Note: Use only Exmark Part No. 109-0071 for
Summer use above 32°F (0°C) or P/N 1-523541
for Winter use below 32°F (0°C). (Refer to the
Hydrostatic Ground Drive System section in
Specifications for filter specifications.)
Every 500 hours thereafter
Torque to 210–250 ft-lb (285–339 N-m).
Check Wheel Lug Nuts
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Service Interval: After the first 100 hours
Every 500 hours thereafter
2. Carefully clean area around filter. It is important
that no dirt or contamination enter hydraulic
system.
Torque to 90–95 ft-lb (122–129 N-m) cross pattern.
3. Unscrew filter to remove and allow oil to drain
from reservoir.
Fuel Tank — Mounting
Hardware Specifications
Important: Before reinstalling new filter, fill
it with Exmark Premium Hydro oil and apply
a thin coat of oil on the surface of the rubber
seal.
Service Interval: As required
When installing the nuts on the fuel tank studs, fully
tighten the nyloc nut and back off 1/2 turn. This
allows for normal fuel tank expansion and contraction
with changes in temperature and fuel levels.
Turn filter clockwise until rubber seal contacts the
filter adapter, then tighten the filter an additional
2/3 to 3/4 turn.
4. Fill reservoir as stated in Check Hydraulic Oil
Level section.
Thread Locking Adhesives
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
Exmark Premium Hydro Oil is recommended.
Refer to the chart for an acceptable alternative:
Hydro Oil
Change Interval
Exmark Premium Hydro
Oil (Preferred)
500 Hours
• Pump drive sheave set screws.
Mobil 1 15W50
250 Hours
• Square head setscrews on Hydro pump control
arms.
• Sheave retaining bolt in the end of engine
crankshaft, blower shaft and jackshaft.
5. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
• Caster wheel spacer nuts.
• Fuel tank bulkhead fitting nuts.
6. Start engine and move throttle control ahead to
full throttle position. Move the speed control
levers to the full speed and run for several
minutes. Shut down machine and recheck oil
level.
Adhesives such as “Loctite RC/609 or RC/680” or
“Fel-Pro Pro-Lock Retaining I or Retaining II” are
used on the following:
29
Maintenance
Fuel tank studs, where studs are inserted into tank.
Adjustments
Dielectric Grease
Note: Disengage PTO, shut off engine, wait for
all moving parts to stop, engage parking brake, and
remove key before servicing, cleaning, or making any
adjustments to the unit.
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
PTO Drive Belt Tension
Self-tensioning - No adjustment necessary.
Pump Drive Belt Tension
Self-tensioning - No adjustment necessary.
PTO Belt Replacement
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. With engine “off ”, engage PTO lever, then
remove the hairpin and clevis pin at the bottom
of the PTO brake band.
3. Rotate the brake band upwards out of the way of
the belts keeping clear of the belt drive.
4. Disengage PTO lever.
5. Loosen belt guides “A” and “B” (See Figure 9).
6. Remove current belts
7. Route new belts onto sheaves as shown in the
decal located on the back of the left drive shield
(see Figure 9).
Figure 9
1.
2.
3.
4.
Idler
Belt Guide “B”
PTO Belt
Jackshaft
5. Engine
6. Belt Guide “A”
7. Blower
8. Engage the PTO lever
9. Rotate brake band back down into original
position
30
Maintenance
10. Re-install clevis pin and hairpin to secure brake
band.
11. Engage the PTO lever.
12. Loosen the jam nuts and adjust linkage until the
top of the idler arm is aligned with the bottom of
notch on tension arm as shown in Figure 10.
Figure 11
1. Pump Drive Belt
2. Pump
3. Idler
4. Pump
5. Idler
6. Engine
5. Reinstall PTO Belts as stated in the PTO Belt
Replacement section
Belt Guide Adjustment
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Figure 10
1. Tension Arm
2. Loosen jam nuts
3. When PTO is engaged, align top of idler arm with bottom
of notch on tension arm, as shown.
4. Idler Arm
2. Engage PTO lever.
3. Adjust belt guides as shown in Figure 12.
13. Tighten jam nuts and disengage PTO lever.
Re-engage PTO lever and check alignment.
14. Check and adjust belt guides as stated in Belt
Guide Adjustment section.
Pump Drive Belt
Replacement
Figure 12
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
1. 1/8 inch (3 mm)
2. Remove PTO Belts. See PTO Belt Replacement
section for removal instructions.
2. 7/16 inch (11 mm)
3. 1/8 inch (3 mm)
Clearance
3. Pull spring idler or remove spring to relieve pump
drive belt tension. Remove old belt.
4. Route new belt onto sheaves as shown in the
decal located on the back of the left drive shield
(see Figure 11).
31
4. Rotate wireform guide to
center belts in guide.
5. 1/4 inch (6 mm)
6. 5/16 inch (8 mm)
Maintenance
Adjust Safety Switch
3. The brakes on both sides can be simultaneously
adjusted by lengthening or shortening the linkage
shown in Figure 15.
Adjust all safety switches so plunger extends 3/16
inch to 1/4 inch (4.8 mm-6.4 mm) from switch body
when plunger is compressed (see Figure 13).
Figure 13
1. 3/16 inch to 1/4 inch (4.8 mm-6.4 mm)
Brake Adjustment
Figure 15
Brake Adjustment for Both Sides
(At the same time)
Check to make sure each brake is adjusted properly.
1. Pull the brake lever up and back to the engaged
position.
2. A gap must exist between the bottom of the brake
bolt head and the top surface of the brake swivel
as shown in Figure 14. If a gap does not exist,
adjust the linkage to a maximum gap of 1/2 inch
±1/8 inch (1.3 cm ±0.33 cm) as shown.
1. Brake Lever in engaged
position
2. Remove clevis pin
3. Rotate yoke
4. Loosen nut here
4. If individual adjustment is necessary, loosen the
jam nut on the brake bolt that is against the clevis
connected to the brake arm on the wheel motor.
Turn the brake bolt to achieve proper adjustment.
5. Tighten the jam nut against the clevis.
6. Repeat for other side of unit.
7. Engage and disengage the brakes to check for
proper engagement and disengagement. Readjust
if necessary. When the brakes are disengaged,
there should be free play in the brake linkage with
no dragging in the brakes.
Adjust Speed Control Lever
Tension
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Tension in speed control lever can be adjusted
by adjusting the tightness of the lever pivot bolt,
which is located under the seat near the speed
control lever (see Figure 16).
3. Set the tension high enough that the speed control
lever position is maintained during operation and
Figure 14
Brake Adjustment for Each Side (Separately)
1. Brake Lever in engaged
position
2. Loosen nut here
3. 1/2 inch ±1/8 inch (1.3
cm ±0.33 cm)
4. Brake Bolt
5. Brake Swivel
32
Maintenance
loose enough to be moved comfortably by the
operator.
CAUTION
Raising the mower deck for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous. The
mechanical or hydraulic jacks may not be
enough support or may malfunction allowing
the unit to fall, which could cause injury.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
• Adjust steering levers
1. Stop engine and wait for all moving parts to
stop.
2. Pull the speed control lever completely back to
the neutral position. The two steering levers
should be straight up and down (vertical). If
necessary, adjust steering levers by changing
the length of the link between the speed
control lever and the control arm on the end
of the steering control shaft (see Figure 17).
Figure 16
1. Speed Control Lever
2. Friction Plate
3. Spring disc washers
4. Hex locknut
Speed Control Linkage
Adjustment
WARNING
Engine must be running and drive
wheels must be turning so motion control
adjustment can be performed. Contact with
moving parts or hot surfaces may cause
personal injury.
Keep fingers, hands, and clothing clear of
rotating components and hot surfaces.
Figure 17
1. Loosen jam nuts here to
adjust linkage
2. Steering levers should
be vertical
• Set neutral:
1. Remove the electrical connection from the
seat safety switch, located directly in front of
the seat switch assembly.
2. The neutral adjustment must be made with
the drive wheels turning. Raise the frame and
place on jack stands so that drive wheels can
rotate freely. Temporarily install a jumper wire
33
Maintenance
across the terminals in the connector of the
wiring harness.
Set forward stop bolt:
1. Remove seat deck (with seat attached) to obtain
a clear view of the steering control shaft to
complete this adjustment.
3. Start the engine.
4. Run the unit at least 5 minutes with the
speed control lever at full forward speed to
bring hydraulic system oil up to operating
temperature. Return speed control lever to
neutral (full rear) position.
2. Push the speed control lever forward to full
forward speed position.
3. If either steering control lever surface does not
contact the stop bar at the full forward speed
position, adjust the stop bolt until contact occurs
(see Figure 19). Once contact occurs, turn the
stop bolt one more full turn to prevent bottoming
of the hydraulic pump internal stops.
5. To obtain the neutral position, adjust the
left and right pump control rod linkages that
connect the steering control to the pump
control arms until the wheels stop, or creep
slightly in reverse.
6. Adjust the left pump linkage by rotating the
tracking adjustment knob.
7. Adjust the right pump linkage by using
a wrench to turn the double nuts on the
assembly (see Figure 18)
Figure 19
1. Speed control Lever
forward stop bolt
2. Contact must be
maintained between
these components at full
forward speed condition
Steering Control Lever
Response Adjustment
1. Stop engine, wait for all moving parts to stop and
remove key. Engage parking brake.
Figure 18
1. Rotate tracking knob on
left side
2. Move the speed control lever to the full forward
position.
2. Rotate double nuts on
right side
3. Lift the seat and locate the pump control springs.
To increase responsiveness, increase spring
tension by hooking the rear spring anchor directly
to the anchor bolt. To decrease responsiveness,
hook the rear spring anchor to the anchor tab.
8. Move the steering levers to the reverse
position. While applying slight pressure to
the levers, allow the steering levers to return
to neutral. The wheels must stop turning (or
slightly creep in reverse).
Note: Be sure both springs maintain the same
adjustment.
9. Stop engine and wait for all moving parts to
stop. Remove jumper wire from wire harness
connector and plug connector into seat switch.
10. Lower from jackstands.
34
Maintenance
inch to 1/16 inch (0.8-1.6 mm). Use a straight
edge to align all three surfaces (see Figure 21).
Figure 20
Figure 21
1. To increase steering responsiveness hook
pump control sprints directly on anchor bolt.
To decrease steering responsiveness hook pump
control springs on anchor tabs as shown.
1. Align three pump drive
pulley surfaces shown
with this pattern within
1/32 inch to 1/16 inch
(0.8-1.6 mm).
Tracking Adjustment
2. Align three PTO drive
pulley surfaces shown
with this pattern within
1/32 inch to 1/16 inch
(0.8-1.6 mm).
10. Tighten the four engine mounting bolts and four
jackshaft mounting bolts. Check alignment after
tightening.
11. Re-install pump belt tension spring.
12. Swing fuel tank in and re-install tank mounting
nuts.
13. Complete the Pump Drive Pulley Alignment
section.
See Motion Control Linkage Adjustment section
PTO Drive Pulley Alignment
PTO drive pulley alignment is necessary for any of
the following conditions:
• The blower has been removed or replaced.
• The engine mounting bolts have been loosened
or the engine has been moved or replaced.
• The jackshaft mounting bolts have been loosened
or the jackshaft has been moved or replaced.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Move the speed control lever to the neutral
position.
3. Disengage the PTO lever.
4. Remove fuel tank mounting nuts and swing out
fuel tank.
5. Verify that the blower is installed and secured
tightly.
6. Loosen the 4 engine mounting bolts.
7. Unhook the pump belt tension spring.
8. Loosen the 4 jackshaft mounting bolts.
9. Measuring from the blower pulley as a baseline,
move the engine and jackshaft until the rear
surface of all 3 pulleys are aligned within 1/32
Pump Drive Pulley Alignment
Pump drive pulley alignment is necessary for any of
the following conditions:
• The engine mounting bolts have been loosened
or the engine has been moved or replaced.
• The pump pulleys have been loosened, moved,
or replaced.
• The PTO pulley alignment has been performed
(see PTO Drive Pulley Alignment section).
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Loosen set screws on both pump pulleys.
3. Using a straight edge, align each pump pulley with
the engine pulley by sliding along the pump shaft
(see Figure 21).
4. Re-tighten pulley set screws and recheck
alignment.
35
Maintenance
Rear Caster Pivot Bearings
Pre-Load Adjustment
Remove dust cap from caster and tighten nyloc
nut until washers are flat. Back off 1/4 of a turn
to properly set the pre-load on the bearings. If
disassembled, make sure the spring disc washers are
reinstalled as shown in Figure 22.
Figure 23
1. Loosen door hinge
nuts-three per side
2. Place a piece of 3/8 inch
(9.5 mm) rubber on this
surface
PTO Brake Spring
Adjustment
PTO brake spring adjustment is only necessary if the
blower has been removed or replaced or if the PTO
drive idler arm has been disassembled.
Figure 22
1. Spring disc washers
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Hopper Door Adjustment
2. Locate the brake spring and thread the two jam
nuts out to the end of the brake spring rod (see
Figure 24).
Door Closing:
Loosen six door hinge nuts (see Figure 23).
3. Tighten jam nuts together at end of brake spring
rod.
Open door and place a 3/8 inch rubber strip or 3/8
inch diameter hose between the hopper and hopper
door (see Figure 23).
Close door and push tight against hopper.
Tighten hinge hardware. Open hopper door and
remove rubber strip.
Figure 24
1. Tighten jam nuts here
2. PTO Brake spring assembly
36
Maintenance
Cleaning
Important: Do Not use water to clean engine.
Use low pressure compressed air. See Engine
Owner’s Manual.
Clean Engine and Exhaust
System Area
Clean Debris From Machine
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
conditions.)
Service Interval: Before each use or daily
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, especially around the fuel tank, around
engine and exhaust area.
CAUTION
Excessive debris around the engine cooling
air intake and inside of the pump drive
belt compartment and damaged or missing
rubber baffles can cause the engine and
hydraulic system to overheat which can
create a fire hazard.
Waste Disposal
Motor Oil Disposal
Engine oil and hydraulic oil are both pollutants to
the environment. Dispose of used oil at a certified
recycling center or according to your state and local
regulations.
Clean all debris from inside of pump drive
belt compartment daily.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Battery Disposal
2. Clean all debris from rotating engine air intake
screen and from around engine shrouding and
exhaust system area.
DANGER
Battery electrolyte contains sulfuric acid,
which is poisonous and can cause severe
burns. Swallowing electrolyte can be fatal or
if it touches skin can cause severe burns.
3. Clean all debris from around engine, drive belts,
and exhaust system area.
Remove Engine Shrouds and
Clean Cooling Fins
• Wear safety glasses to shield eyes, and
rubber gloves to protect skin and clothing
when handling electrolyte.
Service Interval: Every 80 hours
• Do Not swallow electrolyte.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
• In the event of an accident, flush with
water and call a doctor immediately.
2. Remove cooling shroud clean-out covers from
engine and clean cooling fins. Also clean dust,
dirt, and oil from external surfaces of engine,
which can cause improper cooling.
Federal law states that batteries should not be placed
in the garbage. Management and disposal practices
must be within relevant federal, state, or local laws.
3. Make sure cooling shroud clean-out covers are
reinstalled. Operating the engine without cooling
shroud clean-out covers will cause engine damage
due to overheating.
If a battery is being replaced or if the unit containing
the battery is no longer operating and is being
scrapped, take the battery to a local certified recycling
center. If no local recycling is available return the
battery to any certified battery reseller.
4. For 27HP Kohler units: Swing out the fuel tank
and remove debris from around the oil cooler
positioned at right front corner of engine.
37
Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused
by an empty fuel tank.
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major
items or any items that call for special timing or adjustments procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.
Problem
Starter does not crank.
Possible Cause
1. PTO is engaged.
1. Disengage the PTO.
2. Parking brake is not set.
3. Speed control lever is not in neutral
position.
4. Battery does not have a full charge.
6. Fuse is blown.
7. Relay or switch is defective.
2. Set the parking brake.
3. Ensure the speed control lever is in the
neutral position.
4. Charge the battery. See Check
Battery Charge and Recommended
Jump Starting Procedure sections in
Maintenance.
5. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
6. Replace the blown fuse.
7. Contact an Authorized Service Dealer.
1. Fuel tank is empty.
1. Fill the fuel tank.
2. Fuel shutoff valve is closed.
3. Oil level in the crankcase is low.
4. The throttle and choke are not in the
correct position.
2. Open the fuel shutoff valve.
3. Add oil to the crankcase.
4. Be sure the throttle control is midway
between the “SLOW” and “FAST”
positions, and the choke is in the “ON”
position for a cold engine or the “OFF”
position for a warm engine.
5. Replace the fuel filter.
6. Contact an Authorized Service Dealer.
5. Electrical connections are corroded, loose
or faulty.
Engine will not start, starts hard, or fails to
keep running.
5. Dirt in fuel filter.
6. Dirt, water, or stale fuel is in the fuel
system.
7. Air cleaner is dirty.
8. Electrical connections are corroded, loose
or faulty.
Engine loses power.
Corrective Action
9. Relay or switch is defective.
10. Faulty spark plug.
11. Spark plug wire is not connected.
7. Clean or replace the air cleaner element.
8. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
9. Contact an Authorized Service Dealer.
10. Clean, adjust or replace spark plug.
11. Check the spark plug wire connection.
1. Engine load is excessive.
1. Reduce the ground speed.
2. Air cleaner is dirty.
3. Oil level in the crankcase is low.
4. Cooling fins and air passages for the
engine are plugged.
5. Vent hole in the fuel cap is plugged.
6. Dirt in fuel filter.
7. Dirt, water, or stale fuel is in the fuel
system.
2. Clean or replace the air cleaner element.
3. Add oil to the crankcase.
4. Remove the obstructions from the cooling
fins and air passages.
5. Clean or replace the fuel cap.
6. Replace the fuel filter.
7. Contact an Authorized Service Dealer.
38
Troubleshooting
Problem
Engine overheats.
Possible Cause
Corrective Action
1. Engine load is excessive.
1. Reduce the ground speed.
2. Oil level in the crankcase is low.
3. Cooling fins and air passages for the
engine are plugged.
2. Add oil to the crankcase.
3. Remove the obstructions from the cooling
fins and air passages.
Mower pulls left or right (with levers fully
forward).
1. Tracking needs adjustment.
1. Adjust the tracking.
2. Tire pressure in drive tires not correct.
3. Reverse indicator and speed control
linkage need adjustment.
2. Adjust tire pressure in the drive tires.
3. Adjust the reverse indicator and the speed
control linkage.
Machine does not drive.
1. Bypass valve is not closed tight.
1. Tighten the bypass valve.
2. Drive or pump belt is worn, loose or
broken.
3. Drive or pump belt is off a pulley.
4. Broken or missing idler spring.
5. Hydraulic fluid level is low or too hot.
2. Change the belt.
Abnormal vibration.
3. Change the belt.
4. Replace the spring.
5. Add hydraulic fluid to reservoir or let it
cool down.
1. Engine mounting bolts are loose.
1. Tighten the engine mounting bolts.
2. Loose engine pulley, idler pulley, or blade
pulley.
3. Engine pulley is damaged.
4. Belt is damaged.
2. Tighten the appropriate pulley.
39
3. Contact an Authorized Service Dealer.
4. Install new belt.
HOUR METER, ENGINE, PTO SWITCH
TERMINAL X
TERMINAL Y
LT. BLUE
PURPLE
SEAT DELAY
TERMINAL S
HOPPER
SWITCH
START RELAY
TERMINAL I
WIPER
MOTOR
BLACK
PURPLE
BLACK
40
LT. BLUE
HOPPER
FILL
BUZZER
BATTERY
HOUR METER, ENGINE, PTO SWITCH
TERMINAL B
CONNECTIONS
LT. BLUE
LT. BLUE
BLACK
BLACK
B+I+S
B + I + A
NONE
X +Y
CIRCUIT "MAKE"
CONNECTED
HERE
PTO
SWITCH
BATTERY
GROUND
HOUR
METER
IGNITION
SWITCH
NOTE:
CONNECTORS VIEWED FROM WIRE END
HOPPER HARNESS
3. START
2. RUN
1. OFF
POSITION
TERMINAL X
TERMINAL Y
TERMINAL A
TERMINAL B
TERMINAL S
PINK
BLACK
LT. BLUE
BROWN
DK. GREEN
ORANGE
BLACK
BLACK
BLACK
ORANGE
ORANGE
DK. BLUE
ORANGE
ORANGE
ORANGE
TAN
ORANGE
YELLOW
TAN
RED
VIOLET
ORANGE
G006851
PTO
RELAY
BLACK
GRAY
BROWN
ORANGE
SPEED CONTROL SWITCH
IS CLOSED WITH CONTROL LEVER
IN NEUTRAL POSITION
LT. BLUE
VOLTAGE REGULATOR
ORANGE
BLACK
ORANGE
TERMINAL
BLACK
LT. BLUE
TERMINAL A
PINK
BLACK
SEAT DELAY
MODULE CONTROL
LT. BLUE
DK. GREEN
DK. GREEN
SEAT DELAY
MODULE INPUT
CLOSED WITH BRAKE
ENGAGED
SPEED
LT. BLUE
ENGINE
TEMP
SWITCH
BROWN
LT. BLUE
ENGINE
OVERHEAT
BUZZER
GRAY
DK. GREEN
BRAKE
SEAT
SWITCH
BROWN
LT. BLUE
ENGINE
OVERHEAT
LED
TAN
LT. BLUE
TERMINAL I
HOPPER
SWITCH
DK. GREEN
YELLOW
OPEN WITH BRAKE
ENGAGED
START
RELAY
BLACK
TAN
PINK
PINK
ORANGE
ORANGE
IGNITION SWITCH
DK GRN
ORANGE/BLACK STRIPE
CLOSED WITH
HOPPER DOWN
BLACK
DK. GREEN
BATTERY
GROUND
BLACK
BLACK
SWITCH IS CLOSED
WITH OPERATOR IN SEAT
BLACK
BLACK
ACCESSORY PLUG
DK.GREEN
DK GREEN
KILL
RELAY
ORANGE
WHITE
VIOLET
DK. BLUE
ORANGE/BLACK STRIPE
RED
RED
RED
VIOLET
VIOLET
ORANGE
ORANGE
ORANGE
ORANGE
ENGINE
CONNECTOR
STARTER
SOLENOID
BATTERY (+)
FUSE
30 AMP
FUSE
20 AMP
FUSE
20 AMP
Schematics
Schematics
Electrical Diagram
DK. GREEN
DK. GREEN
WHITE
41
3. START
2. RUN
1. OFF
POSITION
+
P
S
VIOLET
WIRES CROSSING
(NOT CONNECTED)
FILL SWITCH OPEN
WHEN SENSOR IN
NEUTRAL POSITION
BUZZER
X +Y
WIRES CONNECTED
B+I+S
B+I + A
NONE
CIRCUIT "MAKE"
TERMINAL X
BLACK
WIPER
MOTOR
HOPPER
FILL
SWITCH
LT. BLUE
IGNITION
SWITCH
TERMINAL Y
TERMINAL A
TERMINAL B
OFF
M
RUN
BLACK
LT. BLUE
PTO
SWITCH
BATTERY
GROUND
Y
X
S
I
B
A
ORANGE
RED
ORANGE
-
HOUR
METER
+
PINK
BLACK
BLACK
BLACK
BLACK
START
PINK
ORANGE
BLACK
LT. BLUE
DK. GREEN
BROWN
ORANGE
BUZZER
DK. BLUE
ORANGE
ORANGE
ORANGE
ORANGE
TAN
TAN
ORANGE
YELLOW
ORANGE
RED
VIOLET
PINK
TERMINAL S
TEMP
SWITCH
PINK
TERMINAL I
GRAY
PTO
RELAY
DK. GREEN
SPEED
CONTROL
G006949
DK. GREEN
SEAT
SWITCH
LT. BLUE
GRAY
SHOWN WITH SPEED CONTROL
LEVER IN NEUTRAL POSITION
SHOWN WITH
BRAKE ENGAGED
BRAKE
BROWN
LT. BLUE
+
S
LT. BLUE
LT. BLUE
P
BLACK
LT. BLUE
ORANGE
TAN
ORANGE/BLACK STRIPE
R
DK. GREEN
START
RELAY
HOPPER
SWITCH
DK. GREEN
LT. BLUE
BATTERY
GROUND
CLOSED WITH
HOPPER DOWN
DK. GREEN
BLACK
SHOWN WITH OPERATOR
IN SEAT
BLACK
KILL
RELAY
WHITE
SEAT DELAY
MODULE
RED
RED
RED
VIOLET
VIOLET
ORANGE
ORANGE
ORANGE
ORANGE
OIL PRESSURE
ENGINE KILL
REGULATOR
FUEL SOLENOID
VIOLET
ORANGE
STARTER
SOLENOID
BATTERY
(+) 12V
DK. BLUE
30 AMP
FUSE
20 AMP
FUSE
20 AMP
FUSE
WHITE
ORANGE/BLACK STRIPE
DK. GREEN
BLACK
BLACK
BROWN
ACCESSORY PLUG
DK. GREEN
ENGINE
OVERHEAT
LED
Schematics
Electrical Logic Schematic
DK. GREEN
DK. GREEN
DK. GREEN
BLACK
BLACK
YELLOW
DK. GREEN
BLACK
BLACK
TAN
ORANGE
LT. BLUE
BLACK
Schematics
Hydraulic Diagram
BYPASS VALVE
BYPASS VALVE
HIGH PRESSURE
REVERSE
HIGH PRESSURE
FORWARD
HIGH PRESSURE
FORWARD
HIGH PRESSURE
REVERSE
HIGH PRESSURE
CHARGE PUMP
CASE DRAIN
42
G006950
Exmark Commercial Turf Equipment
2 Year Limited Warranty
If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:
Exmark Customer Service Department
The Exmark Warranty Company
2101 Ashland Avenue
Beatrice, NE 68310
402-223-6375 or
service@exmark.com
Conditions and Products Covered
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty
Company, pursuant to an agreement between them, jointly
warrant on the terms and conditions herein, that we will repair,
replace or adjust any part on these products and found by us
(in the exercise of our reasonable discretion) to be defective in
factory materials or workmanship for a period of two years.
This warranty applies to Exmark commercial turf equipment
sold in the U.S. or Canada. This warranty may only be
assigned or transferred to a second (or third) owner by an
authorized Exmark dealer. The warranty period commences
upon the date of the original retail purchase.
Warranty Exceptions
Warranty Period
• Bags, Belts and Tires
90 days
• Battery
1 Year Prorated
• Engine
2 years*
* The Engine warranty is covered by the engine manufacturer.
Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet.
This warranty only includes the cost of parts and labor.
Owner’s Responsibilities
If your product requires warranty service it must be returned
to an authorized Exmark service dealer within the warranty
period. This warranty extends only to turf equipment operated
under normal conditions. You must read the operator’s
manual. You must also properly service and maintain your
Exmark product as described in the operator’s manual. Such
routine maintenance, whether performed by a dealer or by
you, is at your expense.
General Conditions
The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair or replacement of
defective components as set forth herein. Neither Exmark
nor Exmark Warranty Company shall be liable for any
incidental or consequential loss or damage.
Items and Conditions Not Covered
This warranty does not cover the following:
• Pickup and delivery charges to and from any authorized
Exmark Service Dealer.
• Any damage or deterioration due to normal use, wear and
tear, or exposure.
• Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune-up parts, and adjustments.
• Any product or part which has been altered or misused or
required replacement or repair due to normal wear,
accidents, or lack of proper maintenance.
• Any repairs necessary due to use of parts, accessories or
supplies, including gasoline, oil or lubricants, incompatible
with the turf equipment or other than as recommended in
the operator's manual or other operational instructions
provided by Exmark.
There are no other express warranties except for engine and
special emission system coverage.
All warranty work must be performed by an authorized
Exmark Service Dealer using Exmark approved replacement
parts.
Such damages include but are not limited to:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other
extraordinary repair charges or charges relating to repairs or
replacements outside of normal business hours at the place
of business of the authorized Exmark Service Dealer.
• Rental of like or similar replacement equipment during the
period of any warranty, repair or replacement work.
• Any telephone or telegram charges or travel charges.
• Loss or damage to person or property other than that
covered by the terms of this warranty.
• Any claims for lost revenue, lost profit or additional cost as
a result of a claim of breach of warranty.
• Attorney's fees.
No Claim of breach of warranty shall be cause for cancellation
or rescission of the contract of sale of any Exmark mower.
All implied warranties of merchantability (that the
product is fit for ordinary use) and fitness for use (that the
product is fit for a particular purpose) are limited to the
duration of the express warranty.
Some states do not allow exclusions of incidental or
consequential damages, or limitations on how long an
implied warranty lasts, so the above exclusions and
limitations may not apply to you.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
Instructions for Obtaining Warranty Service
The product must be registered with original proof of purchase
by an Exmark Service Dealer before obtaining any warranty
service.
Contact any Exmark Service Dealer to arrange service at their
dealership. To locate a dealer convenient to you, access our
website at www.exmark.com. U.S. or Canada customers may
also call 402-223-6375.
G4500-589_B
43
Notes:
44
Service Record
Date:
Description of Work Done:
45
Service Done By:
46
G011841
Figure 25
This page may be copied for personal use.
1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope indicator to determine the
degree of slope of hills before operating. Do Not operate this machine on a slope greater than 15 degrees. Fold
along the appropriate line to match the recommended slope.
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.
3. Example of how to compare slope with folded edge.
47
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS
MID-MOUNT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
OPERATOR CONTROLLED DISCHARGE
FULL SUSPENSION SEAT
ROLL OVER PROTECTION SYSTEM (ROPS)
DECK LIFT ASSIST KIT
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
TURF STRIPER
12V POWER PORT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
OUT-FRONT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
SNOW BLADE
DUAL-TAIL WHEEL
SNOWBLOWER
FLOOR PAN EXTENDER
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
WEATHER CAB
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
TURF STRIPER
MICRO-MULCH SYSTEM
STANDON
Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Model No.
Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Serial No.
© 2010 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
All Rights Reserved
Part No. 4500-628 Rev. B
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com