Exmark 4500-540 Rev. B Lawn Mower User Manual

TURF TRACER HP
®
For Serial Nos.
850,000 & Higher
Part No. 4500-540 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: 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.
To acquire a spark arrester for your unit, see your
Engine Service Dealer.
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.
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
Figure 1
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.
1. Model and serial number location
Model No.
Serial No.
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
Hydro Pump Spring Tension Setting .............. 36
PTO Safety Switch ........................................ 36
Cleaning ........................................................... 37
Clean Engine and Exhaust System
Area .......................................................... 37
Remove Engine Shrouds and Clean Cooling
Fins........................................................... 37
Clean Debris From Machine .......................... 37
Clean Grass Build-Up Under Deck ................ 37
Waste Disposal .............................................. 37
Troubleshooting ................................................... 39
Schematics ........................................................... 41
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ..................... 10
Specifications ....................................................... 14
Model Numbers ............................................ 14
Systems ......................................................... 14
Dimensions................................................... 15
Torque Requirements .................................... 16
Product Overview ................................................ 16
Operation ............................................................. 17
Controls ........................................................ 17
Pre-Start........................................................ 19
Operating Instructions .................................. 19
Transporting ................................................. 23
Maintenance ......................................................... 24
Recommended Maintenance Schedule(s) ........... 24
Periodic Maintenance ....................................... 25
Check Engine Oil Level ................................. 25
Check Battery Charge (Electric Start Units
Only)......................................................... 25
Check Mower Blades ..................................... 27
Check Safety Interlock System ....................... 28
Check for Loose Hardware ............................ 28
Service Air Cleaner ........................................ 28
Change Engine Oil ........................................ 29
Check Hydraulic Oil Level ............................. 29
Check Tire Pressures ..................................... 29
Check Condition Of Belts.............................. 29
Lubricate Grease Fittings............................... 29
Check Spark Plugs ......................................... 30
Change Hydraulic System Filter ..................... 30
Wheel Hub-Slotted Nut Torque
Specification.............................................. 32
Inspect PTO Clutching Belt Tension.............. 32
Thread Locking Adhesives............................. 32
Mobil HTS Grease (Or Food-Grade
Anti-seize)................................................. 33
Copper-Based Anti-seize ............................... 33
Dielectric Grease........................................... 33
Adjustments ..................................................... 33
Deck Leveling ............................................... 33
Pump Drive Belt Tension............................... 33
PTO Clutching Belt Tension.......................... 33
Deck Belt Tension ......................................... 33
Park Brake Adjustment.................................. 33
Hydro Drive Linkage Adjustment .................. 33
Tracking Adjustment ..................................... 36
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.
• 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.
Training
• 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.
• 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.
WARNING
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.
• Check that the operator’s presence controls,
safety switches, and shields are attached and
functioning properly. Do Not operate unless they
are functioning properly.
6
Safety
Operation
damage and make repairs before restarting
and operating the mower).
WARNING
– Before clearing blockages.
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.
– Whenever you leave the mower.
• Stop engine, wait for all moving parts to stop, and
engage parking brake:
• Allow engine parts, especially the muffler, to
cool before touching.
– Before refueling.
• Remove accumulated debris from muffler
and engine area.
– Before making height adjustments.
– Before dumping the grass catcher.
WARNING
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
Hands, feet, hair, clothing, or accessories can
become entangled in rotating parts. Contact
with the rotating parts can cause traumatic
amputation or severe lacerations.
WARNING
• Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can kill
you.
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
Do Not run engine indoors or in a small confined
area where dangerous carbon monoxide fumes
can collect.
• DO NOT operate the mower when people,
especially children, or pets are in the area.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• Operate only in daylight or good artificial light,
keeping away from holes and hidden hazards.
• Be sure all drives are in neutral and parking brake
is engaged before starting engine.
• 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.
• 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.
• Be aware of the mower discharge path and direct
discharge away from others.
• Never mow with the discharge deflector raised,
removed or altered unless there is a grass
collection system or mulch kit in place and
working properly.
• Do Not operate the mower under the influence
of alcohol or drugs.
• Do Not change the engine governor setting or
overspeed the engine.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
• Stop engine, wait for all moving parts to stop,
remove key and engage parking brake:
Slope Operation
• Use extreme care when loading or unloading the
machine into a trailer or truck.
– Before checking, cleaning or working on the
mower.
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.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
7
Safety
• Keep engine and engine area 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
Operating on wet grass or steep slopes can
cause sliding and loss of control. Loss of control
and/or loss of operator’s footing could result in a
fall with an arm or leg getting under the mower
or engine deck which may result in serious
injury, death or drowning.
• Let engine cool before storing and do not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Mow across slopes, never up and down.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
• Do Not mow slopes when grass is wet.
• Do Not mow near drop-offs or near water.
• Do Not mow slopes greater than 20 degrees.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Reduce speed and use extreme caution on
slopes.
• Use jack stands to support components when
required.
• Avoid sudden turns or rapid speed changes.
• Carefully release pressure from components with
stored energy.
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• 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.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• 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.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Keep hands and feet away from moving parts.
If possible, do not make adjustments with the
engine running.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
• 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.
• 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.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
DANGER
Charging or jump starting the battery may
produce explosive gases. Battery gases can
explode causing serious injury.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• Keep sparks, flames, or cigarettes away
from battery.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
• Ventilate when charging or using battery
in an enclosed space.
Maintenance and Storage
• Make sure venting path of battery is
always open once battery is filled with
acid.
• 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.
• Always shield eyes and face from battery.
8
Safety
DANGER
WARNING
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.
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.
• Wear safety glasses to shield eyes, and
rubber gloves to protect skin and clothing
when handling electrolyte.
• If equipped, 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.
• Do Not swallow electrolyte.
• In the event of an accident, flush with
water and call a doctor immediately.
• Keep body and hands away from pinhole
leaks or nozzles that eject high pressure
hydraulic fluid.
CAUTION
• Use cardboard or paper, not your hands, to
find hydraulic leaks.
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
• 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.
Be sure ignition switch is in the “OFF”
position before charging the battery.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Check all bolts frequently to maintain proper
tightness.
• Frequently check for worn or deteriorating
components that could create a hazard.
WARNING
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.
9
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.
1-403143
1-303508
1-303517
1-413206
36 inch Decks Only
1-413214
1-403005
10
Safety
1-413327
48 inch and 52 inch Decks Only
103-1798
1-413421
1-553049
103-1976
20 HP Kawasaki Electric Start
98-5954
11
Safety
103-1977
16 HP and 18 HP Kawasaki Manual Start
103–2242
103–2076
103–2243
103-2103
103-4935
12
Safety
109-3148
116-0404
117–2718
13
Specifications
Specifications
Model Numbers
Serial Nos: 850,000 and Higher
Manual Start Models: THP16KA363; THP16KA483; THP18KA523; THP16KA363CA; THP16KA483CA
Electric Start Models: THP20KAE483; THP20KAE523; THP20KAE483CA
Systems
neutral to each drive wheel for moving forward or
reverse, stopping, and power turning.
Engine
Transmission
• Engine Specifications: See your Engine Owner’s
Manual
• RPM: Full Speed: 3600 (No Load)
Twin Hydrostatic Drive
• Two Hydro Gear variable displacement high
efficiency pumps independently coupled to two
high efficiency Parker/Ross wheel drive motors.
Fuel System
• Capacity: 5.0 gal. (18.9 L)
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher; containing no more than 10%
methanol or ethanol.
• Fuel Filter: Replaceable In-line
• Fuel Shut-Off Valve: 1/4 turn increments
• Hydraulic Oil: Use Exmark Premium Hydro Oil.
• Hydraulic Oil Capacity: 2.4 qt. (2.2 L)
• Hydraulic Filter is replaceable cartridge type.
P/N 109-4180: 25 microns, 10 psi bypass
(Summer use above 32°F (0°C))
P/N 1-523541: 40 microns, 18 psi bypass (Winter
use below 32°F (0°C))
Electrical System (Electric Start)
•
•
•
•
•
•
Charging System: Flywheel Alternator
Charging Capacity: 15 amps
Battery Type: BCI Group U1
Battery Voltage: 12 Volt
Polarity: Negative Ground
Fuses: Two 20 amp blade type
• Speeds:
– 0-6.2 mph (10.0 km/hr) forward.
– 0-2.2 mph (3.5 km/hr) reverse.
• Drive wheels release valves allow machine to be
moved when engine is not running.
Safety Interlock System:
Wheel Drive System
• Operator must have OPC (Operator Presence
Control) levers held in contact with handle
grips, speed control lever in neutral, and PTO
disengaged to start engine. Release of OPC levers
will cause the engine to stop if speed control lever
is not in neutral and/or PTO is engaged.
• Park brake must be disengaged to move speed
control out of neutral or engine will kill.
Drive wheels are direct coupled to Parker wheel drive
motors with 1 inch (25.4 mm) tapered shaft.
Operator Controls
Steering Control: Fingertip drive control levers
provide independent speed control, braking and
14
Specifications
Dimensions
Tires & Wheels
Drive
Front Caster
Pneumatic
(Air-Filled)
Pneumatic
(Air-Filled)
SemiPneumatic
36
48 & 52
All Decks
Quantity
2
2
2
Tread
Turf Master Turf Master Smooth
Size
16 x 6.50–8
16 x 7.50–8
Ply Rating
4
4
Pressure
14 psi
(97 kPa)
14 psi
(97 kPa)
Overall Width:
9 x 3.50-4
36 inch
Deck
48 inch
Deck
52 inch
Deck
Deflector
Up
36.1 inches
(91.7 cm)
48.1 inches
(122.2 cm)
53.0 inches
(134.6 cm)
Deflector
Down
46.25 inches 58.25 inches 62.6 inches
(117.5 cm) (148.0 cm) (159.0 cm)
Overall Length:
Cutting Deck
36 inch Deck
48 inch Deck
52 inch Deck
77.3 inches
(196.3 cm)
73.7 inches
(187.2 cm)
75.9 inches
(192.8 cm)
• Cutting Width:
– 36 inch Deck: 35.25 inches (89.5 cm)
Overall Height:
– 48 inch Deck: 47.25 inches (120.0 cm)
36 inch Deck
48 inch Deck
52 inch Deck
– 52 inch Deck: 52.00 inches (132.1 cm)
44.1 inches
(112.0 cm)
44.1 inches
(112.0 cm)
44.1 inches
(112.0 cm)
• Discharge: Side
• Blade Size:
Tread Width: (Outside to Outside of
Tires, Widthwise)
– 36 inch Deck: 18.00 inches (45.7 cm)—
Quantity: 2
– 48 inch Deck: 16.25 inches (41.3 cm)—
Quantity: 3
– 52 inch Deck: 18.00 inches (45.7 cm)—
Quantity: 3
36 inch Deck
48 inch Deck
52 inch Deck
35.0 inches
(88.9 cm)
39.4 inches
(100.1 cm)
39.4 inches
(100.1 cm)
Curb Weight:
• Deck Drive: Manual engagement of belt with
over-center lock. Blade belt tension is adjustable
via turnbuckle.
• Deck Mounting: Full floating deck is attached to
out-front support frame, removable for service.
36 inch Deck
48 inch Deck
52 inch Deck
565 lb (211 kg)
610 lb (277 kg)
644 lb (292 kg)
Note: Weights will vary slightly depending on engine
and electric start options.
• Deck Depth:
– 36 inch Deck: 5.0 inches (12.7 cm)
– 48 inch Deck: 5.0 inches (12.7 cm)
– 52 inch Deck: 5.0 inches (12.7 cm)
• Cutting Height Adjustment:
Adjusts from 1 1/2 inches (3.8 cm) to 4 1/2
inches (11.4 cm) in 1/2 inch (1.3 cm) increments
• Mulching Kit: Optional
• Bagger: Optional
15
Product Overview
Torque Requirements
Bolt Location
Torque
Cutter Housing Spindle
Nut
140-145 ft-lb
(190-197 N-m)
Blade Mounting Bolt
(lubricate with anti-seize)
55-60 ft-lb (75-81 N-m)
Engine Deck/Mower
Deck Support Mount
Bolts
30-35 ft-lb (41-47 N-m)
Anti-Scalp Roller Nyloc
Nut See Figure 9
30-35 ft-lb (41-47 N-m)
Product Overview
Anti-Scalp Roller Whizlock 30-35 ft-lb (41-47 N-m)
Nut See Figure 9
Engine Mounting Bolts
17-23 ft-lb (23-31 N-m)
Wheel Lug Nuts
90-95 ft-lb (122-129 N-m)
Wheel Hub Slotted Nuts
minimum 100 ft-lb
(136 N-m)
Wheel Motor Mounting
Bolts
30-35 ft-lb (41-47 N-m)
Figure 3
1. Park Brake Lever
2. Controls
16
3. Fuel Cap
4. Height-of-Cut Pins
Operation
Operation
as shown in Figure 4, and the drive levers are released,
the drive wheels are engaged in the forward direction.
Note: Determine the left and right sides of the
machine from the normal operating position.
Operator Presence Control (OPC)
Levers
Squeezing the left hand and/or right hand lever
causes the left hand and/or right hand drive wheel
respectively to slow down, stop, or reverse, depending
on how far each drive lever is “squeezed”. Squeezing
the drive levers beyond the neutral position causes
the drive wheels to engage in the reverse direction
regardless of the position of the neutral lock latches
and the speed control lever.
Located on the upper handle assembly directly above
the handle grips.
Neutral Lock Latches
Controls
Located on the upper handle assembly on the ends
of the handle grips.
When these levers are depressed, the OPC system
senses that the operator is in the normal operator’s
position. When the levers are released, the OPC
system senses that the operator has moved from the
normal operating position and will kill the engine if
either the speed control lever is not in the neutral
position or the PTO is engaged (see Figure 4).
These latches allow the operator to lock the drive
levers in a “neutral” position where the drive wheels
are not engaged in either a forward or reverse
direction.
Choke Control
Located on the front left corner of the fuel tank
support.
Choke is used to aid in starting a cold engine. The
choke control is pulled out to be in the “ON” position
and pushed in to be in the “OFF” position. Do Not
run a warm engine with choke in the “ON” position.
Throttle Control
Located on the control console’s right side.
The throttle is used to control engine speed. Moving
the throttle control forward will increase engine
speed and moving it to the rear will decrease engine
speed. Moving the throttle forward into the detent
is full position.
Figure 4
1. OPC Lever
2. Rotate neutral lock latch
downward for neutral
lock position
3. Neutral Lock Latch
4. Drive Lever in neutral
position
Speed Control Lever
Located in middle of control console.
Drive Levers
The speed control lever controls the maximum
forward speed and is infinitely variable from neutral
0–6.2 mph (10.0 km/hr).
Located on each side of the upper handle assembly
ahead of and below the handle grips.
These levers individually control the speed and
direction of each drive wheel. When the speed control
lever is moved out of the neutral position and the
neutral lock latches are moved into the drive position,
Park brake must be disengaged to move speed control
out of neutral or engine will kill.
17
Operation
Park Brake Lever
transportation to and from the job sites, and when
the machine will not be used for a few days.
Located on the left side of the unit above the
hydraulic tank.
Rotate valve 1/4 turn clockwise to shut fuel off.
Rotate valve 1/4 turn counterclockwise to turn fuel
on.
The brake lever engages the park brake on the drive
wheels.
Pull the lever up and rearward to engage the brake.
Drive Wheel Release Valves
Push the lever forward and down to disengage the
brake.
Located on the left rear corner of the hydrostatic
pumps.
When parking on a steep slope, the wheels must be
chocked or blocked in addition to the brake being
engaged. The unit must be tied down and brake
engaged when transporting.
Drive wheel release valves are used to release the
hydro-static drive system to allow the machine to be
moved by hand without the engine running.
With a 5/8 wrench, turn both valves one turn
counterclockwise to release the drive system.
The park brake must be disengaged to move speed
control out of neutral or engine will kill.
Turn clockwise to reset the drive system. Do Not
overtighten.
For manual start engines: The park brake must be
disengaged before the PTO is engaged or the engine
will kill.
Tracking Adjustment Knob
“Off-Run” Switch (Manual Start Only)
Located on the right-hand side of the rear of the fuel
tank support.
Located on the console.
The knob can be adjusted so that machine will
“track” straight ahead with the drive levers released.
Turn key to the “Run” position to allow the engine
to be started. Turn key to the “Off ” position to shut
engine off.
PTO Engagement
Operator must have speed control lever in neutral
and the PTO disengaged to start engine.
Located on the left side of the upper handle.
To engage the blades, push the lever forward, or away
from the operator, until the linkage locks over-center.
To disengage the blades, pull the lever to the rear,
or towards the operator.
Ignition Switch (Electric Start Only)
Located on the control console.
The ignition switch is used to start and stop the
engine. The ignition 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). Operator must have speed control lever in
neutral, OPC levers depressed and PTO disengaged
to start engine. When engine starts, release key.
For manual start engines: The park brake must be
disengaged before the PTO is engaged or the engine
will kill.
Cold Start Kit (Manual Start Only)
Located below the hydro control shield.
The cold start kit is used to ease the starting of the
unit in cold weather or when the unit has not been
operated for a period of time. The cold start kit
moves the idler pulley away from the pump belt,
releasing the tension on the belt which allows the
engine to turn over with less resistance (see Starting
the Engine (Manual Start) section in Operation).
Fuel Shut-Off Valve
Located in the fuel line midway between the tank
and engine.
The fuel shut-off valve is used to shut off the
flow of fuel when parking inside a building, during
18
Operation
Pre-Start
B. Start engine. Refer to the following
guidelines for further starting suggestions.
Fill fuel tank on level ground. For best results use
only clean, fresh regular grade unleaded gasoline with
an octane rating of 87 or higher.
• To engage pump drive (disengage cold start
kit):
A. Pull chain straight out from the side of the
unit until the split ring can be removed
from the bolt.
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.
B. Slowly release tension on chain.
Do Not add oil to gasoline.
2. Pull out the choke control. Place the throttle
control midway between the “Slow” and “Fast”
positions.
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).
3. Turn the key switch to the “Run” position.
4. Pull recoil rope to start engine.
5. After engine warms up, gradually push in the
choke control. Do Not run warm engine with the
choke in the “ON” position.
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
Note: Kawasaki engines generally need to be
“choked” even when warm.
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
Note: After starting the engine and engaging the
hydro drive, if either of the drive wheels acts sluggish
or will not rotate at all, stop engine and refer to
the Hydraulic System Air Purge Procedure in
Maintenance.
Note: Operator must have PTO disengaged, speed
control lever in neutral position, and OPC levers
depressed when starting the engine.
Operating Instructions
1. Lock drive levers in neutral and engage park
brake.
Starting the Engine (Electric Start)
2. Pull out the choke control. Place the throttle
control midway between the “Slow” and “Fast”
positions.
Open the Fuel Shut-Off Valve
Rotate the valve 1/4 turn counterclockwise to turn
fuel on.
3. Turn the ignition switch to the “Start” position.
Release the switch as soon as the engine starts.
Starting the Engine (Manual Start)
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 starter cool-down period between
starting attempts. Failure to follow these
guidelines can burn out the starter motor.
Note: Operator must have PTO disengaged and
speed control lever in neutral position when starting
the engine.
1. Lock drive levers in neutral and engage park
brake.
4. After engine warms up, gradually push in the
choke control. Do Not run warm engine with the
choke in the “ON” position.
Note: A cold weather starting kit has been added
for ease of starting in either cold weather or when
the unit has not been run for a period of time.
• To use cold start kit:
A. Pull split ring straight out the side of the
unit, and hook the ring over the lower rear
hydro control shield bolt.
Note: Kawasaki engines generally need to be
“choked” even when warm.
19
Operation
PTO Engagement
6. Place the throttle midway between the “SLOW”
and “FAST” positions.
DANGER
7. Allow the engine to run for a minimum of 15
seconds, then turn the ignition switch to the
“OFF” position to stop the engine.
The rotating blades under the mower deck are
dangerous. Blade contact can cause serious
injury or kill you.
8. Remove the key to prevent children or other
unauthorized persons from starting engine.
Do Not put hands or feet under the mower or
mower deck when the blades are engaged.
9. 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.
DANGER
An uncovered discharge opening will allow
objects to be thrown in an operator’s or
bystander’s direction. Also, contact with the
blade could occur. Thrown objects or blade
contact can cause serious injury or death.
Driving the Machine
Drive Lever/Neutral Lock Latch Operation
To lock the drive levers in “neutral lock”, squeeze the
drive levers to the “neutral” position (Do Not squeeze
the drive levers all the way back as this will cause the
drive wheels to go into full reverse direction). See
Figure 5 position 1. Place thumbs on the inner lobe
of the neutral lock latches and rotate them under
the drive levers into the “neutral lock” position. See
Figure 5 position 2. Release the drive levers.
Never operate the mower with the discharge
deflector raised, removed, or altered unless there
is a grass collection system or mulch kit in place
and working properly.
The PTO switch engages the cutting blades. Be sure
that all persons are clear of mower deck and discharge
area before engaging the PTO.
CAUTION
1. Set throttle to “MIDWAY” position.
If the neutral lock latches are not completely
engaged the drive levers could unexpectedly slip
into the forward drive position. If the drive levers
slip into the drive position the unit could lurch
forward and cause injury or property damage.
2. Push the PTO engagement arm forward and
down to engage blades.
3. Place the throttle in the “FAST” position to begin
mowing.
For manual start engines: The park brake must
be disengaged before the PTO is engaged or the
engine will kill.
Be sure the drive levers are past the roller and
securely seated at the bottom of the neutral lock
latches.
Disengaging the PTO
To place the drive levers in the “forward” position,
slightly squeeze the drive levers while placing thumbs
on the outer thumb lobe of the neutral lock latches
(or the index finger on the front lobe) and rotate them
from under the drive levers. Slowly and carefully
release the drive levers. See Figure 5 position 3.
1. Set throttle to “MIDWAY” position.
2. Pull upward and back completely on the PTO
engagement arm to disengage the blades.
Stopping the Engine
To place the drive levers in the “reverse” position,
squeeze the drive levers past the neutral position. See
Figure 5 position 4.
1. Bring the unit to a full stop.
2. Lock drive levers in neutral.
3. Disengage the PTO.
4. Move speed control lever to neutral.
5. Engage the parking brake.
20
Operation
Driving in Reverse
To move rearward in a straight line, squeeze drive
levers into the reverse position.
To turn left or right, squeeze the right hand drive lever
to turn left and the left hand drive lever to turn right.
To make a “zero turn”, squeeze either the left hand
or the right hand drive lever back into the reverse
position while the opposite drive lever is in a forward
position at an equal but opposite speed.
Note: For smooth operation of this machine, avoid
quick, jerky movements of the drive levers. Move the
drive levers smoothly and deliberately.
Figure 5
1. Drive Lever in neutral
position
2. Drive Lever locked in
neutral position
3. Drive Lever in forward
position
4. Drive Lever in reverse
position
To stop, squeeze drive levers back to the “neutral”
position. Move the neutral lock latches into the
“neutral lock” position and release drive levers. Move
the speed control lever to the neutral position.
Driving Forward
Adjusting the Cutting Height
1. Release the parking brake.
WARNING
2. With drive levers locked in “neutral”, shift speed
control lever to desired forward speed.
When the two front support rod hairpins are
removed from the mower deck, the weight of the
tractor section may cause the front frame of the
unit to rise suddenly. If the unit rises suddenly,
injury may occur.
3. Slowly squeeze and hold both drive levers in
the neutral position and rotate both neutral lock
latches from the neutral lock position to the
forward position.
Securely hold down the front of the unit when the
front support rod hairpins are removed.
Note: Do Not squeeze both drive levers all the
way back. This will cause the drive wheels to
engage in the reverse direction.
The cutting height of the mower deck is adjusted
from 1 1/2 to 4 1/2 inches (3.81 cm to 11.4 cm) in
1/2 inch increments.
1. Stop the machine and move the drive levers to the
neutral locked position.
2. Disengage the PTO.
3. Engage the park brake.
4. Stop the engine, remove the key and wait for all
moving parts to stop.
5. Install hairpin clips in the holes for the desired
cutting height. See Figure 6.
4. To move forward in a straight line, smoothly
release both drive levers to engage drive wheels.
To turn left or right, squeeze the right hand drive
lever to turn right and the left hand drive lever
to turn left.
To make a “zero turn”, squeeze either the left
hand or the right hand drive lever back into the
reverse position while the opposite drive lever is in
a forward position at an equal but opposite speed.
Note: For smooth operation of this machine,
avoid quick, jerky movements of the drive levers.
Move the drive levers smoothly and deliberately.
Important: To maintain correct cutting
height and rake, check the following for
proper adjustment.
A. The front and rear hairpins are in the same
holes with the proper spacers under the hair
pins. See Figure 6.
To stop, squeeze drive levers back to the “neutral”
position. Move the neutral lock latches into the
“neutral lock” position and release drive levers.
Move the speed control lever to the neutral
position.
21
Operation
Adjusting the Anti-Scalp Rollers
It is recommended to change the anti-scalp roller
position when the height of cut has changed.
1. Stop the machine and move the drive levers to
the neutral lock position.
2. Disengage the PTO.
3. Engage the park brake.
4. Stop the engine, remove the key and wait for all
moving parts to stop.
5. After adjusting the height of cut, adjust the
anti-scalp rollers by removing the whizlock nut
and spring disc washer.
Figure 6
1. Deck support pin
2. Cutting Height
6. Adjust anti-scalp rollers for Normal Operating
Conditions. Place rollers in one of the positions
shown in Figure 8. Rollers will maintain 3/4
inches (19 mm) clearance to the ground to
minimize gouging and roller wear or damage.
B. The tire pressures are set as directed in Check
Tire Pressures in the Maintenance section.
C. The length of the rear deck support link
assemblies average 6.89 inches (approximately
6 7/8 inches) (175.01 mm) from the center of
the balljoint to the center of the farthest hole.
See Figure 7.
Note: For Maximum Deck Flotation, place
rollers one hole position lower. Rollers should
maintain 1/4 inch (6.35 mm) clearance to ground.
Do Not adjust rollers to support the deck. Be
sure roller bolts are installed with the spring disc
washer between head of the nut and mounting
bracket.
Note: All four pins must equally support the
weight of the deck. Adjustment in the length
of the rear deck support assemblies may be
necessary. If one side is longer than 6.89
inches (approximately 6 7/8 inches) (175.01
mm), than the opposite side must be shorter
by the same amount.
Figure 8
For cutting heights above 3.5 inches (38 mm) use the
bottom hole. The rollers will still be effective against
scalping.
1. Anti-scalp roller
mounting bracket
2. Cutting height
7. Torque the 3/8–16 whizlock nut to 30-35 ft-lb
(41-47 N-m) (Figure 9).
Figure 7
Left Hand Side Shown
8. If the 3/8 nyloc nut has been removed, reinstall
and torque to 30–35 ft-lb (41-47 N-m) (Figure 9).
22
Operation
Figure 9
1. Spring disc washer
(cone towards nut )
2. Front right anti-scalp
bracket shown
3. 3/8 nyloc-torque to 30-35
ft-lb (41-47 N-m)
4. 3/8-16 whizlock nut
torque to 30-35 ft-lb
(41-47 N-m)
Transporting
Transporting a Unit
WARNING
Loading the mower onto a trailer without strong
enough or properly supported ramps could be
dangerous. The ramps could collapse causing
the unit to fall, which could cause injury.
• Use proper ramps that are secured to the
truck or trailer.
• Keep feet and legs out from under the unit
when loading and unloading.
• If necessary, use assistance when loading.
Be sure the fuel shut-off valve is closed.
Use a heavy duty trailer to transport the machine.
Engage neutral lock latches and park brake, then
block wheels.
Securely fasten the machine to the trailer with straps,
chains, cables, or ropes.
Do Not rely solely on the parking brake to hold the
machine on the trailer.
Be sure that the trailer has all necessary lighting and
marking as required by law and use a safety chain.
23
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 2 hours
• Inspect PTO clutching belt tension. Check every 2 hours for the first 8 hours of operation.
After the first 5 hours
• Change the engine oil.
After the first 100 hours
• Check wheel hub-slotted torque specification.
After the first 250 hours
• Change the hydraulic filter.
Before each use or daily
•
•
•
•
•
•
•
•
•
Check the engine oil level.
Check the mower blades.
Check the safety interlock system.
Check for loose hardware.
Grease the caster wheel bearings.
Grease caster pivots.
Clean the engine and exhaust system area.
Clean the grass and debris build-up from the machine and cutting deck.
Clean the grass build-up from under the deck.
Every 25 hours
• Service the foam element. (May need more often under severe conditions. See the Engine
Owner’s manual for additional information.)
Every 40 hours
•
•
•
•
•
•
•
•
Every 100 hours
• Service the paper element. (May need more often under severe conditions. See the Engine
Owner’s manual for additional information.)
• Change the engine oil. (May need more often under severe conditions.)
• Remove engine shrouds and clean cooling fins.
Every 160 hours
• Check the spark plugs.
Every 200 hours
• Replace the paper element.
Check the hydraulic oil level.
Check the tire pressures.
Check the condition of the belts.
Grease the pump drive idler pivot.
Grease the clutch arm pivot.
Grease the pump control bearings.
Grease the mower deck idler pivot.
Inspect PTO clutching belt tension.
24
Maintenance
Maintenance Service
Interval
Every 500 hours
Monthly
Maintenance Procedure
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)
• Check wheel hub-slotted torque specification.
• Check the battery charge.
• Grease the PTO engagement bellcrank.
Periodic Maintenance
storage when the open circuit voltage drops to 12.4
volts.
Check Engine Oil Level
Note: To prevent damage due to freezing, battery
should be fully charged before putting away for
winter storage.
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. Clean area around dipstick. Remove dipstick and
wipe oil off. Reinsert the dipstick and push it all
the way down into the tube. Do Not screw into
place. Remove the dipstick and read the oil level.
4. 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.
Check the voltage of the battery with a digital
voltmeter. Locate the voltage reading of the battery in
the table and charge the battery for the recommended
time interval to bring the charge up to a full charge
of 12.6 volts or greater.
Important: Make sure the negative battery
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
(Electric Start Units Only)
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
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.
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
25
Maintenance
Recommended Jump
Starting Procedure (Electric
Start Units Only)
WARNING
Batteries contain acid and produce explosive
gases.
• Shield the eyes and face from the batteries
at all times.
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.
• Do Not lean over the batteries.
Note: Be sure the vent caps are tight and level.
Place a damp cloth, if available, over any vent
caps on both batteries. Be sure the vehicles do
not touch and that both electrical systems are
off and at the same rated system voltage. These
instructions are for negative ground systems only.
CAUTION
Corrosion or loose connections can cause
unwanted electrical voltage spikes at anytime
during the jump starting procedure.
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 10.
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.
Figure 10
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.
1.
2.
3.
4.
5.
6.
7.
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
CAUTION
4. Connect the other end of the positive cable to the
positive terminal of the booster battery.
Connecting the jumper cables incorrectly
(wrong polarity) can immediately damage the
electrical system.
5. Connect the black negative (–) cable to the other
terminal (negative) of the booster battery.
Be certain of battery terminal polarity and
jumper cable polarity when hooking up
batteries.
6. MAKE THE FINAL CONNECTION ON
THE ENGINE BLOCK OF THE STALLED
VEHICLE (NOT TO THE NEGATIVE POST)
AWAY FROM THE BATTERY. STAND BACK.
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).
7. Start the vehicle and remove the cables in the
reverse order of connection (the engine block
(black) connection is the first to disconnect).
26
Maintenance
Check Mower Blades
C. Apply lubricant to threads of blade bolt as
needed to prevent seizing. Copper-based
anti-seize preferable. Grease acceptable
substitute. Install blade bolt finger tight. Place
wrench on the top spindle nut then torque the
blade bolts to 55-60 ft-lb (75-81 N-m).
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Lift deck and secure in raised position as stated in
the Clean Grass Build-Up Under Deck section.
3. Inspect blades and sharpen or replace as required.
4. Reinstall the blades (if they were removed) in the
following order:
A. Install bushing through blade with bushing
flange on bottom (grass) side of blade.
WARNING
Incorrect installation of the blade or
components used to retain the blade can
be dangerous. Failure to use all original
components and assembled as shown could
allow a blade or blade component to be
thrown out from under the deck resulting in
serious personal injury or death.
Always install the original Exmark blades,
blade bushings, and blade bolts as shown.
Replacing the Discharge
Deflector
Service Interval: As required
Figure 11
1. Install bushing in blade prior to installing bushing in
spindle.
DANGER
An uncovered discharge opening could allow the
lawn mower to throw objects in the operator’s or
bystander’s direction and result in serious injury.
Also, contact with the blade could occur.
B. Install bushing/blade assembly into spindle.
Never operate the lawn mower unless you install
a mulch plate, discharge deflector, or grass
collection system.
1. To remove a damaged or worn discharge
deflector, lift the leg of the spring with the loop
out of the notch in the discharge deflector and
slide the rod out of the discharge deflector
brackets, and discharge deflector.
2. To install new discharge deflector, orient the
spring on the rod as shown in Figure 13. Slide the
rod through the front discharge deflector bracket,
discharge deflector, and rear deflector bracket.
Figure 12
1. Use wrench here for
blade installation. This
nut has been torqued to
140–145 ft-lb (190–197
N-m)
2. Torque to 55-60 ft-lb
(75-81 N-m) Apply
lubricant to threads
as needed to prevent
seizing. Copper-based
anti-seize preferable.
Grease acceptable
substitute.
27
Maintenance
Try to start with, OPC levers depressed, speed
control lever in any speed but neutral and PTO
disengaged–starter must not crank.
Try to start with OPC levers depressed,
speed control lever in neutral and PTO
engaged–starter must not crank. .
2. For All Units: Check OPC circuits. Clear the
area. Disengage the park brake. Run engine at
one-third throttle, then, with drive levers and
neutral lock latches in neutral lock position,
move the speed control lever out of neutral and
release OPC levers–engine must stop. Again,
run engine at one-third throttle, move the speed
control lever to neutral, engage PTO and release
OPC levers–engine must stop.
Note: Park brake must be disengaged before the
speed control lever is moved out of neutral or engine
will kill.
Figure 13
1. Rod
2. Spring
3. Discharge deflector
For Manual Start Engines: The park brake must be
disengaged before the PTO is engaged or the engine
will kill.
4. Mower deck
5. Discharge deflector
bracket
6. Assembled view
Note: If machine does not pass any of these tests,
do not operate. Contact your authorized EXMARK
SERVICE DEALER.
3. Hook the bent end of the rod around the front
discharge deflector bracket to retain it from
sliding out. Place the leg of the spring with the
loop in the notch in the discharge deflector to
hold the discharge deflector in the down position
(see Figure 13).
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
Check for Loose Hardware
Important: The discharge deflector must be
spring loaded in the down position. Lift the
deflector up to test that it snaps to the full
down position.
Service Interval: Before each use or daily
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.
Check Safety Interlock
System
Service Interval: Before each use or daily
Service Air Cleaner
1. For Electric Start Units Only: Check starting
circuit. Starter should crank with: Operator
Presence Control levers depressed, speed control
lever in neutral, and PTO disengaged.
Service Interval: Every 25 hours—Service
the foam element. (May
need more often under
severe conditions. See
the Engine Owner’s
manual for additional
information.)
Every 100 hours—Service
the paper element. (May
Try to start the engine with OPC levers
disengaged, speed control lever in neutral and
PTO disengaged–starter must not crank.
28
Maintenance
need more often under
severe conditions. See the
Engine Owner’s manual
for additional information.)
Every 200 hours/Yearly
(whichever comes
first)—Replace the paper
element.
1. Stop engine, wait for all moving parts to stop, and
remove key or spark plug wire(s). Engage parking
brake.
2. See the Engine Owner’s Manual for maintenance
instructions.
baffle inside the tank. If not, add oil. Use Exmark
Premium Hydro oil. Replace hydraulic reservoir
cap and tighten until snug. Do Not overtighten.
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
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.
Change Engine Oil
Check Tire Pressures
Service Interval: After the first 5 hours
Every 100 hours (May
need more often under
severe conditions.)
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.
3. The oil drain hose assembly is located on the left
side of the engine.
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Check tire pressure in drive tires.
3. Inflate drive tires to 12–16 psi (83–110 kPa).
4. Inflate tires to pressures stated above. Measure
the circumference of each drive tire. Adjust tire
pressures within the above range to try to make
tire circumferences match as closely as possible.
5. Semi-pneumatic caster tires do not need to be
inflated.
Place pan under machine to catch oil. Remove oil
drain plug. Allow oil to drain and replace oil drain
plug. Torque plug to 20-24 ft-lb (27-33 N-m).
4. Replace the oil filter per the Engine Owner’s
Manual. Clean around oil filter and unscrew filter
to remove. Before the new filter is installed,
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 2/3 to 3/4 turn.
5. Clean around oil fill cap and remove cap. Fill to
specified capacity and replace cap.
6. Use oil recommended in engine owner’s manual.
Do Not overfill. Start the engine and check for
leaks. Stop engine and recheck oil level.
Check Condition Of Belts
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Remove the mower deck belt shield to check
mower blade drive belt condition.
3. Look under engine deck to check the pump drive
belt condition.
4. Check all idler arms to be sure they pivot freely.
Disassemble, clean and grease pivot bushings if
necessary.
Check Hydraulic Oil Level
Service Interval: Every 40 hours
1. Stop engine and wait for all moving parts to stop,
and remove key. Engage parking brake.
2. Clean area around hydraulic reservoir cap and
remove cap. Oil level should be to the top of the
Lubricate Grease Fittings
Note: See chart for service intervals.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
29
Maintenance
2. Lubricate fittings with NGLI grade #2
multi-purpose gun grease.
Spray Lubricant Chart (cont'd.)
Pivot Point
Refer to the following chart for fitting locations
and lubrication schedule.
1. PTO Lever
Lubrication Chart
Fitting
Locations
Number of Places
Service Interval
1
40 hours
Check Spark Plugs
Initial
Pumps
Number of Places
Service
Interval
36 inch
Deck
48 inch
Deck
52 inch
Deck
Service Interval: Every 160 hours
1. Caster
Wheel
Bearings
12
2
2
2
Daily
Remove spark plugs, check condition and reset gaps,
or replace with new plugs. See Engine Owner’s
Manual.
2. Caster
Pivots
2
2
2
2
Daily
Change Fuel Filter
3. PTO
Engagement
Bellcrank
1
1
1
1
40 hours
4. Pump
Drive Idler
Pivot
2
1
1
1
Yearly
5. Clutch
Arm Pivot
1
1
1
1
40 hours
6. Pump
Control
Bearings
2
2
2
2
40 hours
7. Mower
Deck Idler
Pivots
2
1
1
1
Yearly
Service Interval: As required
A fuel filter is installed in the fuel line between the
fuel tank and the engine. Replace when necessary.
Change Hydraulic System
Filter
Service Interval: After the first 250 hours
Every 500 hours/Yearly
(whichever comes
first) thereafter
(Every 250 hours/Yearly if
using Mobil 1 15W50)
Note: Use only Exmark Part No. 109-4180 for
Summer use above 32°F (0°C) or P/N 1-523541 for
Winter use below 32°F (0°C) (Refer to Transmission
section in Specifications for filter specifications).
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Carefully clean area around filter. It is important
that no dirt or contamination enter hydraulic
system.
3. Unscrew filter to remove and allow oil to drain
from reservoir.
Number 4 Idler Pivot (Pump Drive) Located
under engine deck.
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.
Number 5 (Clutch Arm Pivot) Located under
engine deck.
3. Lubricate pivot points with a spray penetrating
lubricant as shown in the Spray Lubricant Chart.
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.
Spray Lubricant Chart
30
Maintenance
The critical area for purging air from the hydraulic
system is between the oil reservoir and each
charge pump located on the top of each variable
displacement pump (Figure 14). Air in other parts of
the hydraulic system will be purged through normal
operation once the charge pump is “primed”.
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
Mobil 1 15W50
250 Hours
5. Loosen filter 1/2 turn and allow a small amount
of oil to leak from the oil filter (this allows air to
be purged from the oil filter and supply hose from
the hydraulic reservoir). Turn filter clockwise
until rubber seal contacts the filter adapter. Then
tighten the filter an additional 2/3 to 3/4 turn.
6. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
CAUTION
Raising the mower 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.
Figure 14
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
1. Charge pump cap
2. Loosen 1 1/2 turns only
1. Stop engine and wait for all moving parts to stop.
Raise the rear of the machine up onto jack stands
high enough to raise the drive wheels off the
ground.
2. Check oil level as stated in Check Hydraulic Oil
Level section.
3. Start engine and move throttle control ahead to
full throttle position. Move the speed control
lever to the middle speed position and place the
drive levers in the “drive” position.
7. If either drive wheel does not rotate, one or both
of the charge pumps (located on the top of the
main pump as shown in Figure 14) may have lost
their “prime”. Refer to Hydraulic System Air
Purge section.
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.
If either drive wheel does not rotate, it is possible
to assist the purging of the charge pump by
carefully rotating the tire in the forward position.
Hydraulic System Air Purge
Note: It is necessary to lightly touch the charge
pump cap with your hand to check the pump
temperature. If the cap is too hot to touch, turn
off engine. The pumps may be damaged if the
pump becomes too hot.
Service Interval: As required
Air must be purged from the hydraulic system
when any hydraulic components, including oil
filter, are removed or any of the hydraulic lines are
disconnected.
If either drive wheel still does not rotate continue
with step 4.
31
Maintenance
1. Stop engine and wait for all moving parts to stop.
4. Thoroughly clean the area around each of the
charge pump housings.
5. To “prime” charge pump, loosen two hex socket
head capscrews (shown in Figure 14) 1 1/2 turns
only. Make sure engine is not running. Lift
the charge pump housing upward and wait for
a steady flow of oil to flow out from under the
housing. Retighten the capscrews. Do this for
both pumps.
2. Engage PTO lever.
3. Look through the round hole in the left rear
corner of the engine deck to inspect blade
clutching belt tension. Bolt on blade engagement
linkage bellcrank and indicator arm should align
within 1/16 inch (1.6 mm) (see Figure 15). Refer
to PTO Engagement Linkage for adjustment.
Note: Hydraulic reservoir can be pressurized up
to 5 psi to speed this process.
6. If either drive wheel still does not rotate, stop
and repeat steps 4 and 5 above for the respective
pump. If wheels rotate slowly, the system may
prime after additional running. Check oil level
as stated in Check the Hydraulic Oil Level
section.
7. Allow unit to run several minutes after the charge
pumps are “primed” with drive system in the full
speed position. Check oil level as stated in Check
the Hydraulic Oil Level section.
8. Check hydro drive linkage adjustment as stated in
Hydro Drive Linkage Adjustment section in
Adjustments.
Figure 15
1. Engine deck
2. Indicator
Wheel Hub-Slotted Nut
Torque Specification
3. Align bolt to indicator
within 1/16 inch (1.6
mm)
4. Turnbuckle
Thread Locking Adhesives
Service Interval: After the first 100 hours
Every 500 hours thereafter
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
When tightening the slotted nut on the wheel motor
tapered shaft:
1. Torque the slotted nut to 100 ft-lb (136 N-m).
2. Further tighten the nut until the next set of slots
line up with the cross hole in the shaft.
3. Replace cotter pin.
• Pump sheave setscrews.
• Square head setscrews on hydro pump control
arms.
• OPC lever setscrews.
• Lower sheave retaining bolt on clutch arm.
Note: Do not use anti-seize compound on the wheel
hub.
• Shoulder bolts in ends of speed control crank.
Inspect PTO Clutching Belt
Tension
• Fuel tank bulkhead fitting threads
• Sheave retaining bolt in end of engine crankshaft.
Adhesives such as “Loctite RC/609 or RC/680” or
“Fel-Pro Pro-Lock Retaining I or Retaining II” are
used on the following:
Service Interval: After the first 2 hours
Check every 2 hours
for the first 8 hours of
operation.
Every 40 hours thereafter.
• OPC lever hubs and cross-shaft.
Note: Care must be used not to bond the
bearing, next to each OPC hub, to the cross-shaft
32
Maintenance
Adjustments
which could cause binding of the OPC levers and
erratic operation.
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.
• Fuel tank studs, where studs are inserted into tank.
Mobil HTS Grease (Or
Food-Grade Anti-seize)
Deck Leveling
Mobil HTS grease (or food-grade anti-seize) is used
in the following locations:
See Adjusting the Cutting Height section in
Operation.
• Between the cutter housing spindle and bearings.
• Between the cutter housing spindle and sheave.
Pump Drive Belt Tension
• Under top cutter housing bearing guard.
Self-tensioning - No adjustment necessary.
Copper-Based Anti-seize
PTO Clutching Belt Tension
Copper-based anti-seize is used in the following
locations:
See Inspect PTO Clutching Belt Tension section.
• On threads of Blade Bolts. See Check Mower
Blades section.
Deck Belt Tension
Self-tensioning - No adjustment necessary.
• Between engine crankshaft and pump and blade
drive sheaves.
Park Brake Adjustment
• On clutch arm assembly between bearings and
shaft and between lower sheave and shaft.
1. Shut off engine and wait for all moving parts to
stop.
2. Disengage the park brake.
3. Remove the hairpin in the park brake linkage.
Turn the linkage in the yoke until there is 3/16
inch (4.8 mm) to 1/4 inch (6.4 mm) clearance
between the park brake tire bars and the tires with
the park brake disengaged. Re-install the hairpin.
• Between pump shafts and sheaves.
Dielectric Grease
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
Hydro Drive Linkage
Adjustment
• Adjust Speed Control Linkage and Neutral
Safety Switch:
1. Stop engine and wait for all moving parts to
stop. Engage parking brake. Remove key or
spark plug wire(s).
2. Move the speed control lever (located on
the console) to the full forward position and
check the orientation of the tabs on the ends
of the speed control crank (see Figure 16).
These tabs should be pointing straight down
at the 6 o’clock position or slightly forward.
Adjust the threaded yoke at the bottom of the
33
Maintenance
speed control linkage (see Figure 16) until the
tabs are positioned correctly.
Figure 16
Viewed from Left Side of Unit
1. Neutral Safety Switch
2. Actuating Tab in neutral
position
3. 5/16 inch (7.9 mm)
Figure 17
Viewed from Left Side of Unit
1. Neutral Control Linkage
2. Hydro Control Linkage
3. Pull the speed control lever back to neutral.
Check that the neutral safety switch actuating
tab has depressed the plunger of the switch
so that there is about 5/16 inch (7.9 mm)
between the tab and the switch (see Figure 16).
If necessary, move the switch fore and aft.
3. Drive Lever Linkage
4. Speed Control Crank
• Adjust Neutral Control Linkages:
5. Speed Control Linkage
6. Adjust here-rotate at
approximately 1/4
turn increments and
re-check.
7. Loosen nut
8. Yoke
4. Loosen the nut against the neutral control
linkage yoke as shown in Figure 17.
5. Adjust the neutral control linkage until
the respective drive wheel stops when the
lever is pulled against the neutral spring
(neutral position). Turn the adjusting bolt
approximately 1/4 turn clockwise if the
wheel is turning in reverse or turn the bolt
approximately 1/4 turn counterclockwise if
the wheel is turning forward. Release the
drive lever to the forward drive position and
squeeze back into the neutral position. Check
to see if the wheel stops. If not, repeat the
above adjustment procedure.
6. Make this adjustment on both sides.
7. After adjustments are made and the wheels
stop when the drive levers are in the neutral
position, tighten the nuts against the yokes.
• Adjust Hydro Control Linkages:
1. Place the speed control lever in the “neutral”
position. This adjustment is again made with
rear of machine on jack stands and engine
running at full throttle. OPC levers will have
to be held down and the park brake must be
1. Raise the rear of the machine up onto jack
stands high enough to raise the drive wheels
off of the ground.
2. Start the engine and move the throttle ahead
to the full throttle position. Place the neutral
lock latches in the “forward” position as
shown in Figure 4. Release the park brake
and move the speed control lever to the
“mid-speed” position.
Note: The OPC levers must be held down
and the park brake must be disengaged
whenever the speed control lever is moved
out of neutral or the engine will kill.
3. Squeeze the respective drive lever until an
increased resistance is felt, this is where
neutral should be.
If the wheel turns while holding the drive
lever in neutral, the neutral control linkages
need to be adjusted. If the wheel stops then
go to step 7.
34
Maintenance
disengaged whenever speed control levers are
moved out of the neutral position.
to neutral. Recheck the drive wheel rotation
to see if further adjustment is necessary.
4. The spring that keeps tension on the knob
should normally not need adjustment.
However, if adjustment is needed, adjust to
where length of spring is about 1 inch (2.5 cm)
between the washers. Adjust spring length by
turning nut at front of spring.
Note: The neutral lock latches should be
“unlocked” and in the forward position.
2. Loosen the front nut on left hydro control
linkage as shown in Figure 17. Turn the rear
control linkage adjusting nut counterclockwise
until wheel rotates forward. Turn the rear nut
of left control linkage clockwise 1/4 of a turn
at a time, stopping to move the speed control
forward and back to neutral, until left wheel
stops rotating forward.
• Drive Lever Linkage Adjustment:
1. With rear of machine still on jack stands and
engine running at full throttle, disengage
the park brake and move the speed control
lever to the midway position. Move the
respective drive lever upward until it reaches
the neutral position and engage neutral lock
latches (Figure 19). If the tire rotates in either
direction, the length of the drive lever link will
need to be adjusted.
Turn the rear nut an additional 1/2 turn and
tighten the front nut making sure not to put
a bind on the linkage. Make sure flat part of
linkage is perpendicular to pin part of swivel
(see Figure 18).
Figure 18
1. Left Hydro Control Link
(left side shown)
2. Front nut
3. Rear nut
4. Linkage is perpendicular
to pin (correct position)
5. Linkage in incorrect
position
6. End view of swivel
After adjusting the left hydro control linkage,
move the speed control lever to the mid-speed
position and then back to the neutral position.
Recheck the left drive wheel rotation to see if
further adjustment is necessary - be sure the
speed control lever is in the neutral position.
Figure 19
2. Adjust the linkage length by loosening the jam
nuts at both ends of the linkage and rotating
the linkage in the ball joints. Lengthen the
linkage if the tire is turning in reverse and
shorten the linkage if the tire is creeping
forward. Tighten the jam nuts at both ends.
Release and re-engage the neutral lock latch
checking that the tire stops. Continue this
process until the tire is at a dead stop.
Important: If inconsistent neutral occurs,
check to be sure both springs are properly
tightened on the speed control lever under
the console–especially the rear pivot
spring.
Repeat above adjustments if necessary.
3. Place the speed control lever in neutral. Adjust
the right side linkage by turning the quick track
knob counterclockwise until the tire begins to
rotate forward. Begin to retighten the knob
clockwise about 1/4 turn at a time, stopping
to move the speed control forward and back
3. Make this adjustment for both sides.
4. Stop engine and wait for all moving parts
to stop. Raise rear of machine, remove jack
stands, and carefully lower machine to the
ground.
35
Maintenance
Tracking Adjustment
PTO Safety Switch
1. Stop engine and wait for all moving parts to stop.
Mounted to a tab on the inside left side of the fuel
tank support.
2. Check the drive tire pressures and tire
circumferences as stated in Check the Tire
Pressures section in Maintenance.
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove ignition key or
spark plug wire(s).
3. Run the unit and observe the tracking on a level,
smooth, hard surface such as concrete or asphalt.
2. With PTO disengaged and the bellcrank touching
the rear of the slot in the engine deck, adjust the
PTO safety switch (if needed) until the bellcrank
arm is 5/16 inch (7.9 mm) from the switch body.
4. If the unit tracks to one side or the other, turn the
quick track knob. Turn the knob right to “steer”
right, turn the knob left to “steer” left.
3. Be sure the bellcrank Does Not touch the switch
body or damage to the switch could occur.
Hydro Pump Spring Tension
Setting
4. Retighten PTO switch mounting hardware.
1. For medium or heavy duty drive conditions such
as operation with a sulky on steep slopes, a higher
spring force may be required on the hydro pump
control arms to prevent the drive system from
stalling.
2. For a heavier drive setting, relocate the spring
anchor link as shown in Figure 13. The spring
anchor links are located under the engine deck on
the left and right hand sides.
Note: In “medium” or “heavy duty” positions,
the drive lever forces at the upper handle will also
be increased.
Figure 20
1. Heavy duty
2. Medium duty
3. Standard
4. Retaining bolt
36
Maintenance
Clean Debris From Machine
Cleaning
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 and cutting deck, especially under deck
belt shields, around the fuel tank, around engine
and exhaust area.
Clean Engine and Exhaust
System Area
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
conditions.)
Clean Grass Build-Up Under
Deck
CAUTION
Excessive debris around engine cooling air
intake and exhaust system area can cause engine,
exhaust area, and hydraulic system to overheat
which can create a fire hazard.
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Raise deck to the transport (maximum cutting
height) position. Lift the front of unit and support
unit using jack stands or equivalent support.
3. Clean out any grass build-up from underside of
deck and in discharge chute.
Clean all debris from engine and exhaust system
area.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Clean all debris from rotating engine air intake
screen, around engine shrouding, and exhaust
system area.
Waste Disposal
3. Wipe up any excessive grease or oil around the
engine and exhaust system area
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.
Remove Engine Shrouds and
Clean Cooling Fins
Battery Disposal
Service Interval: Every 100 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
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.
• Wear safety glasses to shield eyes, and rubber
gloves to protect skin and clothing when
handling electrolyte.
• Do Not swallow electrolyte.
• In the event of an accident, flush with water
and call a doctor immediately.
2. Remove cooling shrouds from engine and clean
cooling fins. Also clean dust, dirt, and oil from
external surfaces of engine which can cause
improper cooling.
3. Make sure cooling shrouds are properly
reinstalled. Operating the engine without
cooling shrouds will cause engine damage due to
overheating.
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.
37
Maintenance
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.
38
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 of 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 (Electric Start Units).
Possible Cause
1. PTO is engaged.
1. Disengage the PTO.
2. Speed control lever is are not in neutral
lock position.
3. OPC levers are released.
4. Battery does not have a full charge.
6. Fuse is blown.
7. Relay or switch is defective.
2. Ensure the speed control lever is in the
neutral lock position.
3. Depress OPC levers.
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. The throttle and choke are not in the
correct position.
2. Open the fuel shutoff valve.
3. 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.
4. Replace the fuel filter.
5. Contact an Authorized Service Dealer.
5. Electrical connections are corroded, loose
or faulty.
Engine will not start, starts hard, or fails to
keep running
4. Dirt in fuel filter.
5. Dirt, water, or stale fuel is in the fuel
system.
6. Air cleaner is dirty.
7. Electrical connections are corroded, loose
or faulty.
8. Relay or switch is defective.
9. Faulty spark plug.
10. Spark plug wire is not connected.
Engine loses power
Corrective Action
6. Clean or replace the air cleaner element.
7. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
8. Contact an Authorized Service Dealer.
9. Clean, adjust or replace spark plug.
10. 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.
39
Troubleshooting
Problem
Engine overheats
Mower pulls left or right (with levers fully
forward).
Machine does not drive.
Uneven cutting height.
Possible Cause
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.
1. Tracking needs adjustment.
1. Adjust the tracking by turning knob on the
right hydro control linkage in the direction
that the mower needs to be adjusted to.
Turn the knob in 1/4 turn increments
until the mower tracks correctly.
2. Tire pressure in drive tires not correct.
2. Adjust tire pressure in the drive tires.
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.
2. Change the belt.
1. Blade(s) not sharp.
1. Sharpen the blade(s).
2. Cutting blade(s) is/are bent.
3. Mower deck is not level.
2. Install new cutting blade(s).
3. Level mower deck from side-to-side and
front-to-rear.
4. Clean the underside of the mower.
5. Adjust tire pressure in the drive tires.
6. Contact an Authorized Service Dealer.
7. Replace blades, spindles and (or) check
for damage to mower deck.
4.
5.
6.
7.
Abnormal vibration
Blades do not rotate.
Corrective Action
Underside of mower is dirty.
Tire pressure in drive tires not correct.
Blade spindle bent.
Tips of adjacent blades are at an uneven
cutting height. Blades tips should be even
within 3/16 inch which is approximately
one blade thickness.
3. Change the belt.
1. Cutting blade(s) is/are bent or unbalanced.
1. Install new cutting blade(s).
2. Blade mounting bolt is loose.
3. Engine mounting bolts are loose.
4. Loose engine pulley, idler pulley, or blade
pulley.
5. Engine pulley is damaged.
6. Blade spindle is bent.
7. Belt is damaged.
2. Tighten the blade mounting bolt.
3. Tighten the engine mounting bolts.
4. Tighten the appropriate pulley.
5. Contact an Authorized Service Dealer.
6. Contact an Authorized Service Dealer.
7. Install new belt.
1. Drive belt is worn, loose or broken.
1. Check the belt tension.
2. Drive belt is off pulley.
2. Check belt for damage; replace if
necessary. Install drive belt and check
adjusting shafts and belt guides for correct
position.
3. Install new deck belt.
4. Install deck pulley and check the idler
pulley, idler arm and spring for correct
position and function.
5. Replace the spring.
6. Contact an Authorized Service Dealer.
3. Deck belt is worn, loose or broken.
4. Deck belt is off pulley.
5. Broken or missing idler spring.
6. PTO clutch does not engage.
40
Schematics
Schematics
Electrical Diagram
Electrical Diagram
41
Schematics
Hydraulic Diagram
42
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 21
This page may be copied for personal use.
1. The maximum slope you can safely operate the machine on is 20 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 20 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. 4500-540 Rev. B
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com