Exmark Lawn Mower LZ27KC604 User Manual

For Serial Nos.  
720,000 & Higher  
LAZER Z®  
LZ27KC604 MODEL ONLY  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
Part No. 4500-246 Rev.  
A
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®
EXMARK PARTS PLUS PROGRAM  
EFFECTIVE DATE: September 1, 1995  
Program  
If your Exmark dealer does not have the Exmark part in stock, Exmark will  
get the parts to the dealer the next business day or the part will be FREE*  
Guaranteed!!  
How the Program Works  
1. If dealer does not have part in stock for a "down" unit at the time of request by customer, the dealer contacts his distributor  
®
by 1:00 p.m., local time, and requests Exmark Parts Plus shipment of six (6) line items or less.  
2. Distributor ships part(s) to dealer or customer, as requested by dealer, same day, overnight UPS Distributor bills dealer for  
part and freight charges where applicable.  
®
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus order, he contacts Exmark by 3:00 p.m., central  
®
time, with an Exmark Parts Plus order of six (6) line items or less.  
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by distributor,  
same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.  
®
5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the  
program.  
6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program?  
A. Under any circumstance the customer does not pay.  
B. If the part does not arrive overnight due to:  
®
1. The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1:00 p.m., the dealer  
pays for the part and freight.  
®
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order  
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.  
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,  
Exmark pays for the part and freight.  
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark  
pays for the part.  
®
* The following restrictions apply -- The Exmark Parts Plus Program is available only through participating Exmark  
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in  
the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States  
and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday  
delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery  
®
shipments. To qualify, all Exmark Parts Plus orders must be received by Exmark by 3:00 p.m., central time. Orders must be  
®
six (6) line items or less. Exclusions from the Exmark Parts Plus Program are: Any wholegood or accessory in its entirety,  
engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel  
motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.  
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or  
Second Day Air.  
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered  
for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.  
3
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum  
amount of dependability and years of trouble-free  
operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Figure 1  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
1. Model and serial number location  
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.  
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.  
4
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Belt Guide Adjustment.................................. 35  
Reverse Indicator Adjustment........................ 36  
Motion Control Damper Adjustment............. 37  
Contents  
Introduction ........................................................... 4  
Torque Requirements .................................... 17  
Periodic Maintenance ....................................... 26  
5
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Safety  
• Never let children or untrained people operate  
or service the equipment. Local regulations may  
restrict the age of the operator.  
Safety  
Safety Alert Symbol  
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  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Preparation  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
• 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.  
Figure 2  
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.  
CAUTION  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
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.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
Wear hearing protection when operating this  
machine.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
• 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.  
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.  
Safe Operating Practices  
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.  
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Safety  
DANGER  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
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.  
A fire or explosion from gasoline can burn  
you, others, and cause property damage.  
• Fill the fuel tank outdoors 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. Add gasoline to the fuel tank until  
the level is 1/4 to 1/2 inch (6–13 mm)  
below the bottom of the filler neck. This  
empty space in the tank allows gasoline  
to expand.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Never smoke when handling gasoline,  
and stay away from an open flame or  
where gasoline fumes may be ignited by  
spark.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Add fuel before starting the engine.  
Never remove the cap of the fuel tank or  
add fuel when engine is running or when  
the engine is hot.  
WARNING  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
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Safety  
damage and make repairs before restarting  
and operating the mower).  
Operation  
– Before clearing blockages.  
WARNING  
– Whenever you leave the mower.  
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.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
– Before refueling.  
• Allow engine parts, especially the muffler,  
to cool before touching.  
– Before dumping the grass catcher.  
• Remove accumulated debris from muffler  
and engine area.  
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.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
WARNING  
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.  
NEVER carry passengers. DO NOT operate  
the mower when people, especially children, or  
pets are in the area.  
Do Not run engine indoors or in a small  
confined area where dangerous carbon  
monoxide fumes can collect.  
• 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.  
• 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 sure all drives are in neutral and parking brake  
is engaged before starting engine. Use seat belts.  
• 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.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• 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.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• 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  
– 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  
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Safety  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
DANGER  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. Wheels  
dropping over edges, ditches, steep banks, or  
water can cause rollovers, which may result  
in serious injury, death or drowning.  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
• Be aware that loss of traction may occur going  
downhill. Weight transfer to the front wheels  
may cause drive wheels to slip and cause loss of  
braking and steering.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Do Not mow slopes greater than 15  
degrees.  
• Reduce speed and use extreme caution  
on slopes.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Avoid sudden turns or rapid speed  
changes.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
• Use a walk behind mower and/or a hand trimmer  
near drop-offs, ditches, steep banks or water.  
(Figure 3).  
Using the Rollover Protection System  
(ROPS)  
A Rollover Protection System (roll bar) is installed  
on the unit.  
WARNING  
There is no rollover protection when the roll  
bar is down. Wheels dropping over edges,  
ditches, steep banks, or water can cause  
rollovers, which may result in serious injury,  
death or drowning.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
• Lower the roll bar only when absolutely  
necessary.  
Figure 3  
• Do Not wear seat belt when the roll bar  
is down.  
1. Safe Zone-Use the  
mower here on slopes  
less than 15 degrees  
3. Water  
2. Danger Zone-Use a walk  
behind mower and/or  
hand trimmer near  
• Drive slowly and carefully.  
• Raise the roll bar as soon as clearance  
permits.  
drop-offs and water.  
• Check carefully for overhead clearances (i.e.  
branches, doorways, and electrical wires) before  
driving under any objects and do not contact them.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
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Safety  
Maintenance and Storage  
WARNING  
• 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.  
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.  
• Keep engine, engine area, and pump drive belt  
compartment free from accumulation of grass,  
leaves, excessive grease or oil, and other debris  
which can accumulate in these areas. These  
materials can become combustible and may result  
in a fire.  
• 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.  
• Let engine cool before storing and do not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Use cardboard or paper, not your hands,  
to find hydraulic leaks.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
• 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.  
• Use jack stands to support components when  
required.  
• Carefully release pressure from components with  
stored energy.  
• 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.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace blades. Never straighten or  
weld them.  
• Keep hands and feet away from moving parts.  
If possible, do not make adjustments with the  
engine running.  
• 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.  
• 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.  
• All replacement parts must be the same as  
or equivalent to the parts supplied as original  
equipment.  
10  
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• 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.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
1-303508  
1-523552  
1–633462  
1-403005  
1-513742  
1-633706  
1-513748  
11  
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Safety  
103-1798  
1–633922  
103–3270  
1–643222  
103–4474  
1–643339  
98-5954  
12  
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Safety  
103-4930  
103-5881  
107-2102  
107-2112  
103–6319  
13  
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Safety  
109-3148  
109–7949  
109-1214  
109-1215  
103–9255  
14  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 720,000 and Higher  
LZ27KC604  
Systems  
Operator Controls  
• Steering and Motion Control:  
Engine  
Note: Motion control levers are adjustable to  
two heights.  
• Engine Specifications: See your Engine Owner’s  
Manual  
– Separate levers, on each side of the console,  
control speed and direction of travel of the  
respective drive wheels.  
• RPM: Full Speed: 3750 ±50 RPM (No Load)  
Idle: 1500 RPM  
Fuel System  
• Capacity: 13.5 gal. (51.0 L)  
– Steering is controlled by varying the position  
of the levers relative to each other.  
– Moving motion control levers outward (in  
slots) locks the drive system in neutral.  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher.  
• Fuel Filter: In-line 15 Micron  
Kohler P/N 2405010.  
• PTO Engagement Switch: Engages electric clutch  
(to drive belt) which engages mower blades.  
• Fuel Shut-Off Valve: 1/4 turn increments (“ON”,  
“OFF”).  
• Parking Brake Lever: Engages parking brake.  
• Deck Height Adjustment Lever: Sets cutting  
height to desired position.  
• Fuel gauge in left hand fuel tank.  
• Deck Lift Assist Lever: Foot pedal that assists  
in raising the deck.  
Electrical System  
• Charging System: Flywheel Alternator  
• Charging Capacity: 15 amps  
• Battery Type: BCI Group U1  
• Battery Voltage: 12 Volt  
Seat  
• Type: Standard seat with high back, foam padded  
(internal suspension) and armrests.  
• Polarity: Negative Ground  
• Fuses: Two 20 amp blade type  
Optional seat accessories:  
– Custom ride suspension system to enhance  
Standard Seat.  
Safety Interlock System  
– Deluxe suspension seat with high back, low  
profile foam-in-place cushion (dampened,  
adjustable spring suspension) and armrests.  
• PTO must be disengaged, brake engaged, and  
motion control levers out (neutral lock) to start  
engine. (It is not necessary for the operator to be  
in the seat to start the engine.)  
• Mounting: Hinged to tilt up for access to  
hydraulic pumps, battery and other components.  
Held in tilted position with prop rod. Adjustable  
fore and aft seat track.  
• Operator must be in seat when PTO is engaged,  
brake is disengaged, or motion control levers are  
moved in or engine will stop.  
• Armrests:  
• Engine will stop if either the left, the right, or  
both levers are moved from neutral lock position  
while brake is engaged.  
– Standard seat: foam padded flip-up armrests.  
15  
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Specifications  
– Optional suspension seat: molded adjustable  
flip-up armrests.  
• Deck Drive:  
– Electric clutch mounted on horizontal engine  
shaft. “B” Section belt (with self-tensioning  
idler) from electric clutch to transfer shaft  
mounted on deck.  
• Seat Safety Switch: Incorporated into the  
Safety Interlock System. Time delay seat switch  
eliminates rough ground cut-outs.  
– Blades are driven by one “B” Section belt  
(w/self-tensioning idler) from transfer shaft  
on deck to blade spindles.  
Hydrostatic Ground Drive System  
• Hydrostatic Pumps: Two Hydro Gear variable  
displacement piston pumps.  
• Deck:  
• Wheel Motors: Two Parker with 1 1/4 inch  
tapered shafts.  
Full floating deck is attached to out-front support  
frame. Six anti-scalp rollers provide maximum  
turf protection. Deck design allows for bagging,  
mulching or side discharge.  
• Hydraulic Oil Type: Use Mobil 1 15W-50  
Synthetic motor oil.  
• Hydraulic Oil Capacity: 2.1 qt. (2.0 L)  
• Hydraulic Filter: Replaceable cartridge type.  
– Summer use above 32°F (0°C)  
P/N 109-4180: 25 microns, 10 psi bypass  
– Winter use below 32°F (0°C)  
P/N 1-523541: 40 microns, 18 psi bypass  
• Speeds:  
• Deck Depth: 5.5 inches (14.0 cm)  
• Cutting Height Adjustment:  
An extra-long cushioned lever is used to adjust  
the cutting height from 1 1/2 inch (3.8 cm) to 5  
inches (12.7 cm) in 1/4 inch (6.4 mm) increments.  
The cutting height adjustment handle has a  
transport position and all adjustments can be  
made while the operator remains seated. Units  
also have a foot operated deck lift assist lever to  
aid in raising the deck.  
– 0–9.8 mph (15.8 km/hr) forward.  
– 0-6.3 mph (10.1 km/hr) reverse.  
• Mulching Kit: Optional.  
• Drive wheel release valves allow machine to be  
moved when engine is not running.  
Dimensions  
Tires & Wheels  
Overall Width:  
Drive  
Front Caster  
Pneumatic  
(Air-Filled)  
Semi-Pneumatic  
Without Deck  
Deflector Up  
53.5 inches (135.9 cm)  
61.4 inches (156.0 cm)  
72.2 inches (183.4 cm)  
Quantity  
2
2
Deflector Down  
Tread Size  
“Multi- Trac  
C/S”  
Smooth  
Overall Length:  
Size  
24 x 12.00-12  
4
13 x 6.50-6  
Roll Bar - Up  
81.9 inches (208.0 cm)  
92.6 inches (235.2 cm)  
Ply Rating  
Pressure  
Roll Bar - Down  
13 psi (90 kPa)  
Cutting Deck  
• Cutting Width: 60 inch (152.4 cm)  
• Discharge: Side  
• Blade Size: (3 ea.) 20.50 inches (52.1 cm)  
• Blade Spindles: Solid steel spindles with 1 inch  
(25.4 mm) I.D. bearings.  
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Product Overview  
Overall Height:  
Product Overview  
Roll Bar - Up  
Roll Bar - Down  
71.9 in. (182.6 cm)  
53.8 inches (136.7 cm)  
Tread Width: (Center to Center of  
Tires, Widthwise)  
Drive Wheels  
Caster Wheels  
41.9 inches (106.4 cm)  
37.3 inches (94.7 cm)  
Wheel Base: (Center of Caster Tire to  
Center of Drive Tire)  
53.7 inches (136.4 cm)  
Curb Weight:  
1290 lb (585 kg)  
Figure 4  
5. Controls  
Torque Requirements  
1. Motion Control Lever  
2. Parking Brake Lever  
Bolt Location  
Torque  
6. Seat Belt  
3. Height-of-Cut Lever  
4. Fuel Cap (Both Sides)  
7. Roll Bar  
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)  
30-35 ft-lb (41-47 N-m)  
30-35 ft-lb (41-47 N-m)  
Engine Deck/Front Frame  
Mount Bolts  
Anti-Scalp Roller Nyloc  
Nut See Figure 10  
Anti-Scalp Roller Whizlock 30-35 ft-lb (41-47 N-m)  
Nut See Figure 10  
Engine Mounting Bolts  
Wheel Lug Nuts  
30-35 ft-lb (41-47 N-m)  
90-95 ft-lb (122-129 N-m)  
72-77 ft-lb (98-104 N-m)  
Wheel Motor Mounting  
Bolts  
Wheel Hub Slotted Nut  
minimum 125 ft-lb (169  
N-m)  
Rollover Protection System 30-35 ft-lb (41-47 N-m)  
(Roll Bar) Mounting Bolts  
Deck Drive Jackshaft Nut 75-80 ft-lb (102-108 N-m)  
Clutch Retaining Bolt  
55-60 ft-lb (75-81 N-m)  
(secured with threadlocker)  
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Operation  
Push the lever forward and down to disengage the  
brake.  
Operation  
Note: Determine the left and right sides of the  
The unit must be tied down and brake engaged when  
transporting.  
machine from the normal operating position.  
Ignition Switch  
Controls  
Located on right fuel tank.  
Motion Control Levers  
The ignition switch is used to start and stop the  
engine. The switch has three positions “OFF”, “ON”  
and “START”. Insert key into switch and rotate  
clockwise to the “ON” position. Rotate clockwise to  
the next position to engage the starter (key must be  
held against spring pressure in this position).  
The motion control levers located on each side of the  
console control the forward and reverse motion of  
the machine. The levers control the flow of hydraulic  
oil from the hydrostatic pump to the drive wheel  
motor for each side.  
Moving the levers forward or backward turns the  
wheel on the same side forward or in reverse. Wheel  
speed is proportional to the amount the lever is  
moved.  
Note: Brake must be engaged, motion control levers  
out (neutral lock position) and PTO switch “OFF” to  
start engine. (It is not necessary for the operator to  
be in the seat to start the engine.)  
Moving the levers outward from the center position  
into the T-slot locks them in the neutral position  
(Figure 6).  
Hour Meter  
Located on the right fuel tank.  
Choke Control  
The hour meter is connected to a pressure switch  
installed in the engine block and it records the  
number of hours that the engine has run. If the  
ignition switch is left on without engine running,  
hour meter will not run.  
Located on right fuel tank.  
The choke is used to aid in starting a cold engine.  
Moving the choke lever forward will put the choke in  
the “ON” position and moving the choke lever to the  
rear, to the detent, will put the choke in the “OFF”  
position. Do Not run a warm engine with choke in  
the “ON” position.  
Note: This switch is not a low oil sensor and will not  
alert the operator if the engine oil is low.  
Fuel Shut-Off Valve  
Throttle Control  
The fuel shut-off valve is used to shut off the fuel  
when the machine will not be used for a few days,  
during transport to and from the jobsite, and when  
parked inside a building.  
Located on right fuel tank.  
The throttle is used to control engine speed. Moving  
the throttle lever forward will increase engine speed  
and moving the throttle lever to the rear will decrease  
engine speed. Moving the throttle forward into the  
detent is full throttle.  
The valve is located in the fuel line behind and to the  
right of the seat.  
Rotate the valve 1/4 turn clockwise to shut off fuel.  
Rotate the valve 1/4 turn counterclockwise to turn  
on fuel.  
Brake Lever  
Located on left side of unit, just to the front of the  
console.  
Fuel Gauge  
Located on the left fuel tank.  
The brake lever engages a parking brake on the drive  
wheels.  
The fuel gauge monitors the amount of fuel in both  
tanks. Fuel is used evenly from both tanks.  
Pull the lever up and rearward to engage the brake.  
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Operation  
Drive Wheel Release Valves  
1. Remove the hairpin cotter pins and remove the  
two roll bar pins (Figure 5).  
Located on the top right front corner of hydrostatic  
pumps.  
2. Raise the roll bar to the upright position and  
install the two pins and secure them with the  
hairpin cotter pins (Figure 5).  
Drive wheel release valves are used to release the  
hydrostatic drive system to allow the machine to be  
pushed without the engine running. Unhook seat  
latch and tilt seat up to gain access to pumps.  
Important: Always use the seat belt with the  
roll bar in the raised position. Ensure that the  
rear part of the seat is secured with the seat  
latch.  
With a 7/16 inch wrench, turn both valves one  
turn counterclockwise to release drive system. Turn  
clockwise to reset system. Do Not overtighten. Do  
Not tow machine.  
PTO Engagement Switch  
Located on right fuel tank.  
Switch must be pulled out to the “ROTATE”  
position to engage the blades. Switch is pushed in to  
the “STOP” position to stop the blades.  
Pre-Start  
Fill fuel tanks. For best results use only clean, fresh  
regular grade unleaded gasoline with an octane rating  
of 87 or higher. Regular grade leaded gasoline may  
also be used; however, combustion chamber and  
cylinder head will require more frequent service. See  
Engine Owner’s Manual.  
Figure 5  
Do Not add oil to gasoline.  
1. Roll bar  
2. Raised position  
3. Pin  
4. Hairpin cotter pin  
Do Not overfill fuel tank. Never fill the fuel tank so  
that the fuel level rises above a level that is 1/2 inch  
(13 mm) below the bottom of the filler neck to allow  
for fuel expansion and prevent fuel spillage.  
Open the Fuel Shut-Off Valve  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
The fuel shut off valve is located in the fuel line  
behind and to the right or left of the seat. Rotate the  
valve 1/4 turn counterclockwise to turn on fuel.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Starting the Engine  
1. Move the motion control levers out to the neutral  
lock position.  
Operating Instructions  
2. Pull up and back on the parking brake lever to  
engage the parking brake.  
Raise the Rollover Protection System  
(ROPS)  
3. Push in on the PTO switch to the “STOP”  
position.  
Important: Lower the roll bar only when  
absolutely necessary.  
Note: It is not necessary for the operator to be  
in the seat to start the engine.  
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Operation  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
2. Pull the PTO switch outward to the “ROTATE”  
position.  
5. On a cold engine, push the choke lever forward  
into the “ON” position.  
3. Place the throttle in the “FAST” position to begin  
mowing.  
On a warm engine, leave the choke in the “OFF”  
position.  
Disengaging the PTO  
1. Set the throttle to the “MIDWAY” position.  
6. Turn ignition switch to the “START” position.  
Release the switch as soon as the engine starts.  
2. Push the PTO switch in to the “STOP” position  
to disengage the blades.  
Important: Do Not crank the engine  
continuously for more than ten seconds at a  
time. If the engine does not start, allow a 60  
second cool-down period between starting  
attempts. Failure to follow these guidelines  
can burn out the starter motor.  
Stopping the Engine  
1. Bring the unit to a full stop.  
2. Disengage the PTO.  
3. Move the motion control levers out to the neutral  
lock position.  
7. If the choke is in the “ON” position, gradually  
return choke to the “OFF” position as the engine  
warms up.  
4. Engage the parking brake.  
5. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
Engaging the PTO  
6. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
DANGER  
The rotating blades under the mower deck  
are dangerous. Blade contact can cause  
serious injury or kill you.  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
Do Not put hands or feet under the mower  
or mower deck when the blades are engaged.  
Driving the Machine  
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.  
CAUTION  
Machine can spin very rapidly by positioning  
one lever too much ahead of the other.  
Operator may lose control of the machine,  
which may cause damage to the machine  
or injury.  
Never operate the mower with the discharge  
deflector raised, removed, or altered unless  
there is a grass collection system or mulch  
kit in place and working properly.  
• Use caution when making turns.  
• Slow the machine down before making  
sharp turns.  
The PTO push-pull switch engages the cutting blades.  
Be sure that all persons are clear of the mower deck  
and discharge area before engaging PTO.  
Important: To begin movement (forward or  
backward) the operator must be in the seat, the  
brake lever must be disengaged (pushed down)  
before the motion control levers can be moved in  
or the engine will stop.  
Important: Operator must be in seat before the  
PTO can be engaged.  
1. Set the throttle to the “MIDWAY” position.  
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Operation  
When levers are centered in the T-slot the drive  
system is in the neutral position. With levers moved  
out in the T-slot the drive system is in the neutral lock  
position (Figure 6).  
Figure 6  
Figure 7  
1. Handles Out (Neutral  
4. Forward  
1. Handles Out (Neutral  
Lock)  
2. Handles In (Neutral)  
3. Front of Unit  
4. Forward  
5. Neutral  
6. Reverse  
7. Neutral Lock  
Lock)  
2. Handles In (Neutral)  
3. Front of Unit  
5. Reverse  
Driving Forward  
Driving in Reverse  
1. Release the parking brake.  
1. Move the motion control levers inward to the  
center to the neutral unlocked position.  
2. Move the motion control levers inward to the  
center to the neutral unlocked position.  
2. To move rearward in a straight line applying equal  
pressure pull both motion control levers rearward.  
3. To move forward in a straight line apply equal  
forward pressure to both levers.  
To turn left or right, release pressure on the  
motion control lever toward the direction desired.  
To turn left or right, pull the motion control lever  
back toward neutral in the direction desired.  
3. To stop, push the motion control levers to the  
neutral position.  
The machine will move faster the farther the  
motion control levers are moved away from  
neutral.  
Adjusting the Cutting Height  
The cutting height of the mower deck is adjusted  
from 1 1/2 to 5 inches (3.8 cm to 12.7 cm) in 1/4  
inch (6.4 mm) increments.  
4. To stop, pull the motion control levers back to  
the neutral position.  
1. Stop the machine and move the motion control  
levers outward to the neutral locked position.  
2. Disengage the PTO.  
3. Raise the deck height lever to the transport  
position (also the 5 inch (12.7 cm) cutting height  
position)(Figure 8).  
The deck can be raised by pulling the deck lever  
up and/or by pushing down on the foot operated  
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Operation  
deck lift assist lever located at the front right  
corner of the floor pan.  
6. Place the rollers in one of the positions shown  
(Figure 9). Rollers will maintain 3/4 inch (19 mm)  
clearance to the ground to minimize gouging and  
roller wear or damage.  
Note: When changing the cutting height  
positions, always come to a complete stop  
and disengage the PTO.  
Figure 9  
For cutting heights above 3.5 inches (90 mm) use the  
bottom hole. The rollers will still be effective against  
scalping.  
Figure 8  
1. Anti-scalp roller  
mounting bracket  
2. Cutting height  
1. Lever in transport and 5 inch (12.7 cm) cutting height  
position  
For Maximum Deck Flotation, place the rollers  
one hole position lower. Rollers should maintain  
1/4 inch (6.4 mm) clearance to the ground. Do  
Not adjust the rollers to support the deck.  
4. Insert the height adjustment pin into the hole  
corresponding to the desired cutting height and  
install the hairpin cotter pin.  
See the decal on the side of the deck lift plate for  
cut heights.  
7. Be sure the whizlock nuts are installed with the  
spring disc washer between the head of the nut  
and the mounting bracket.  
5. Move the deck height lever out of the transport  
position (or 5 inch (12.7 cm) cutting height) and  
down onto the height adjustment pin to mow at  
selected height.  
Note: The foot operated deck lift assist lever  
can be used to momentarily lift the deck to clear  
objects. Be sure that PTO is disengaged.  
Note: The foot operated deck lift assist lever  
can be used to momentarily lift the deck to clear  
objects. Be sure that PTO is disengaged.  
8. Torque the 3/8–16 whizlock nut to 30-35 ft-lb  
(41-47 N-m) (Figure 10).  
9. Torque the 3/8 nyloc nut to 30–35 ft-lb (41-47  
N-m).  
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 motion control  
levers outward 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. After adjusting the height of cut, adjust the  
anti-scalp rollers by removing the nyloc nut,  
bushing, spring disc washer and whizlock nut.  
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Operation  
WARNING  
Loading a unit on a trailer or truck increases  
the possibility of backward tip-over.  
Backward tip-over could cause serious injury  
or death.  
• Use extreme caution when operating a  
unit on a ramp.  
• Use only a single, full width ramp; Do  
Not use individual ramps for each side  
of the unit.  
• If individual ramps must be used, use  
enough ramps to create an unbroken  
ramp surface wider than the unit.  
Figure 10  
3. 3/8 nyloc-torque to 30-35  
1. Spring disc washer  
(cone towards nut )  
ft-lb (41-47 N-m)  
2. Front right anti-scalp  
bracket shown  
4. 3/8-16 whizlock nut  
torque to 30-35 ft-lb  
(41-47 N-m)  
• Do Not exceed a 15° angle between ramp  
and ground or between ramp and trailer  
or truck.  
• Avoid sudden acceleration while driving  
unit up a ramp to avoid tipping backward.  
Transporting  
• Avoid sudden deceleration while backing  
unit down a ramp to avoid tipping  
backward.  
Transporting a Unit  
Use a heavy-duty trailer or truck to transport the  
machine. Lock brake and block wheels. Securely  
fasten the machine to the trailer or truck with straps,  
chains, cable, or ropes. Be sure that the trailer or truck  
has all necessary lighting and marking as required by  
law. Secure a trailer with a safety chain.  
Loading a Unit  
Use extreme caution when loading units on trailers or  
trucks. One full width ramp that is wide enough to  
extend beyond the rear tires is recommended instead  
of individual ramps for each side of the unit. The  
lower rear section of the tractor frame extends back  
between the rear wheels and serves as a stop for  
tipping backward. Having a full width ramp provides  
a surface for the frame members to contact if the  
unit starts to tip backward. If it is not possible to use  
one full width ramp, use enough individual ramps to  
simulate a full width continuous ramp.  
CAUTION  
This unit does not have proper turn  
signals, lights, reflective markings, or a  
slow moving vehicle emblem. Driving on a  
street or roadway without such equipment  
is dangerous and can lead to accidents  
causing personal injury. Driving on a street  
or roadway without such equipment may also  
be a violation of State laws and the operator  
may be subject to traffic tickets and/or fines.  
Ramp should be long enough so that the angles  
between the ramp and the ground and the ramp and  
the trailer or truck do not exceed 15°. A steeper angle  
may cause mower deck components to get caught as  
the unit moves from ramp to trailer or truck. Steeper  
angles may also cause the unit to tip backward. If  
loading on or near a slope, position the trailer or  
truck so it is on the down side of the slope and the  
ramp extends up the slope. This will minimize the  
ramp angle. The trailer or truck should be as level  
as possible.  
Do Not drive a unit on a public street or  
roadway.  
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Operation  
Important: Do Not attempt to turn the unit  
while on the ramp, you may lose control and  
drive off the side.  
Avoid sudden acceleration when driving up a ramp  
and sudden deceleration when backing down a ramp.  
Both maneuvers can cause the unit to tip backward.  
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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  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
After the first 100 hours  
After the first 250 hours  
• Check the wheel hub slotted nut torque specifications.  
• Check the wheel lug nuts.  
• Change the hydraulic filter.  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check the rollover protections systems (roll bar) pins.  
• Check the seat belt.  
Before each use or daily  
• Check for loose hardware.  
• Clean the engine cooling system.  
• Clean the grass build-up from under the deck.  
• Check the hydraulic oil level.  
• Check the tire pressures.  
• Check the condition of the belts.  
• Grease the height adjustment shaft bearings.  
• Grease the rear deck struts.  
Every 40 hours  
Every 50 hours  
• Service the air cleaner. (May need more often under severe conditions. See the Engine  
Owner’s Manual for additional information.)  
• Remove the engine shrouds and clean the cooling fins.  
Every 80 hours  
Every 100 hours  
• Change the engine oil. (May need more often under severe conditions.)  
• Lubricate the brake handle pivot.  
• Lubricate the brake rod bushings.  
• Lubricate the motion control bronze bushings.  
• Lubricate the seat switch actuator.  
• Check the spark plugs.  
Every 160 hours  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Grease the brake brackets.  
Every 200 hours  
Every 500 hours  
Monthly  
• Check the wheel hub slotted nut torque specifications.  
• Check the wheel lug nuts.  
• Check the battery charge.  
• Grease front caster pivots.  
• Grease the deck drive belt idler arm.  
• Grease the mule drive belt idler arm.  
• Grease the pump drive belt idler arm.  
• Lubricate the caster wheel hubs.  
• Change the hydraulic filter.  
Yearly  
Periodic Maintenance  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
performance and service life. To preserve optimum  
battery performance and life, recharge batteries in  
storage when the open circuit voltage drops to 12.4  
volts.  
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.  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
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. Remove the dipstick  
and read the oil level.  
Check the voltage of the battery with a digital  
voltmeter. Locate the voltage reading of the battery in  
the table and charge the battery for the recommended  
time interval to bring the charge up to a full charge  
of 12.6 volts or greater.  
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.  
Important: Make sure the negative battery  
cables are disconnected and the battery charger  
used for charging the battery has an output of  
16 volts and 7 amps or less to avoid damaging  
the battery (see chart for recommended charger  
settings).  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
Check Battery Charge  
Service Interval: Monthly  
WARNING  
CALIFORNIA  
Proposition 65 Warning  
Battery posts, terminals, and related  
accessories contain lead and lead  
compounds, chemicals known to the State of  
California to cause cancer and reproductive  
harm. Wash hands after handling.  
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Maintenance  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
1 Hour  
16 volts/7  
amps  
12.0–12.2  
11.7–12.0  
25–50%  
0–25%  
2 Hours  
3 Hours  
14.4 volts/4  
amps  
14.4 volts/4  
amps  
Figure 12  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
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.  
Check Mower Blades  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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).  
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:  
WARNING  
A. Install bushing through blade with bushing  
flange on bottom (grass) side of blade.  
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.  
Figure 11  
Check Safety Interlock  
System  
1. Install bushing in blade prior to installing bushing in  
spindle.  
Service Interval: Before each use or daily  
B. Install bushing/blade assembly into spindle.  
Note: To prevent engine cut-outs on rough terrain  
the seat kill switch has a 1/2 second delay.  
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Maintenance  
1. Check starting circuit. Starter should crank with,  
parking brake engaged, PTO disengaged and  
motion control levers moved out in the neutral  
lock position. The operator does not need to be  
in the seat to start the engine.  
Check Rollover Protections  
Systems (Roll Bar) Pins  
Service Interval: Before each use or daily  
Make sure latch pin and hair pin are fully installed  
and lanyard is in good condition.  
Try to start with operator in seat, parking brake  
disengaged, PTO disengaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Check Seat Belt  
Service Interval: Before each use or daily  
Try to start with operator in seat, parking brake  
engaged, PTO engaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Visually inspect seat belt for wear, cuts, and proper  
operation of retractor and buckle. Replace before  
operating if damaged.  
Try to start with operator in seat, parking  
brake engaged, PTO disengaged, and the left  
motion control lever in, starter must not crank,  
repeat again with the right lever in, then with  
both levers in - starter must not crank.  
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. Check the kill circuits. Run engine at one-third  
throttle, disengage parking brake and raise off  
of seat (but do not get off of machine) engine  
must initiate shutdown after approximately 1/2  
second has elapsed (seat has time delay kill switch  
to prevent cut-outs on rough terrain).  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
Run engine at one-third throttle, engage PTO  
and raise offof seat (but do not get off of  
machine) engine must initiate shutdown after  
1/2 second has elapsed.  
Service Air Cleaner  
Service Interval: Every 50 hours—Service  
the air cleaner. (May  
need more often under  
severe conditions. See  
the Engine Owner’s  
Manual for additional  
information.)  
Run engine at one-third throttle, with brake  
disengaged, move levers in and raise off seat (but  
do not get off of machine) engine must initiate  
shutdown after 1/2 second has elapsed.  
Again, run engine at one-third throttle, brake  
engaged, and move left motion control lever in  
- engine must initiate shutdown.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Unhook seat latch and tilt seat up to gain access  
to the air cleaner.  
Repeat again moving the right lever in, then  
moving both levers in - engine must initiate  
shutdown whether operator is on seat or not.  
3. Loosen retaining clips and remove air cleaner  
compartment cover.  
Note: If machine does not pass any of these tests,  
do not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
4. Remove paper element. Check the condition  
of the paper element. Replace if dirty, bent or  
damaged.  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
5. Check the condition of the inner element. Replace  
whenever it appears dirty, typically every other  
time the paper element is replaced. Clean the base  
around the inner element before removing, so  
dirt does not get into the engine.  
28  
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Maintenance  
6. Do Not wash or use pressurized air to clean  
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.  
paper element or inner element.  
7. Reinstall elements. Position the cover so that the  
rubber dust ejector is pointing downward and  
secure with retaining clips.  
Change Engine Oil  
Service Interval: After the first 5 hours  
Check Tire Pressures  
Service Interval: Every 40 hours  
Every 100 hours/Yearly  
(whichever comes first)  
(May need more often  
under severe conditions.)  
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. Check tire pressure in drive tires.  
3. Inflate drive tires to 13 psi (90 kPa).  
2. Drain oil while engine is warm from operation.  
4. Semi-pneumatic caster tires do not need to be  
inflated.  
3. The oil drain hose is located on right hand side  
of engine. Place pan under machine to catch oil.  
Remove plug from end of drain hose. Allow oil  
to drain and replace oil drain plug. Torque plug to  
20-24 ft-lb (27-33 N-m).  
Note: Do Not add any type of tire liner or foam  
fill material to the tires. Excessive loads created by  
foam filled tires may cause failures to the hydro drive  
system, frame, and other components. Foam filling  
tires will void the warranty.  
4. Replace the oil filter every other oil change. Clean  
around oil filter and unscrew filter to remove.  
Before reinstalling new filter, apply a thin coating  
of oil on the surface of the rubber seal. Turn  
filter clockwise until rubber seal contacts the filter  
adapter then tighten filter an additional 1/2 to  
3/4 turn.  
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.  
5. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
2. Unhook seat latch and tilt seat up. Lift the rubber  
flap on front side of the engine to check pump  
drive belt.  
6. Use oil recommended in engine owner’s manual.  
Do Not overfill. Start the engine and check for  
leaks.  
3. Remove left and right belt shields on deck and lift  
up floor pan to inspect deck drive belt.  
Check Hydraulic Oil Level  
Service Interval: Every 40 hours  
4. Check under machine to inspect the mule drive  
belt. See Mule Drive Belt Tension Adjustment  
section.  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
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 only  
Mobil 1 15W-50 synthetic motor oil. Replace  
hydraulic reservoir cap and tighten until snug. Do  
Not overtighten.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate fittings with one to two pumps of  
NGLI grade #2 multi-purpose gun grease.  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
temperature of the oil. The “HOT” level shows  
Refer to the following chart for fitting locations  
and lubrication schedule.  
29  
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Maintenance  
Lubrication Chart  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
1. Front  
Caster  
Wheel Hubs  
*0  
*0  
1
2
2
5
*Yearly  
2. Front  
Caster  
Pivots  
*Yearly  
3. Height  
Adjustment  
Shaft  
40 Hours  
Bearings  
1
1
4. Deck  
Drive Belt  
Idler Arm  
Yearly  
Number 6 (Mule Drive Belt Idler Arm) Located  
Under Engine Frame  
1
1
2
1
200 Hours  
Yearly  
5. Brake  
Brackets  
Number 7 (Pump Drive Belt Idler Arm) Located  
Under Engine Frame  
6. Mule  
Drive Belt  
Idler Arm  
3. Lubricate front caster pivots once a year. Remove  
hex plug and cap. Thread grease zerk in hole and  
pump with grease until it oozes out around top  
bearing. Remove grease zerk and thread plug back  
in. Place cap back on.  
7. Pump  
Drive Belt  
Idler Arm  
1
1
1
2
Yearly  
8. Deck  
Rear Struts  
40 Hours  
* See step 3 for special lubrication instructions on  
the front caster pivots and the Lubricate Caster  
Wheel Hubs section for special lubrication  
instructions on the front casters wheel hubs.  
Lubricate Caster Wheel Hubs  
Service Interval: Yearly  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Figure 13  
1. Seal guard  
2. Spacer nut with wrench  
flats  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
30  
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Maintenance  
4. Remove one of the spacer nuts from the axle  
assembly in the caster wheel. Note that thread  
locking adhesive has been applied to lock the  
spacer nuts to the axle. Remove the axle (with  
the other spacer nut still assembled to it) from  
the wheel assembly.  
Lubricate Brake Handle Pivot  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate bronze bushings on brake handle pivot  
with a spray type lubricant or light oil.  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
Lubricate Brake Rod  
Bushings  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
7. Insert one bearing, one new seal into the wheel.  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Note: Seals (Exmark P/N 103-0063) must be  
replaced.  
2. Unhook seat latch and tilt seat up.  
8. If the axle assembly has had both spacer nuts  
removed (or broken loose), apply a thread locking  
adhesive to one spacer nut and thread onto the  
axle with the wrench flats facing outward. Do  
Not thread spacer nut all of the way onto the end  
of the axle. Leave approximately 1/8 inch (3 mm)  
from the outer surface of the spacer nut to the  
end of the axle inside the nut.  
3. Lubricate bronze bushings on each end of brake  
rod shaft with a spray type lubricant or a light oil  
(bushings are located to the inside of the flange  
bearings).  
Lubricate Motion Control  
Bronze Bushings  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
10. With the open end of the wheel facing up, fill  
the area inside the wheel around the axle full of  
NGLI grade #1 multi-purpose grease.  
2. Unhook seat latch and tilt seat up.  
3. Lubricate bronze bushings on flange bearings  
securing the motion control arm shafts with a  
light oil or a spray type lubricant.  
11. Insert the second bearing and new seal into the  
wheel.  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
Lubricate Seat Switch  
Actuator  
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,  
then re-torque to 20-25 in-lb (2-3 N-m). Make  
sure axle does not extend beyond either nut.  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall caster bolt  
and tighten nut fully.  
2. Unhook seat latch and tilt seat up.  
3. Lubricate switch actuator rod with spray type  
lubricant or light oil.  
Important: To prevent seal and bearing damage,  
check the bearing adjustment often. Spin the  
caster tire. The tire should not spin freely  
(more than 1 or 2 revolutions) or have any side  
play. If the wheel spins freely, adjust torque on  
spacer nut until there is a slight amount of drag.  
Reapply thread locking adhesive.  
Check Spark Plugs  
Service Interval: Every 160 hours  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner’s  
Manual.  
31  
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Maintenance  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminates into the system.  
Change Fuel Filter  
Service Interval: As required  
A fuel filter is installed between the fuel tanks and the  
engine. Replace when necessary.  
Wheel Hub - Slotted Nut  
Torque Specification  
Replacement Filters  
Service Interval: After the first 100 hours  
Kohler  
Kohler P/N 2405010  
Every 500 hours thereafter  
When tightening the slotted nut on the wheel motor  
tapered shaft:  
Change Hydraulic System  
Filter  
1. Torque the slotted nut to 125 ft-lb (169 N-m).  
Service Interval: After the first 250 hours  
2. Check distance from bottom of slot in nut to  
inside edge of hole. Two threads (0.1 inch) or less  
should be showing.  
Yearly thereafter  
Note: Use only Exmark Part No. 109-4180 for  
summer use above 32°F (0°C) or Part No. 1-523541  
for winter use below 32°F (0°C).  
3. If more than two threads (0.1 inch) are showing  
remove nut and install washer (P/N 1-523157)  
between hub and nut.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
4. Torque the slotted nut to 125 ft-lb (169 N-m).  
2. Raise seat.  
5. Then tighten nut until the next set of slots line up  
with the cross hole in shaft.  
3. Carefully clean area around filter. It is important  
that no dirt or contamination enter hydraulic  
system.  
6. Replace cotter pin.  
Note: Do Not use anti-seize on wheel hub.  
4. Unscrew filter to remove and allow oil to drain  
from reservoir.  
Fuel Tank — Mounting  
Hardware Specifications  
Service Interval: As required  
Important: Before reinstalling new filter, fill  
it with Mobil 1 15W-50 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.  
When installing the nuts on the fuel tank studs, fully  
tighten the nyloc nut and back off 1/2 turn. This  
allows for normal fuel tank expansion and contraction  
with changes in temperature and fuel levels.  
5. Fill reservoir as stated in Check Hydraulic Oil  
Level section.  
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.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
7. Start engine and move throttle control ahead to  
full throttle position. Move the speed control  
levers to the full speed and run for several  
minutes. Shut down machine and recheck oil  
level.  
• Pump drive sheave set screws.  
• Square head setscrews on Hydro pump control  
arms.  
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.  
• Sheave retaining bolt in the end of engine  
crankshaft.  
32  
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Maintenance  
• Caster wheel spacer nuts.  
Adjustments  
• Fuel tank bulkhead fitting nuts.  
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.  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
Fuel tank studs, where studs are inserted into tank.  
Deck Leveling  
1. Position mower on a flat surface.  
Mobil HTS Grease (Or  
Food-Grade Anti-seize)  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Check tire pressure in drive tires. Proper inflation  
pressure for tires is 13 psi (90 kPa). Proper  
inflation pressure for tires is 13 psi (90 kPa).  
Adjust if necessary.  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
• Between the cutter housing spindle and bearings.  
• Between the jackshaft and bearings and the  
jackshaft and sheaves.  
4. Set anti-scalp rollers to top holes or remove them  
completely for this adjustment.  
5. Raise the deck to the 5 inch (12.7 cm) height  
position (also transport position) and take all force  
off of the two large deck lift springs by loosening  
the nuts at the front of each spring (Figure 14).  
Copper-Based Anti-seize  
Copper-based anti-seize is used in the following  
location:  
6. Lower the deck to the 1 1/2 inch (3.81 cm) height  
position.  
On threads of Blade Bolts. See Check Mower  
Blades section.  
7. Place a 3/4 inch (19 mm) thick block of wood  
under each of the two rear anti- scalp roller  
brackets and place one under one of the front  
center anti-scalp roller brackets.  
Dielectric Grease  
8. Loosen the two top chain bolts in slots in the rear  
deck lift arms. Loosen jam nuts and back off the  
socket head adjusting screws on the bottom of  
the arms until the chains are just loose. Turn the  
socket head adjusting screws in until slack is taken  
out of each chain. Tighten the jam nuts. Tighten  
the chain bolts in the deck lift arms making sure  
they don’t move while tightening.  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
9. Loosen the four nuts which secure the front  
swivels (two per side) until the front chains are  
loose and front of deck is supported by the 3/4  
inch (19 mm) block. Do Not loosen the front  
chain hardware.  
10. On left side, adjust front swivel using the locking  
nut behind the swivel until the front chain is tight  
and all slack is removed from linkage. Do Not lift  
front of deck off 3/4 inch (19 mm) block. Secure  
front swivel using locking nut in front of swivel.  
Repeat for right side.  
11. Recheck that the 3/4 inch (19 mm) blocks fit just  
snugly under the brackets and that the tension on  
33  
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Maintenance  
all the chains is approximately equal. Make sure  
all chain attachment bolts are tight. Reposition  
anti-scalp rollers and tighten securely.  
center of the bolt head is at or below the center  
of the bottom alignment hole.  
3. When adjustment is necessary, loosen the idler  
pulley on the right-hand side so it can move up  
and down in the slot.  
Place a wrench on the 3/8 inch nut in the center  
of the spring loaded pulley and apply upward  
pressure to relieve tension on the spring (a 1/2  
inch drive breaker bar and 9/16 inch socket works  
best).  
Figure 14  
Reposition the adjusting pulley to the bottom of  
the slot.  
1. Apply downward pressure here  
2. Place locking pliers here to hold spring  
3. 10 1/2 inches (26.7 cm)  
Note: When installing a new belt, it is necessary  
to reposition the right adjusting pulley upward in  
the slot in order to position the center of the spring  
loaded pulley between the alignment holes.  
4. Remove force on deck springs by loosening nuts here  
5. Swivel  
6. Front of unit  
7. Socket head adjusting screw  
8. Jam nut  
12. Raise deck lift lever to the 5 inch (12.7 cm)  
cutting height position (Figure 8). Adjust spring  
compression until proper distance is obtained  
between the two large washers (Figure 14).  
Adjustment is made by turning the nut at the  
front of each spring (clockwise will shorten the  
spring, counterclockwise will lengthen the spring).  
Lock in position with jam nuts.  
Note: When above adjustments have been made,  
the front of the deck will be slightly lower than the  
rear of the deck.  
Figure 15  
1. Front of unit  
2. Alignment holes  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
Mule Drive Belt Tension  
Adjustment  
Self-tensioning idler, adjust as follows:  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Check to make sure the center of the bolt head  
in the center of the spring loaded pulley, on left  
side engine deck support, is positioned between  
the centers of the two alignment holes in the  
left support plate (Figure 15 and Figure 16). It  
is necessary to adjust the belt tension when the  
34  
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Maintenance  
Brake Link Adjustment  
Check to make sure brake is adjusted properly.  
1. Disengage brake lever (lever down).  
2. Measure the length of the spring. Measurement  
should be 2 3/4 inches (7.0 cm) between washers.  
(Figure 18).  
3. If adjustment is necessary, tighten the nut directly  
below the yoke and loosen the bottom nut  
(bottom one of the two tightened together) below  
the spring. Turn the nut directly below the washer  
(top nut of the two tightened together) until the  
correct measurement is obtained. Tighten the two  
nuts together and repeat on opposite side of unit.  
Turn clockwise to shorten spring length and turn  
counterclockwise to lengthen the spring.  
Figure 16  
3. Right side idler pulley  
1. Spring idler pulley  
2. Front of unit  
(adjustable)  
Deck Belt Tension  
Self-tensioning - No adjustment necessary.  
Belt Guide Adjustment  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove the belt shield on the right side of mower  
deck.  
Figure 18  
1. Lever down  
(disengaged)  
2. Lever up (engaged)  
3. 1/4 to 5/16 inch (6.4 to  
7.9 mm)  
6. Yoke  
3. Note belt guide bolted to deck near the shield  
support stud and right-hand pulley. Guide should  
be 1/8 inch (3.2 mm) away from the belt, with  
bolt-end of guide near end of slot (Figure 17).  
7. Lock nut  
8. Spring adjustment  
4. Collar  
5. Trunnion roller  
9. 2 3/4 inches (7.0 cm)  
4. If adjustment is necessary, loosen the bolt securing  
the belt guide and make proper adjustment.  
Tighten hardware.  
Brake Adjustment  
1. Check for brake link 2 3/4 inches (7.0 cm)  
measurement as described in the Brake Link  
Adjustment section.  
2. Engage the brake lever (lever up). The space  
between the trunnion roller and the rod collar  
should measure 1/4 inch to 5/16 inch (6.4–7.9  
mm).  
Figure 17  
3. If adjustment is necessary, loosen nut above the  
trunnion roller. Adjust the nyloc nut under the  
trunnion roller until distance listed above exists  
1. End of slot  
2. Belt guide  
35  
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Maintenance  
between the spring retainer bracket and the  
adjacent nyloc nut. Tighten the jam nut above  
the trunnion roller.  
4. If adjustment is necessary, loosen the nut  
directly below the yoke. Turn the bottom nut  
(below washer) until the correct measurement  
is obtained (see Figure 18) turn nut clockwise  
to lengthen the gap (screws rod into yoke) and  
turn counterclockwise to shorten the gap (screws  
rod out of yoke). Tighten nut against yoke and  
check opposite side of unit, repeat if necessary.  
Lengthen (or shorten) the brake rod until the  
correct gap can be achieved by following steps  
2 and 3.  
Figure 19  
4. Yoke  
2. Lever centered in notch 5. Loosen here  
3. End of slot  
6. Reverse indicator  
1. Turn bolt here  
Electric Clutch Adjustment  
No adjustment necessary.  
Reverse Indicator  
Adjustment  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Motion Control Linkage  
Adjustment  
WARNING  
2. Unhook seat latch and tilt seat forward.  
Engine must be running and drive  
wheels must be turning so motion control  
adjustment can be performed. Contact with  
moving parts or hot surfaces may cause  
personal injury  
3. Begin with either the left or right motion control  
lever. Move lever to the neutral position and pull  
lever back until the clevis pin (on arm below pivot  
shaft) contacts the end of the slot (just beginning  
to put pressure on spring). (Figure 19).  
Keep fingers, hands, and clothing clear of  
rotating components and hot surfaces.  
4. Check where lever is relative to notch in console  
(should be centered allowing lever to pivot  
outward to the neutral lock position).  
5. If adjustment is needed, loosen the nut against the  
yoke and while applying slight rearward pressure  
on the motion control lever, turn the head of the  
adjustment bolt in the appropriate direction until  
lever is centered (keeping rearward pressure on  
the lever will keep the pin at the end of the slot  
and allow the adjustment bolt to move the lever  
to the appropriate position). Tighten lock nut.  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
6. Repeat on opposite side of unit.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support  
36  
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Maintenance  
1. This adjustment must be made with the drive  
wheels turning. First raise the frame and block up  
so that drive wheels can rotate freely.  
appropriate direction until the wheels slightly  
creep in reverse (Figure 20). Move the motion  
control lever to the reverse position and while  
applying slight pressure to the lever allow the  
reverse indicator spring to bring the levers back to  
neutral. The wheel must stop turning or slightly  
creep in reverse. When adjustment is complete,  
tighten lock nuts onto ball joints.  
2. Remove the electrical connection from the seat  
safety switch, located directly to the left of the seat  
switch assembly beside the hydraulic oil reservoir.  
3. Temporarily install a jumper wire across the  
terminals in the connector of the main wiring  
harness.  
10. Adjustment for the RH motion control lever:  
Bring the RH motion control lever into the  
neutral position.  
4. Run the unit at least 5 minutes with the drive  
levers at full forward speed to bring hydraulic  
system oil up to operating temperature.  
Adjust the RH pump control rod length by  
rotating the double nuts on the rod in the  
appropriate direction until the wheels slightly  
creep in reverse. Move the motion control lever  
to the reverse position and while applying slight  
pressure to the lever allow the reverse indicator  
spring to bring the levers back to neutral. The  
wheel must stop turning or slightly creep in  
reverse (Figure 21).  
5. Unhook seat latch and tilt seat forward.  
6. Loosen lock nuts from the ball joints at each end  
of the pump control linkage (Figure 20).  
Figure 20  
Left-Hand Side of Unit  
Figure 21  
1. Turn here to adjust  
3. Loosen here (right-hand  
thread)  
Right-Hand Side of Unit  
2. Loosen here (left-hand  
thread)  
1. Loosen here (right-hand 3. Loosen here (left-hand  
thread)  
thread)  
2. Turn here to adjust  
7. Start engine. Brake must be engaged and  
motion control levers out to start engine.  
Operator does not have to be in the seat  
because of the jumper wire being used.Run  
engine at full throttle and release brake.  
11. Shut off unit. Remove jumper wire from wire  
harness connector and plug connector into seat  
switch.  
8. The reverse indicator spring must be correct  
before the following adjustments can be made.  
See the Reverse Indicator Adjustment section.  
Motion Control Damper  
Adjustment  
The top damper mounting bolt can be adjusted to  
obtain a more desired motion control lever resistance.  
See Figure 22 for mounting options.  
Note: The motion control lever needs to be in  
neutral while making any necessary adjustments.  
9. Bring the motion control lever into the neutral  
position. Adjust pump control rod length by  
rotating the double nuts on the rod in the  
37  
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Maintenance  
Caster Pivot Bearings  
Pre-Load Adjustment  
Remove dust cap from caster and tighten nyloc nut  
until washers are flat and back off 1/4 of a turn  
to properly set the pre-load on the bearings. If  
disassembled, make sure the spring disc washers are  
reinstalled as shown in Figure 23.  
Figure 22  
1. Motion control bracket  
2. Least resistance (softest feel)  
3. Medium resistance (medium feel)  
4. Most resistance (firmest feel)  
5. Torque nyloc nut to 200 in-lb (16.7 ft-lb). Bolt must  
protrude past end of nyloc nut after torque.  
6. Damper  
7. Damper must move freely on bolt.  
Adjust Seat Switch  
Figure 23  
1. If necessary, adjust the seat actuator rod length  
to where the machine will shut off when the  
operator raises off the seat (with brake disengaged  
or PTO engaged) but will continue to run with  
operator in seat (a slight shift in weight should  
not shut machine off).  
1. Spring disc washers  
Normal adjustment is when length of spring is  
2.09 inches (5.3 cm) (with seat up).  
Note: To prevent the engine from cutting out  
when operating over rough ground, the unit is  
equipped with a time-delayed seat switch. When  
the operator raises off the seat with either the  
brake disengaged or the PTO engaged, the engine  
should stop after 1/2 second has elapsed.  
2. To adjust seat switch actuator rod length, loosen  
lock nut on bottom of the actuator rod (5/16  
x 7 inch bolt) and adjust the nuts to move the  
actuator plate/washer up or down on the rod,  
then retighten.  
38  
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Maintenance  
Clean Grass Build-Up Under  
Deck  
Cleaning  
Clean Engine Cooling  
System  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
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 (5 inch (12.7 cm)  
cutting height) position. Lift the front of unit  
and support unit using jack stands or equivalent  
support.  
conditions.)  
CAUTION  
CAUTION  
Excessive debris around the engine cooling  
air intake and inside of the pump drive  
belt compartment and damaged or missing  
rubber baffles can cause the engine and  
hydraulic system to overheat which can  
create a fire hazard.  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
Clean all debris from inside of pump drive  
belt compartment daily.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Clean out any grass build-up from underside of  
deck and in discharge chute.  
2. Clean all debris from rotating engine air intake  
screen and from around engine shrouding.  
3. Clean all debris from inside of pump drive belt  
compartment.  
Waste Disposal  
4. Inspect rubber engine baffles for proper fit.  
Replace if necessary.  
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  
Service Interval: Every 80 hours  
Battery Disposal  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
DANGER  
2. Remove cooling shroud clean-out covers from  
engine and clean cooling fins. Also clean dust,  
dirt, and oil from external surfaces of engine,  
which can cause improper cooling.  
Battery electrolyte contains sulfuric acid,  
which is poisonous and can cause severe  
burns. Swallowing electrolyte can be fatal or  
if it touches skin can cause severe burns.  
3. Make sure cooling shroud clean-out covers are  
reinstalled. Operating the engine without cooling  
shroud clean-out covers will cause engine damage  
due to overheating.  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
• Do Not swallow electrolyte.  
39  
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Maintenance  
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.  
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.  
40  
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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  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
2. Parking brake is not.  
2. Set the parking brake.  
3. Drive levers are not in neutral lock  
position.  
3. Ensure the drive levers are in the neutral  
lock position.  
4. Battery does not have a full charge.  
4. Charge the battery.  
5. Electrical connections are corroded, loose 5. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
6. Fuse is blown.  
6. Replace the blown fuse.  
7. Relay or switch is defective.  
7. Contact an Authorized Service Dealer.  
Engine will not start, starts hard, or fails to  
keep running  
1. Fuel tank is empty.  
1. Fill the fuel tank.  
2. Fuel shutoff valve is closed.  
3. Oil level in the crankcase is low.  
2. Open the fuel shutoff valve.  
3. Add oil to the crankcase.  
4. The throttle and choke are not in the  
correct position.  
4. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions, and the choke is in the “ON”  
position for a cold engine or the “OFF”  
position for a warm engine.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
7. Air cleaner is dirty.  
8. Seat switch is not properly adjusted.  
7. Clean or replace the air cleaner element.  
8. Adjust the seat switch.  
9. Electrical connections are corroded, loose 9. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
10. Relay or switch is defective.  
11. Faulty spark plug.  
12. Spark plug wire is not connected.  
10. Contact an Authorized Service Dealer.  
11. Clean, adjust or replace spark plug.  
12. Check the spark plug wire connection.  
Engine looses power  
1. Engine load is excessive  
1. Reduce the ground speed.  
2. Air cleaner is dirty.  
3. Oil level in the crankcase is low.  
2. Clean or replace the air cleaner element.  
3. Add oil to the crankcase.  
4. Cooling fins and air passages for the  
engine are plugged.  
4. Remove the obstructions from the cooling  
fins and air passages.  
5. Vent hole in the fuel cap is plugged.  
6. Dirt in fuel filter.  
5. Clean or replace the fuel cap.  
6. Replace the fuel filter.  
7. Dirt, water, or stale fuel is in the fuel  
system.  
7. Contact an Authorized Service Dealer.  
41  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Engine overheats  
1. Engine load is excessive  
1. Reduce the ground speed.  
2. Add oil to the crankcase.  
2. Oil level in the crankcase is low.  
3. Cooling fins and air passages for the  
engine are plugged.  
3. Remove the obstructions from the cooling  
fins and air passages.  
Mower pulls left or right (with levers fully  
forward)  
1. Tracking needs adjustment  
1. Adjust the tracking.  
2. Tire pressure in drive tires not correct.  
2. Adjust tire pressure in the drive tires.  
3. Reverse indicator and motion control  
linkage need adjustment.  
3. Adjust the reverse indicator and the  
motion control linkage.  
Machine does not drive  
1. Bypass valve is not closed tight.  
1. Tighten the bypass valve.  
2. Change the belt.  
2. Drive or pump belt is worn, loose or  
broken.  
3. Drive or pump belt is off a pulley.  
4. Broken or missing idler spring.  
5. Hydraulic fluid level is low or too hot.  
3. Change the belt.  
4. Replace the spring.  
5. Add hydraulic fluid to reservoir or let it  
cool down.  
Uneven cutting height.  
1. Blade(s) not sharp.  
1. Sharpen the blade(s).  
2. Install new cutting blade(s).  
3. Level mower deck from side-to-side and  
front-to-rear.  
2. Cutting blade(s) is/are bent.  
3. Mower deck is not level.  
4. Underside of mower is dirty.  
5. Tire pressure in drive tires not correct.  
6. Blade spindle bent.  
4. Clean the underside of the mower.  
5. Adjust tire pressure in the drive tires.  
6. Contact an Authorized Service Dealer.  
7. 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.  
7. Replace blades, spindles and (or) check  
for damage to mower deck.  
Abnormal vibration  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Engine mounting bolts are loose.  
4. Loose engine pulley, idler pulley, or blade  
pulley.  
2. Tighten the blade mounting bolt.  
3. Tighten the engine mounting bolts.  
4. Tighten the appropriate pulley.  
5. Engine pulley is damaged.  
6. Blade spindle is bent.  
5. Contact an Authorized Service Dealer.  
6. Contact an Authorized Service Dealer.  
Blades do not rotate.  
1. Drive belt is worn, loose or broken.  
2. Drive belt is off pulley.  
1. Check the belt tension.  
2. Install drive belt and check adjusting  
shafts and belt guides for correct position.  
3. Deck belt is worn, loose or broken.  
4. Deck belt is off pulley.  
3. Install new deck belt.  
4. Install deck pulley and check the idler  
pulley, idler arm and spring for correct  
position and function.  
5. Broken or missing idler spring.  
5. Replace the spring.  
42  
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Schematics  
Schematics  
Electrical Diagram  
. G R E E N D K  
. G R E E N D K  
. G R D E K E N / W H I T E S T R I P E  
W H I T E  
C A K  
C A K  
C A K  
C A K  
B L  
B L  
B L  
B L  
C A K B L  
C A K B L  
. G R E E N D K  
. G R E E N D K  
C A K B L  
G R E Y  
C A K S T R I P E O R A N G E / B L  
. G R D E K E N / W H I T E S T R I P E  
W O Y E L L  
A T N  
. B T L L U E  
W O N R B  
. G R E E N D K  
. G R E E N D K  
C A K S T R I P E P I N K / B L  
. B T L L U E  
W O N R B  
. B T L L U E  
. B T L L U E  
. B T L L U E  
C A K B L  
. G R E E N D K  
. G T R L E E N  
A T N  
A T N  
G R E Y  
. G T R L E E N  
. B T L L U E  
G006132  
43  
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Schematics  
Hydraulic Diagram  
44  
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2-Year Limited Warranty  
Exmark Turf Equipment  
(For units purchased on or after October 1, 2004)  
Contact any Exmark Service Dealer to arrange service at their  
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 manufactured by Exmark 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.  
dealership. To locate a dealer convenient to you, access our  
402-223-6375.  
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  
This warranty applies to Exmark turf equipment purchased on  
or after October 1, 2004 sold in the US 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.  
Owner’s Responsibilities  
The Exmark turf equipment, including any defective part,  
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.  
Products  
Warranty Period  
2 years  
1 year  
1 year  
90 days  
1 Year Prorated  
• All Products (except as noted below)  
• All Attachments and Accessories  
• Metro 21 and Metro 26 Series  
• Belts and Tires  
• Battery  
• Engine*  
Warranty is covered by engine manufacturer  
* Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet. We are not authorized  
to handle warranty adjustments on engines.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair and replacement  
of defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall have any liability for any  
other cost, loss or damage, including but not limited to, any  
incidental or consequential loss or damage.  
This warranty only includes the cost of parts and labor.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer beyond first warrantable service.  
• 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.  
In particular, we shall have no liability or responsibility for:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charge 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.  
There are no other express warranties except for engine and  
special emission system coverage stated elsewhere herein or  
included with the product.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
Some states do not allow exclusions of incidental or  
consequential damages, so the above exclusions and  
limitations may not apply to you.  
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.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G006117  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
46  
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See Exmark’s Complete  
Line of Accessories  
Riding Accessories  
Custom Ride Seat Suspension System  
Deck Lift Assist Kit  
Hitch Kit  
Light Kit  
Micro-mulch System  
Roll Over Protection System (ROPS)  
Snow Blade  
Sun Shade  
Trash Container  
Turf Striper  
Ultra Vac Collection System  
Ultra Vac Quick Disposal System  
Walk Behind Accessories  
Grass Catcher  
Micro-mulch System  
Steerable Sulky  
Sulky Hitch Kit  
Turf Striper  
Standon  
Check Us Out On The Web:  
© 2007 Exmark Mfg. Co., Inc.  
Part No. 4500-246 Rev. A  
(402) 223-6300  
Fax (402) 223–5489  
Printed in the USA.  
Industrial Park Box 808  
Beatrice, NE 68310  
All Rights Reserved  
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