Owner`s manual | Exmark 920000 Automobile Parts User Manual

VIKING™ HYDRO
For Serial Nos.
920,000 & Higher
Part No. 4500-693 Rev. A
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
Important: The engine in this product is not
equipped with a spark arrester muffler. It is a
violation of California Public Resource Code
(CPRC) Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126.
Other states or federal areas may have similar
laws.
To acquire a spark arrester for your unit, see your
Engine Service Dealer.
This spark ignition system complies with the
Canadian standard 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.
Figure 1
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
1. Model and serial number location
Model No.
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
Serial No.
All Exmark equipment dealers and distributors are
kept informed of the latest methods of servicing
and are equipped to provide prompt and efficient
service in the field or at their service stations. They
carry ample stock of service parts or can secure them
promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.
3
Contents
Engine to Mower Deck Belt
Adjustment ............................................... 31
Blade Brake Adjustment ................................ 32
Belt Guide Adjustment .................................. 33
Pump Drive Belt Tension............................... 33
Hydro Drive Linkage Adjustment .................. 33
Tracking Adjustment ..................................... 36
Hydro Pump Spring Tension Setting .............. 36
Park Brake Adjustment.................................. 36
Cleaning ........................................................... 37
Clean Engine Air Cooling System................... 37
Remove Engine Shrouds and Clean Cooling
Fins........................................................... 37
Clean Grass Build-Up Under Deck ................ 37
Waste Disposal .............................................. 37
Troubleshooting ................................................... 38
Schematics ........................................................... 40
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ..................... 10
Specifications ....................................................... 13
Model Numbers ............................................ 13
Systems ......................................................... 13
Dimensions................................................... 14
Torque Requirements .................................... 14
Product Overview ................................................ 15
Operation ............................................................. 15
Controls ........................................................ 15
Pre-Start........................................................ 17
Operating Instructions .................................. 17
Transporting ................................................. 19
Maintenance ......................................................... 20
Recommended Maintenance Schedule(s) ........... 20
Periodic Maintenance ....................................... 21
Check Engine Oil Level ................................. 21
Check Mower Blades ..................................... 21
Check Safety Interlock System ....................... 22
Check for Loose Hardware ............................ 22
Service Air Cleaner ........................................ 23
Change Engine Oil ........................................ 23
Check Hydraulic Oil Level ............................. 23
Check Tire Pressures ..................................... 23
Check Condition Of Belts.............................. 23
Lubricate Grease Fittings............................... 24
Check Spark Plugs ......................................... 24
Change Hydraulic System Filter ..................... 24
Replace Emissions Air Intake Filter................ 26
Wheel Hub-Slotted Nut Torque
Specification.............................................. 26
Thread Locking Adhesives............................. 27
Mobil HTS Grease (Or Food-Grade
Anti-seize)................................................. 27
Copper-Based Anti-seize .............................. 27
Dielectric Grease........................................... 27
Adjustments ..................................................... 28
Adjusting the Cutting Height ......................... 28
Adjusting the Axle Position............................ 29
Adjusting the Number of Spacers below
Caster Support Hub................................... 30
Adjusting the Cutting Height with Blade
Spacers...................................................... 30
PTO Engagement Linkage
Adjustment ............................................... 31
PTO Safety Switch Adjustment...................... 31
4
Safety
Safety
Safety Alert Symbol
•
This lawn mower meets or exceeds the B71.4
specifications of the American National Standards
Institute in effect at the time of production.
•
•
Exmark designed and tested this lawn mower to offer
reasonably safe service; however, failure to comply
with the following instructions may result in personal
injury.
•
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.
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
•
Figure 2
1. Safety alert symbol
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.
Never let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.
Only adults and mature teenagers should operate
a mower, and even mature teenagers should have
adult supervision. Be sure a teenager:
1. has read and understands the Operator’s
Manual and recognizes the risks 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.
The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
Preparation
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.
• 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.
• 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.
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
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 machine produces sound levels in excess
of 85 dBA at the operator’s ear and can cause
hearing loss through extended periods of
exposure.
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.
Wear hearing protection when operating this
machine.
Safe Operating Practices
• 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
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.
• 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.
• Allow engine parts, especially the muffler, to
cool before touching.
• Remove accumulated debris from muffler
and engine area.
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
– Whenever you leave the mower.
• Stop engine, wait for all moving parts to stop, and
engage parking brake:
– Before refueling.
– Before dumping the grass catcher.
– Before making height adjustments.
WARNING
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.
• 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.
• 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.
• 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 change the engine governor setting or
overspeed the engine.
• Park machine on level ground. Stop engine, wait
for all moving parts to stop, remove key and
engage parking brake:
– Before checking, cleaning or working on the
mower.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• Stop the blades, slow down, and use caution when
crossing surfaces other than grass and when
transporting the mower to and from the area to
be mowed.
• Be aware of the mower discharge path and direct
discharge away from others.
• Do Not operate the mower under the influence
of alcohol or drugs.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
Slope Operation
Use Extreme caution when mowing and/or turning
on slopes as loss of traction and/or tip-over could
occur. The operator is responsible for safe operation
on slopes.
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.
• 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.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Keep hands and feet away from moving parts.
If possible, do not make adjustments with the
engine running.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
• Check all bolts frequently to maintain proper
tightness.
• 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.
• Frequently check for worn or deteriorating
components that could create a hazard.
WARNING
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
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.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
Replace all parts including, but not limited to,
tires, belts, and blades with original Exmark
parts.
Maintenance and Storage
• 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.
8
Safety
WARNING
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.
• 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.
• Keep body and hands away from pinhole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Use cardboard or paper, not your hands, to
find hydraulic leaks.
• 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.
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.
1-303508
1-403005
1-303517
1-403143
1-413214
1-323427
36 inch Deck Units Only
98-5954
10
Safety
103-1798
103-2196
103-2076
103–2242
103-2103
11
Safety
116-0404
103–2243
117–2718
103-4935
103-5626
48 inch Deck Units Only
12
Specifications
Specifications
Model Numbers
Serial Nos: 920,000 and Higher
VH16KA362; VH16KA483; VH16KA362CA; VH16KA483CA
Systems
Transmission
Engine
• Two Hydro Gear variable displacement piston
pumps independently coupled to two high
efficiency Parker wheel drive motors.
• Engine Specifications: See your Engine Owner’s
Manual
• Hydraulic Oil: Use Exmark Premium Hydro Oil.
• Engine Oil Type: Exmark 4–Cycle Premium
Engine Oil
• Hydraulic Oil Capacity: 2.4 qt. (2.2 L)
• Hydraulic Filter is replaceable cartridge type.
• RPM: Full Speed: 3600 (No Load)
P/N 109–4180: 25 microns, 10 psi bypass
(Summer use above 32°F (0°C))
Idle: 1550 RPM
P/N 1–523541: 40 microns, 18 psi bypass (Winter
use below 32°F (0°C))
Fuel System
• Capacity: 5.0 gal. (18.9 L)
• Speeds:
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher; containing no more than 10%
methanol or ethanol.
– 0-6.2 mph (10.0 km/hr) forward.
– 0-2.2 mph (3.5 km/hr) reverse.
• Fuel Filter: Replaceable In-line
Wheel Drive System
• Fuel Shut-Off Valve: 1/4 turn increments
Drive wheels are direct coupled to Parker wheel drive
motors with 1 inch (25.4 mm) tapered shaft.
Safety Interlock 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.
Tires & Wheels
Drive
Pneumatic
(Air-Filled)
• Park brake must be disengaged to move speed
control out of neutral or engine will kill.
Steering/Brake Controls
Fingertip drive control levers provide independent
speed control, braking and neutral to each drive
wheel for moving forward or reverse, stopping and
power turning.
13
Front Caster
SemiPneumatic
Quantity
2
2
Tread
Turf Master
Smooth
Size
16 x 6.50–8
9 x 3.50-4
Ply Rating
4
Pressure
14 psi
(97 kPa)
Specifications
Cutting Deck
Tread Width: (Outside to Outside of
Tires, Widthwise)
• Cutting Width:
– 36 inch Deck: 35.38 inches (89.9 cm)
– 48 inch Deck: 47.25 inches (120.0 cm)
• Discharge: Side
• Blade Size:
– 36 inch Deck: 18.00 inches (45.7 cm)—
Quantity: 2
– 48 inch Deck: 16.25 inches (41.3 cm)—
Quantity: 3
• Deck Drive: Manual engagement of belt with
over-center lock. Blade belt tension is adjustable
via turnbuckle.
• Blade Brake: When the PTO engagement control
is moved to the disengaged position a friction
brake pad stops the rotation of the blades.
• Deck Mounting: Bolted directly to engine deck.
• Deck Depth:
– 36 inch Deck: 5.0 inches (12.7 cm)
– 48 inch Deck: 5.0 inches (12.7 cm)
• Cutting Height Adjustment:
Overall Width:
Deflector Up
36.4 inches
(92.5 cm)
48.1 inches
(122.2 cm)
Deflector Down
47.0 inches
(119.4 cm)
57.9 inches
(147.1 cm)
Overall Length:
36 inch Deck
48 inch Deck
77.3 inches (196.3 cm)
72.3 inches (183.6 cm)
Overall Height:
36 inch Deck
48 inch Deck
43.2 inches (109.7 cm)
43.2 inches (109.7 cm)
35.6 inches
(90.4 cm)
40.4 inches
(102.6 cm)
36 inch Deck
48 inch Deck
573 lb (260 kg)
633 lb (287 kg)
Torque Requirements
Dimensions
48 inch Deck
48 inch Deck
Curb Weight:
Adjusts from 1 inch (2.5 cm) to 4 1/4 inches (10.8
cm) in 1/4 inch (6.4 mm) increments by various
adjustments of caster spacers, blade spacers, and
axle height.
36 inch Deck
36 inch Deck
14
Bolt Location
Torque
Blade/Cutter Housing
Spindle Bolt
75-80 ft-lb (102-109 N-m)
Caster Bracket Mounts
30-35 ft-lb (41-48 N-m)
Mower Deck/Engine
Deck Mount
30-35 ft-lb (41-48 N-m)
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 Nut
(Style A)
140-155 ft-lb
(190-210 N-m)
Wheel Hub Slotted Nut
(Style B)
minimum 100 ft-lb
(136 N-m)
Wheel Motor Mounting
Bolts
30-35 ft-lb (41-48 N-m)
Operation
Product Overview
Operation
Note: Determine the left and right sides of the
machine from the normal operating position.
Controls
Operator Presence Control (OPC)
Levers
Located on the upper handle assembly directly above
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).
Figure 3
1. ECS Handles
2. Controls
3. Fuel Cap
4. Blade Spacers
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
Drive Levers
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,
15
Operation
speed and moving it to the rear will decrease engine
speed. Moving the throttle forward into the detent
is full position.
as shown in Figure 4, and the drive levers are released,
the drive wheels are engaged in the forward direction.
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.
The speed control lever controls the maximum
forward speed and is infinitely variable from neutral
0–6.2 mph (10.0 km/hr).
Neutral Lock Latch
Park brake must be disengaged to move speed control
out of neutral or engine will kill.
Speed Control Lever
Located in middle of control console.
Located at the end of the handles.
“Off-Run” Switch
The purpose of these latches is to allow the operator
to lock the drive levers in a "neutral" position where
neither of the drive wheels are engaged in either a
forward or reverse direction (see Figure 4).
Located on the control console.
Turn the key to the “Run” position to allow the
engine to be started. Turn the key to the “Off ”
position to shut engine off.
Park Brake Lever
Located on the right side of the unit above the
hydraulic tank.
Fuel Shut-Off Valve
The brake lever engages the park brake on the drive
wheels.
Located in the fuel line midway between the tank
and engine.
Pull the lever up and rearward to engage the brake.
The fuel shut-off valve is used to shut off the
flow of fuel when parking inside a building, during
transportation to and from the job sites, and when
the machine will not be used for a few days.
Push the lever forward and down to disengage the
brake.
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.
Rotate valve 1/4 turn clockwise to shut fuel off.
Rotate valve 1/4 turn counterclockwise to turn fuel
on.
Park brake must be disengaged to move speed control
out of neutral or engine will kill.
Drive Wheel Release Valves
Located on the top rear corner of the hydrostatic
pumps.
Choke Control
Located on the front left corner of the fuel tank
support.
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.
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.
With a 5/8 wrench, turn both valves one turn
counterclockwise to release the drive system.
Turn clockwise to reset the drive system. Do Not
overtighten.
Throttle Control
Located on the on the control console right side.
Tracking Adjustment Knob
The throttle is used to control engine speed. Moving
the throttle control forward will increase engine
Located on the right-hand side of the rear of the fuel
tank support.
16
Operation
Operating Instructions
The knob can be adjusted so that machine will
“track” straight ahead with the drive levers released.
Open the Fuel Shut-Off Valve
PTO Engagement Control
Rotate the valve 1/4 turn counterclockwise to turn
fuel on.
Located on left side of control console.
To engage the blades, the knob must be pulled
toward the operator until the turnbuckle (attached
to the blade engagement idler) locks over-center. To
disengage the blades, push the knob down until the
assist arm contacts the pin on the deck.
Starting the Engine
Note: Operator must have PTO disengaged and
speed control lever in neutral position when starting
the engine.
Lock drive levers in neutral and engage park brake
Park brake must be disengaged before PTO is
engaged or engine will kill.
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.
Cold Start Kit
• To use cold start kit:
Located on the right hand side of engine deck, below
and slightly ahead of the hydro control shield.
1. Pull split ring straight out the side of the unit,
and hook the ring over the lower front hydro
control shield bolt.
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 section in Operation).
2. Start engine. Refer to the following guidelines
for further starting suggestions.
• To engage pump drive (disengage cold start kit):
1. Pull chain straight out from the side of the
unit until the split ring can be removed from
the bolt.
Pre-Start
2. Slowly release tension on chain.
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.
1. Pull out the choke control. Place the throttle
control midway between the “Slow” and “Fast”
positions. Turn the key switch to the “Run”
position.
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.
2. Pull recoil rope to start engine. After engine
warms up, gradually push in the choke control.
Do Not run warm engine with the choke in the
“ON” position.
Do Not add oil to gasoline.
Note: Kawasaki engines generally need to be
“choked” even when warm.
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.
Engaging the PTO
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
The rotating blades under the mower deck are
dangerous. Blade contact can cause serious
injury or kill you.
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
Do Not put hands or feet under the mower or
mower deck when the blades are engaged.
DANGER
17
Operation
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. Pull the PTO engagement knob up to engage
blades.
3. Place the throttle in the “FAST” position to begin
mowing.
Note: Park brake must be disengaged before PTO is
engaged or 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. Push down on the PTO engagement knob 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.
6. Place the throttle midway between the “SLOW”
and “FAST” positions.
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.
8. Remove the key to prevent children or other
unauthorized persons from starting engine.
9. Close the fuel shut-off valve when the machine
will not be in use for a few days, when
18
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
1. Release the parking brake.
Transporting
2. With drive levers locked in “neutral”, shift speed
control lever to desired forward speed.
Transporting a Unit
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.
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.
Note: Do Not squeeze both drive levers all the
way back. This will cause the drive wheels to
engage in the reverse direction.
• Use proper ramps that are secured to the
truck or trailer.
4. To move forward in a straight line, smoothly
release both drive levers to engage drive wheels.
• Keep feet and legs out from under the unit
when loading and unloading.
To turn left or right, squeeze the right hand drive
lever to turn right and the left hand drive lever
to turn left.
• If necessary, use assistance when loading.
Be sure the fuel shut-off valve is closed.
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.
Use a heavy duty trailer to transport the machine.
Engage neutral lock latches and park brake, then
block wheels.
Note: For smooth operation of this machine,
avoid quick, jerky movements of the drive levers.
Move the drive levers smoothly and deliberately.
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.
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.
Be sure that the trailer has all necessary lighting and
marking as required by law and use a safety chain.
19
Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could seriously
injure you or other bystanders.
The engine can become very hot. Touching a hot
engine can cause severe burns.
Allow the engine to cool completely before
service or making repairs around the engine area.
Remove the key from the ignition switch, engage
parking brake, and pull the wire(s) off the spark
plug(s) before you do any maintenance. Also
push the wire(s) aside so it does not accidentally
contact the spark plug(s).
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 5 hours
• Change the engine oil.
After the first 100 hours
• Check 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 engine air cooling system (See Engine Owner’s Manual)
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.
Every 500 hours
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)
• Replace the emissions air intake filter.
• Check wheel hub-slotted torque specification.
Monthly
Check the hydraulic oil level.
Check the tire pressures.
Check the condition of the belts.
Grease the pump drive idler pivot.
Grease the pump control bearings.
Grease the mower deck idler pivot
• Grease the PTO engagement bellcrank.
20
Maintenance
Periodic Maintenance
Check Engine Oil Level
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. Exmark 4-Cycle Premium
Engine Oil is recommended; refer to the Engine
Owner’s manual for an acceptable alternative. Do
Not overfill.
Figure 6
1. Spring disc washer (cone towards bolt head)
2. Blade bolt torque to 75-80 ft-lb (102-109 N-m).
Important: Do Not operate the engine with the
oil level below the “LOW” (or “ADD”) mark on
the dipstick, or over the “FULL” mark.
Replacing the Discharge
Deflector
Service Interval: As required
Check Mower Blades
Service Interval: Before each use or daily
DANGER
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
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.
2. Lift deck and secure in raised position as stated
in the Clean Grass Build-Up Under Deck
procedure.
Never operate the lawn mower unless you install
a mulch plate, discharge deflector, or grass
collection system.
3. Inspect blades and sharpen or replace as required.
4. Re-install the blades (if they were removed) and
torque blade bolts to 75-80 ft-lb (102-109 N-m).
Be sure the spring disc washer cone is installed
toward the bolt head (see Figure 6).
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 7. Slide the
rod through the front discharge deflector bracket,
discharge deflector, and rear deflector bracket.
21
Maintenance
Check Safety Interlock
System
Service Interval: Before each use or daily
1. For your safety, your Exmark mower is equipped
with Operator Presence Controls, referred to as
(OPC). When either the PTO is engaged, or
the speed control lever is not in neutral and the
operator removes both hands from the handles,
the mower engine must stop.
2. To determine if the OPC is in operating condition,
clear area of bystanders. Run the engine at
one-third throttle, then with the drive levers and
neutral lock latches in the “neutral lock” position,
move the speed control lever out of neutral and
release the OPC levers–the engine must stop.
3. Again, run the engine at one-third throttle, move
the speed control lever to neutral, engage the
PTO and release the OPC levers–the engine
must stop.
Figure 7
1. Rod
2. Spring
3. Discharge deflector
4. Mower deck
5. Discharge deflector
bracket
6. Assembled view
Note: Park brake must be disengaged before the
speed control lever is moved out of neutral or
PTO is engaged or engine will kill.
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 7).
Note: If machine does not pass any of these tests,
do not operate. Contact your authorized EXMARK
SERVICE DEALER.
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
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.
Check for Loose Hardware
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.
22
Maintenance
Service Air Cleaner
5. Clean around oil fill cap and remove cap. Fill to
specified capacity and replace cap.
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.)
6. Use oil recommended in the Check Engine Oil
Level section. Do Not overfill. Start the engine
and check for leaks. Stop engine and recheck oil
level.
Check Hydraulic Oil Level
Every 100 hours—Service
the paper element. (May
need more often under
severe conditions. See the
Engine Owner’s manual
for additional information.)
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
baffle inside the tank. If not, add oil. Use Exmark
Premium Hydro Oil. Replace hydraulic reservoir
cap and tighten until snug. Do Not overtighten.
Every 200 hours/Yearly
(whichever comes
first)—Replace the paper
element.
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.
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.
Change Engine Oil
Service Interval: After the first 5 hours
Every 100 hours (May
need more often under
severe conditions.)
Check Tire Pressures
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
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.
2. Check tire pressure in drive tires.
3. Inflate drive tires to 12–14 psi (83–97 kPa).
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. 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.
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 Exmark 4–Cycle Premium
Engine 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. Semi-pneumatic caster tires Do Not need to be
inflated.
Check Condition Of Belts
Service Interval: Every 40 hours
23
Maintenance
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.
Lubricate Grease Fittings
Note: See chart for service intervals.
Number 4 Idler Pivot (Pump Drive) Located
under engine deck
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Number 4 and 6 (Idler Pivots) Disassemble and grease
once a month under a “No Load” condition.
2. Lubricate fittings with NGLI grade #2
multi-purpose gun grease.
3. Lubricate pivot points with a spray penetrating
lubricant as shown in the Spray Lubricant Chart.
Refer to the following chart for fitting locations
and lubrication schedule.
Spray Lubricant Chart
Lubrication Chart
Pivot Point
Number of Places
Service Interval
1
40 hours
Fitting
Locations
Initial
Pumps
Number of
Places
Service
Interval
1. Caster Wheel
Bearings
12
2
Daily
2. Caster Pivots
2
2
Daily
3. PTO
Engagement
Bellcrank
1
1
Monthly
Service Interval: Every 160 hours
4. Pump Drive
Idler Pivot
2
1
40 hours
Remove spark plugs, check condition and reset gaps,
or replace with new plugs. See Engine Owner’s
Manual.
5. Pump
Control
Bearings
2
2
40 hours
6. Mower Deck
Idler Pivots
2
1
40 hours
1. PTO Engagement
Upper Bellcrank
Check Spark Plugs
Change Fuel Filter
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)
24
Maintenance
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).
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.
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.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
3. Unscrew filter to remove and allow oil to drain
from reservoir.
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 8) may have lost
their “prime”. Refer to Hydraulic System Air
Purge section.
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.
Turn filter clockwise until rubber seal contacts the
filter adapter, then tighten the filter an additional
2/3 to 3/4 turn.
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.
4. Fill reservoir as stated in Check Hydraulic Oil
Level.
Exmark Premium Hydro Oil is recommended.
Refer to the chart for an acceptable alternative:
Hydro Oil
Change Interval
Hydraulic System Air Purge
Exmark Premium Hydro
Oil (Preferred)
500 Hours
Service Interval: As required
Mobil 1 15W50
250 Hours
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.
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.
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 8). Air in other parts of
the hydraulic system will be purged through normal
operation once the charge pump is “primed”.
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.
25
Maintenance
a steady flow of oil to flow out from under the
housing. Retighten the capscrews. Do this for
both pumps.
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 8
1. Charge pump cap
Replace Emissions Air Intake
Filter
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.
Service Interval: Every 500 hours
1. Stop engine, wait for all moving parts to stop, and
remove key or spark plug wire(s). Engage parking
brake.
2. Remove the filter from the vent hose.
3. Insert a new filter into the end of the vent hose.
Wheel Hub-Slotted Nut
Torque Specification
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.
Service Interval: After the first 100 hours
Every 500 hours thereafter
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.
See Figure 9 to determine which slotted nut has been
installed on the unit.
If either drive wheel still does not rotate continue
with step 4.
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 8) 1 1/2 turns
only. Make sure engine is not running. Lift
the charge pump housing upward and wait for
Figure 9
1. Style A (black finish)
2. .03 inch (.76 mm)
• Style A (black finish):
26
3. Style B (yellow zinc)
4. .24 inch (6 mm)
Maintenance
• Sheave retaining bolt in end of engine crankshaft.
Torque the slotted nut to 140-155 ft-lb (190-210
N-m).
• Fuel tank bulkhead fitting threads
Note: Do Not use anti-seize on wheel hub.
1. Remove and discard the cotter pin.
Adhesives such as “Loctite RC/609 or RC/680” or
“Fel-Pro Pro-Lock Retaining I or Retaining II” are
used on the following:
2. Torque the slotted nut to 100 ft-lb (136 N-m).
• OPC lever hubs and cross-shaft.
• Style B (yellow zinc):
Note: Care must be used not to bond the
bearing, next to each OPC hub, to the cross-shaft
which could cause binding of the OPC levers and
erratic operation.
3. Check distance from bottom of slot in nut to
inside edge of hole. Two threads (0.1 inch) or
less should be showing.
• Fuel tank studs, where studs are inserted into tank.
Mobil HTS Grease (Or
Food-Grade Anti-seize)
Mobil HTS grease (or food-grade anti-seize) is used
in the following locations:
• Between the cutter housing spindle and bearings.
Figure 10
1. 0.1 inch max
• Between the cutter housing spindle and sheave.
2. No more than two
threads (0.1 inch max)
should be showing here.
• Under top cutter housing bearing guard.
Copper-Based Anti-seize
4. If more than two threads (0.1 inch) are
showing remove nut and install washer (P/N
1-523157) between hub and nut.
Copper-based anti-seize is used in the following
locations:
5. Torque the slotted nut to 100 ft-lb (136 N-m).
Between the blade drive and pump drive sheaves and
engine crankshaft.
6. Then tighten nut until the next set of slots line
up with the cross hole in shaft. Do Not loosen
nut to align the slot. If required, tighten to
the next set of slots.
Dielectric Grease
7. Install new cotter pin (P/N 1-806800).
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
Note: Do Not use anti-seize on wheel hub.
Thread Locking Adhesives
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
• Pump sheave setscrews.
• Square head setscrews on hydro pump control
arms.
• OPC lever setscrews.
• Shoulder bolts in ends of speed control crank.
27
Maintenance
Adjustments
than adjusting axle position and number of spacers
below caster support hub).
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.
Note that:
• For the best cut and discharge, place a minimum
of two spacers between the blade and the spindle.
• For highest quality cut, place all four spacers
between the blade and the spindle.
Adjusting the Cutting Height
• If mulching kit is installed, the highest quality cut
can be obtained with 3 spacers between the blade
and the spindle (minimum is 1 for a good cut).
The cutting height of the mower deck is adjusted
from 1 inch to 4 1/4 inches (2.54 cm to 11.4 cm) in
1/4 inch (.64 cm) increments by adjusting the axle
position, number of spacers below the caster hub,
and number of spacers between blade and spindle.
• When mulching leaves it is best to have fewer
spacers between blade and spindle.
Refer to the Cutting Height Adjustment table and
select a cutting height range in the left hand column
which corresponds to the range of cutting heights
you will most often be using. Adjustments within this
range can then be made by adjusting the number of
blade spacers between the blade and the bottom of
the spindle (this is a much easier adjustment to make
Refer to the table and select desired cutting height
range. Refer to Adjusting the Axle Position,
Adjusting the Number of Spacers below Caster
Support Hub, and Adjusting the Cutting
Height with Blade Spacers and sections to make
adjustments make adjustment to obtain specific
cutting height.
Cutting Height Adjustment Table (1 inch to 4 1/4 inches (2.5 cm-10.8 cm))
Cutting
Height
Range
Axle
Position
(Figure 11)
Number Of Spacers
Below Caster
Support Hub
1/2
inch
(1.2 cm)
3/16
inch
(.48 cm)
Number of 1/4 inch (.64 cm) Blade Spacers Below Spindle
4
3
2
1
0
1–2 inches
(2.5–5.0 cm)
A
0
0
1 inch
(2.5 cm)
1 1/4 inch
(3.2 cm)
1 1/2 inch
(3.5 cm)
1 3/4 inch
(4.4 cm)
2 inch
(5.0 cm)
1 1/8–
2 1/8 inches
(2.9–5.4 cm)
A
0
1
1 1/8 inch
(2.9 cm)
1 3/8 inch
(3.5 cm)
1 5/8 inch
(4.1 cm)
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
1 3/8–
2 3/8 inches
(3.5–6.0 cm)
A
1
0
1 3/8 inch
(3.5 cm)
1 5/8 inch
(4.1 cm)
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
1 3/8–
2 3/8 inches
(3.5–6.0 cm)
B
0
1
1 3/8 inch
(3.5 cm)
1 5/8 inch
(4.1 cm)
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
1 5/8–
2 5/8 inches
(4.1–6.7 cm)
B
1
0
1 5/8 inch
(4.1 cm)
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
2 5/8 inch
(6.7 cm)
1 3/4–
2 3/4 inches
(4.4–7.0 cm)
B
1
1
1 3/4 inch
(4.4 cm)
2 inch
(5.0 cm)
2 1/4 inch
(5.7 cm)
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
2–3 inches
(5.0–7.6 cm)
B
2
0
2 inch
(5.0 cm)
2 1/4 inch
(5.7 cm)
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
1 7/8–
2 7/8 inches
(4.8–7.3 cm)
C
1
1
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
2 5/8 inch
(6.7 cm)
2 7/8 inch
(7.3 cm)
28
Maintenance
Cutting Height Adjustment Table (1 inch to 4 1/4 inches (2.5 cm-10.8 cm)) (cont'd.)
Cutting
Height
Range
Axle
Position
(Figure 11)
Number Of Spacers
Below Caster
Support Hub
1/2
inch
(1.2 cm)
3/16
inch
(.48 cm)
Number of 1/4 inch (.64 cm) Blade Spacers Below Spindle
4
3
2
1
0
2 1/8–
3 1/8 inches
(5.4–7.9 cm)
C
2
0
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
2 5/8 inch
(6.7 cm)
2 7/8 inch
(7.3 cm)
3 1/8 inch
(7.9 cm)
2 1/4–
3 1/4 inches
(5.7–8.3 cm)
C
2
1
2 1/4 inch
(5.7 cm)
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
2 1/2–
3 1/2 inches
(6.4–8.9 cm)
C
3
0
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
2 3/8–
3 3/8 inches
(6.0–8.6 cm)
D
2
1
2 3/8 inch
(6.0 cm)
2 5/8 inch
(6.7 cm)
2 7/8 inch
(7.3 cm)
3 1/8 inch
(7.9 cm)
3 3/8 inch
(8.6 cm)
2 1/2–
3 1/2 inches
(6.4–8.9 cm)
D
3
0
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
2 3/4–
3 3/4 inches
(7.0–9.5 cm)
D
3
1
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
3 3/4 inch
(9.5 cm)
3–4 inches
(7.6–10.1 cm)
D
4
0
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
3 3/4 inch
(9.5 cm)
4 inch
(10.1 cm)
2 7/8–
3 7/8 inches
(7.3–9.8 cm)
E
3
1
2 7/8 inch
(7.3 cm)
3 1/8 inch
(7.9 cm)
3 3/8 inch
(8.6 cm)
3 5/8 inch
(9.2 cm)
3 7/8 inch
(9.8 cm)
3 1/8–
4 1/8 inches
(7.9–10.5 cm)
E
4
0
3 1/8 inch
(7.9 cm)
3 3/8 inch
(8.6 cm)
3 5/8 inch
(9.2 cm)
3 7/8 inch
(9.8 cm)
4 1/8 inch
(10.5 cm)
3 1/4–
4 1/4 inches
(8.3–10.8 cm)
E
4
1
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
3 3/4 inch
(9.5 cm)
4 inch
(10.1 cm)
4 1/4 inch
(10.8 cm)
Important: Always adjust the Number of Spacers below Caster Hub to correspond to the Axle
Position as shown in table to obtain proper “rake” (blades should always be level to the ground
or tipped slightly down at the front).
Adjusting the Axle Position
3. Raise the rear of the machine up onto jack stands
and remove the drive wheels.
Desired cutting height range can be obtained by
adjusting the rear axle and placing caster spacers
above or below the caster arm (see Figure 11 and
Figure 12 along with the Cutting Height Adjustment
Chart).
4. Loosen but do not remove the top two bolts
on each hydraulic motor mounting bracket (see
Figure 11).
To adjust rear axle:
5. Remove the bottom sets of hardware for each
bracket.
1. Stop the machine and move the drive levers to
the neutral lock position.
6. Reposition the mounting bracket to the desired
height and reinstall the bottom hardware.
2. Disengage the PTO.
7. Tighten all hardware and remount drive wheels.
29
Maintenance
8. Remove jack.
9. Adjust wheel drive and brake linkages as
required (see Brake and Wheel Drive Linkage
Adjustment section).
Figure 12
1. Four 1/2 inch (127 mm)
spacers
2. Quick Pin
7. Adjust the number of 1/2 inch spacers between
bottom of hub and caster yoke to obtain the
desired cutting height from the Cutting Height
Adjustment Table in the Adjusting the Cutting
Height section.
Figure 11
1. Position A
2. Position B
3. Position C
3. 3/16 inch (4.8 mm)
spacer
4. Caster support
8. Install remaining spacers on top of hub.
4. Position D
5. Position E
6. Axle Pivot Bolt-loosen
but Do Not remove
9. Install “quick pin”.
10. Repeat for other caster.
Adjusting the Cutting Height
with Blade Spacers
Note: The axle positions are in 1/2 inch (1.3 cm)
increments and the large caster spacers are 1/2
inch (1.3 cm) thick. Therefore, by adjusting the
same number of 1/2 inch (1.3 cm) caster spacers as
axle hole positions the blades will retain the same
front-to-back tip (rake).
1. Stop the machine and move the drive levers to the
neutral locked position.
2. Disengage the PTO.
3. Engage the park brake.
Adjusting the Number
of Spacers below Caster
Support Hub
4. Stop the engine, remove the key and wait for all
moving parts to stop.
4. Push down on handles to lift front casters off the
ground.
5. Blades may be adjusted for cutting height by using
the four 1/4 inch (.64 cm) spacers found on the
blade spindle bolts (factory setting is two above
and two below). This allows a 1 inch (2.5 cm)
range in 1/4 inch (.64 cm) increments of cutting
height in any axle position. The same number
of blade spacers must be used on all blades to
achieve a level cut (two above and two below, one
above and three below, etc.).
5. Support with jackstands.
6. Raise front of deck and support with jack stands.
6. Remove “quick pin” from one caster and remove
caster from hub (see Figure 12).
7. Hold blade bolt on bottom and loosen spindle
nut on top.
1. Stop the machine and move the drive levers to
the neutral lock position.
2. Disengage the PTO.
3. Place the drive levers in the “park brake” position.
8. Adjust number of spacers between bottom of
spindle and blade as indicated in the Cutting
30
Maintenance
Height Adjustment Table and notes in the
Adjusting the Cutting Height section.
9. Install unused spacers between top of spindle and
spindle nut.
10. Torque bolt to 75–80 ft-lb (102–109 N-m) (see
Figure 13).
Figure 14
1. The bellcrank just clears the gusset with the PTO
engaged
2. PTO Safety Switch (located beneath the engine deck)
3. Bellcrank
PTO Safety Switch
Adjustment
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. With PTO disengaged and assist arm against the
front assist arm stop, adjust the blade safety switch
mounting bracket (if needed) until the bellcrank
depresses the plunger by 1/4 inch (.64 cm).
3. Be sure the bellcrank Does Not touch the switch
body or damage to the switch could occur.
4. Retighten switch mounting bracket.
Figure 13
2. Blade bolt torque to
1. Spring disc washer
75–80 ft-lb (102–109
(cone towards bolt head)
N-m)
PTO Engagement Linkage
Adjustment
Located between the PTO engagement bellcrank and
PTO engagement assist arm beneath the front, left
hand corner of the engine deck.
Engine to Mower Deck Belt
Adjustment
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. Engage PTO.
3. Check belt guides under rear engine and front
mower deck to see that they are properly set (see
Belt Guide Adjustment section for instructions).
4. Belt must be tight enough so it does not
slip during heavy loads while cutting grass.
Over-tensioning will reduce belt and spindle
bearing life. To adjust belt tension, loosen the
5/16 inch whizlock nut on turnbuckle and rotate
the turn buckle; rotate turnbuckle toward rear of
2. With PTO engaged (lever pulled up, adjust the
linkage length to where the lower end of the
bellcrank just clears the axle support gusset (see
Figure 14). Make sure the assist arm is against the
rear assist arm stop on the deck (see Figure 15).
Push the lever down to the disengaged position.
The assist arm should contact the front assist arm
stop on the deck. If it does not contact, readjust
so that the bellcrank is closer to the gusset.
31
Maintenance
mower to tighten, and toward front of mower to
loosen belt tension (see Figure 15).
For 48 inch Decks: If there is no adjustment left
in the turnbuckle and the belt is still loose, the rear
idler pulley can be repositioned in the front hole
(see Figure 15). The belt guide located next to the
pulley must also be repositioned in the front hole
when the pulley is moved. The turnbuckle will
need to be readjusted.
Check belt tension after the first hour of operation
and at least twice during the first 24 hours of
operation. Adjust as necessary.
Figure 16
36 inch Mower Deck
Note: After readjusting the belt tension check
the belt guide adjustment as stated in the
Belt Guide Adjustment and Blade Brake
Adjustment sections.
Figure 15
48 inch Deck Shown for Reference Only
Figure 17
48 inch Mower Deck
1. Pulley location for Viking Hydro
2. Belt guide must be moved to the front position if the
pulley is moved (48 inch deck only)
3. Pulley can be moved to the front position to tighten the
belt when there is no adjustment left in the turnbuckle
(48 inch deck only)
4. Turnbuckle
5. 5/16 inch (.79 cm) minimum engagement
6. 5/16 inch whizlock nut
7. Rear Assist Arm Stop
8. Assist Arm
9. Front Assist Arm Stop
10. Point “A”
Blade Brake Adjustment
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. Disengage PTO.
3. Make sure the blade brake pad rests against
the sheave. Adjust the spring mounting bolts
to properly align the pad on the sheave (see
Figure 18).
5. Proper belt tension will require about 10 lb (4.5
kg) side pull on belt, halfway between pulleys (see
Figure 15, item 10–Point A) to deflect belt 1/2
inch (1.3 cm).
Mower Deck Belt Routings:
32
Maintenance
Figure 18
Shown with Blades Disengaged
1. Blade Brake Rod
Figure 20
48 inch Belt Guide Location
(Viewed from underneath the engine deck)
3. 1/8 inch to 3/16 inch
(.32–.47 cm)
2. Spring Mounting Bolts
1. 1 3/8 inch (3.5 cm)
2. 1/4 inch (.64 cm)
clearance
4. Check the distance between the spacer and the
nut at the end of the blade brake rod. The
distance should be between 1/8 inch (.32 cm) and
3/16 inch (.47 cm) (see Figure 18).
5. Engage the PTO and check to make sure the
blade brake pad clears the sheave.
3. End of slot
Pump Drive Belt Tension
Self-tensioning - No adjustment necessary.
Belt Guide Adjustment
Hydro Drive Linkage
Adjustment
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. Engage the PTO.
3. Check belt guide under the engine deck for proper
adjustment (see Figure 19 and Figure 20). Adjust
as necessary.
• 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 21).
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
speed control linkage (see Figure 21) until the
tabs are positioned correctly.
Figure 19
36 inch Belt Guide Location
(Viewed from underneath the engine deck)
1. 1 1/4 inch (3.1 cm)
2. 1/4 inch (.64 cm)
clearance
3. End of slot
33
Maintenance
Figure 21
Viewed from Left Side of Unit
1. Neutral Safety Switch
2. Actuating Tab in neutral
position
3. 5/16 inch (7.9 mm)
Figure 22
Viewed from Left Side of Unit
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 21).
If necessary, move the switch fore and aft.
1. Neutral Control Linkage
2. Hydro Control Linkage
3. Drive Lever Linkage
4. Speed Control Crank
• Adjust Neutral Control Linkages:
1. Raise the rear of the machine up onto jack
stands high enough to raise the drive wheels
off of the ground.
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 22.
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
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 22. 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 24). 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 23).
Figure 23
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 24
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
Park Brake Adjustment
1. Stop engine and wait for all moving parts to stop.
1. Stop engine and wait for all moving parts to stop.
2. Check the drive tire pressures and tire
circumferences as stated in Check the Tire
Pressures section in Maintenance.
2. Disengage the park brake.
3. Remove the hairpin in the lower park brake
linkage. Turn the linkage in the yoke until there is
3/16 inch (.48 cm) to 1/4 inch (.64 cm) clearance
between the park brake tire bars and the tires with
the park brake disengaged. Re-install the hairpin.
3. Run the unit and observe the tracking on a level,
smooth, hard surface such as concrete or asphalt.
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.
Hydro Pump Spring Tension
Setting
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 links to either the “medium” or “heavy
duty” positions as shown in Figure 25. The spring
anchor links are attached to the upper rear corner
of the hydro drive shields on the left and right
hand sides of the machine.
Note: In the “medium” or “heavy duty”
positions, the drive lever forces at the upper
handle will also be increased.
Figure 25
1. Heavy duty
2. Medium duty
3. Standard
4. Retaining bolt
36
Maintenance
Cleaning
recycling center or according to your state and local
regulations.
Clean Engine Air Cooling
System
Service Interval: Before each use or daily
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. Clean all debris from engine air intake screen and
from around engine shrouding.
Remove Engine Shrouds and
Clean Cooling Fins
Service Interval: Every 100 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
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.
Clean Grass Build-Up Under
Deck
Service Interval: Before each use or daily
1. Disengage PTO.
2. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
3. Raise deck and support unit using jack stands or
equivalent support.
4. Clean out any grass build-up from underside of
deck and in discharge chute.
Waste Disposal
Motor Oil Disposal
Engine oil and hydraulic oil are both pollutants to
the environment. Dispose of used oil at a certified
37
Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused
by an empty fuel tank.
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major
items or any items that call for special timing 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
Engine will not start, starts hard, or fails to
keep running.
Possible Cause
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.
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.
Relay or switch is defective.
Faulty spark plug.
Spark plug wire is not connected.
PTO is engaged.
Speed control lever is not in neutral
position.
13. OPC levers are released.
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.
11. Disengage the PTO.
12. Ensure the shifter lever is in the neutral
position.
13. Depress OPC levers.
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.
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.
8.
9.
10.
11.
12.
Engine loses power
Engine overheats
Mower pulls left or right (with levers fully
forward).
Corrective Action
38
Troubleshooting
Problem
Machine does not drive.
Uneven cutting height.
Possible Cause
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.
Blades do not stop when disengaged.
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. Deck belt is worn, loose or broken.
1. Install new deck belt.
2. Deck belt is off pulley.
2. Install deck pulley and check the idler
pulley, idler arm and spring for correct
position and function.
1. Blade brake is not adjusted properly.
1. Adjust blade brake.
2. Belt guide is not properly set
3. PTO engagement is not properly set.
2. Adjust belt guide to proper position.
3. Check the PTO engagement position.
39
Schematics
Schematics
Wiring Diagram
PTO
SWITCH
N.O.
NGE
ORA
OPC
SWITCH
N.O.
E
BLU
AB C D E F
FROM SAFETY
INTERLOCK MODULE
BROWN
TRANSMISSION
SWITCH
N.O.
GREEN
YELLOW
GREEN
RED
BLACK
KEY
SWITCH
PARK BRAKE
SWITCH
N.O.
RED
BLACK
CONNECTORS ARE VIEWED FROM WIRE END
N.C. = NORMALLY CLOSED
N.O. = NORMALLY OPEN
ENGINE
G006968
40
Schematics
41
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
*
* 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_C
42
Notes:
43
Notes:
44
Service Record
Date:
Description of Work Done:
45
Service Done By:
46
G011841
Figure 26
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. 4500-693 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com
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