Exmark Lawn Mower TTS16KA363 User Manual

TURF TRACER®  
S-SERIES  
For Serial Nos.  
920,000 & Higher  
Part No. 4500-696 Rev. B  
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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.  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
Exmark parts manuals are available online at  
Figure 1  
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.  
3
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Tracking Adjustment..................................... 36  
Contents  
Torque Requirements .................................... 16  
Periodic Maintenance ....................................... 25  
Replace Emissions Air Intake Filter................ 32  
Wheel Hub-Slotted Nut Torque  
4
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Safety  
not read English it is the owner’s responsibility to  
explain this material to them.  
Safety  
Safety Alert Symbol  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
This lawn mower meets or exceeds the B71.4  
specifications of the American National Standards  
Institute in effect at the time of production.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
• Never let children or untrained people operate  
or service the equipment. Local regulations may  
restrict the age of the operator.  
Exmark designed and tested this lawn mower to offer  
reasonably safe service; however, failure to comply  
with the following instructions may result in personal  
injury.  
• Only adults and mature teenagers should operate  
a mower, and even mature teenagers should have  
adult supervision. Be sure a teenager:  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents.  
1. has read and understands the Operator’s  
Manual and recognizes the risks involved;  
2. is sufficiently mature to use caution; and  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
3. is of sufficient size and weight to operate  
the controls comfortably and to manage the  
mower without taking risks.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Figure 2  
1. Safety alert symbol  
Preparation  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
CAUTION  
This machine produces sound levels in excess  
of 85 dBA at the operator’s ear and can cause  
hearing loss through extended periods of  
exposure.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
Wear hearing protection when operating this  
machine.  
Safe Operating Practices  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
5
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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 on level ground,  
in an open area, when the engine is cold.  
Wipe up any gasoline that spills.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• Do Not fill gasoline containers inside a  
vehicle or on a truck or trailer bed because  
interior carpets or plastic truck bed liners  
may insulate the container and slow the  
loss of any static charge.  
• Do Not fill the fuel tank completely full.  
Fill the fuel tank to the bottom of the filler  
neck. The empty space in the tank allows  
gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine  
or emission system.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Never smoke when handling gasoline, and  
stay away from an open flame or where  
gasoline fumes may be ignited by spark.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Add fuel before starting the engine. Never  
remove the cap of the fuel tank or add  
fuel when engine is running or when the  
engine is hot.  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
WARNING  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
6
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Safety  
damage and make repairs before restarting  
Operation  
WARNING  
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.  
and operating the mower).  
– Before clearing blockages.  
– Whenever you leave the mower.  
• 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.  
– Before making height adjustments.  
• Remove accumulated debris from muffler  
and engine area.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
WARNING  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can kill  
you.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
Do Not run engine indoors or in a small confined  
area where dangerous carbon monoxide fumes  
can collect.  
DO NOT operate the mower when people,  
especially children, or pets are in the area.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Never raise deck with blades running.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• 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.  
• Park machine on level ground. 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  
7
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Safety  
• Keep engine and engine area free from  
accumulation of grass, leaves, excessive grease  
or oil, and other debris which can accumulate  
in these areas. These materials can become  
combustible and may result in a fire.  
DANGER  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. Loss of control  
and/or loss of operator’s footing could result in a  
fall with an arm or leg getting under the mower  
or engine deck which may result in serious  
injury, death or drowning.  
• Let engine cool before storing and do not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Mow across slopes, never up and down.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Do Not mow slopes greater than 20 degrees.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
• Use jack stands to support components when  
required.  
• Reduce speed and use extreme caution on  
slopes.  
• Carefully release pressure from components with  
stored energy.  
• Avoid sudden turns or rapid speed changes.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
• Disconnect battery or remove spark plug wire  
before making any repairs. Disconnect the  
negative terminal first and the positive last.  
Reconnect positive first and negative last.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
• Keep hands and feet away from moving parts.  
If possible, do not make adjustments with the  
engine running.  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
• Be aware that operating on wet grass, across steep  
slopes or downhill may cause the mower to lose  
traction. Loss of traction to the drive wheels may  
result in sliding and a loss of braking and steering.  
• Charge batteries in an open well ventilated area,  
away from spark and flames. Unplug charger  
before connecting or disconnecting from battery.  
Wear protective clothing and use insulated tools.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
DANGER  
Charging or jump starting the battery may  
produce explosive gases. Battery gases can  
explode causing serious injury.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Keep sparks, flames, or cigarettes away  
from battery.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
• Ventilate when charging or using battery  
in an enclosed space.  
Maintenance and Storage  
• Make sure venting path of battery is  
always open once battery is filled with  
acid.  
• Disengage drives, lower implement, set parking  
brake, stop engine and remove key or disconnect  
spark plug wire. Wait for all movement to stop  
before adjusting, cleaning or repairing.  
• Always shield eyes and face from battery.  
8
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Safety  
DANGER  
WARNING  
Battery electrolyte contains sulfuric acid,  
which is poisonous and can cause severe  
burns. Swallowing electrolyte can be fatal or  
if it touches skin can cause severe burns.  
Hydraulic fluid escaping under pressure  
can penetrate skin and cause injury. Fluid  
accidentally injected into the skin must be  
surgically removed within a few hours by a doctor  
familiar with this form of injury or gangrene may  
result.  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
• If equipped, make sure all hydraulic fluid  
hoses and lines are in good condition and all  
hydraulic connections and fittings are tight  
before applying pressure to hydraulic system.  
• Do Not swallow electrolyte.  
• In the event of an accident, flush with  
water and call a doctor immediately.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
CAUTION  
• Use cardboard or paper, not your hands, to  
find hydraulic leaks.  
If the ignition is in the “ON” position there  
is potential for sparks and engagement  
of components. Sparks could cause an  
explosion or moving parts could accidentally  
engage causing personal injury.  
• Safely relieve all pressure in the hydraulic  
system by placing the motion control levers  
in neutral and shutting off the engine before  
performing any work on the hydraulic system.  
Be sure ignition switch is in the “OFF”  
position before charging the battery.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
WARNING  
Removing standard original equipment parts,  
or using non-Exmark replacement parts and  
accessories may alter the warranty, traction, and  
safety of the machine. Failure to use original  
Exmark parts could cause serious injury or  
death.  
Replace all parts including, but not limited to,  
tires, belts, and blades with original Exmark  
parts.  
9
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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.  
1-403143  
1-303508  
1-303517  
1-413206  
36 inch Decks Only  
1-413214  
1-403005  
10  
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Safety  
1-413327  
48 inch and 52 inch Decks Only  
103-1798  
1-413421  
1-553049  
98-5954  
103-1976  
20 HP Kawasaki Electric Start  
11  
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Safety  
103-1977  
16 HP and 18 HP Kawasaki Manual Start  
103–2242  
103-2076  
103–2243  
103-2103  
103-4935  
12  
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Safety  
109-3148  
116-0404  
117–2718  
13  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 920,000 and Higher  
Manual Start Models: TTS16KA363; TTS16KA363CA; TTS16KA483; TTS16KA483CA; TTS18KA523  
Electric Start Models: TTS20KAE483; TTS20KAE483CA; TTS20KAE523  
Systems  
Operator Controls  
Steering Control: Fingertip drive control levers  
provide independent speed control, braking and  
neutral to each drive wheel for moving forward or  
reverse, stopping, and power turning.  
Engine  
• Engine Specifications: See your Engine Owner’s  
Manual  
• Engine Oil Type: Exmark 4–Cycle Premium  
Engine Oil  
Transmission  
• RPM: Full Speed: 3600 (No Load)  
Idle: 1550 RPM  
Twin Hydrostatic Drive  
• Two Hydro Gear variable displacement high  
efficiency pumps independently coupled to two  
high efficiency Parker/Ross wheel drive motors.  
Fuel System  
• Capacity: 5.0 gal. (18.9 L)  
• Hydraulic Oil: Use Exmark Premium Hydro Oil.  
• Hydraulic Oil Capacity: 2.4 qt. (2.2 L)  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher; containing no more than 10%  
methanol or ethanol.  
• Hydraulic Filter is replaceable cartridge type.  
• Fuel Filter: Replaceable In-line  
P/N 109-4180: 25 microns, 10 psi bypass  
(Summer use above 32°F (0°C))  
• Fuel Shut-Off Valve: 1/4 turn increments  
P/N 1-523541: 40 microns, 18 psi bypass (Winter  
use below 32°F (0°C))  
Electrical System (Electric Start)  
• Charging System: Flywheel Alternator  
• Charging Capacity: 15 amps  
• Speeds:  
– 0-6.2 mph (10.0 km/hr) forward.  
– 0-2.2 mph (3.5 km/hr) reverse.  
• Battery Type: BCI Group U1  
• Battery Voltage: 12 Volt  
• Drive wheels release valves allow machine to be  
moved when engine is not running.  
• Polarity: Negative Ground  
• Fuses: Two 20 amp blade type  
Wheel Drive System  
Safety Interlock System:  
Drive wheels are direct coupled to Parker wheel drive  
motors with 1 inch (25.4 mm) tapered shaft.  
• Operator must have OPC (Operator Presence  
Control) levers held in contact with handle  
grips, speed control lever in neutral, and PTO  
disengaged to start engine. Release of OPC levers  
will cause the engine to stop if speed control lever  
is not in neutral and/or PTO is engaged.  
• Park brake must be disengaged to move speed  
control out of neutral or engine will kill.  
14  
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Specifications  
Tires & Wheels  
Dimensions  
Drive  
Front Caster  
Semi-  
Overall Width:  
Pneumatic  
(Air-Filled)  
Pneumatic  
36 inch  
Deck  
48 inch  
Deck  
52 inch  
Deck  
Quantity  
Tread  
2
2
Deflector  
Up  
36.1 inches 48.1 inches 53.0 inches  
(91.7 cm) (122.2 cm) (134.6 cm)  
Turf Master  
16 x 6.50–8  
4
Smooth  
9 x 3.50-4  
Size  
Deflector  
Down  
45.9 inches 57.9 inches 62.8 inches  
(116.6 cm) (147.1 cm) (159.5 cm)  
Ply Rating  
Pressure  
14 psi  
(97 kPa)  
Overall Length:  
36 inch Deck  
48 inch Deck  
52 inch Deck  
Cutting Deck  
77.7 inches  
(197.4 cm)  
73.7 inches  
(187.2 cm)  
75.9 inches  
(192.8 cm)  
• Cutting Width:  
– 36 inch Deck: 35.25 inches (89.5 cm)  
– 48 inch Deck: 47.25 inches (120.0 cm)  
– 52 inch Deck: 52.00 inches (132.1 cm)  
• Discharge: Side  
Overall Height:  
36 inch Deck  
48 inch Deck  
52 inch Deck  
42 inches  
(106.7 cm)  
42 inches  
(106.7 cm)  
42 inches  
(106.7 cm)  
• Blade Size:  
– 36 inch Deck: 18.00 inches (45.7 cm)—  
Quantity: 2  
Tread Width: (Outside to Outside of  
Tires, Widthwise)  
– 48 inch Deck: 16.25 inches (41.3 cm)—  
Quantity: 3  
36 inch Deck  
48 inch Deck  
52 inch Deck  
35.0 inches  
(88.9 cm)  
39.4 inches  
(100.1 cm)  
39.4 inches  
(100.1 cm)  
– 52 inch Deck: 18.00 inches (45.7 cm)—  
Quantity: 3  
• Deck Drive: Manual engagement of belt with  
over-center lock. Blade belt tension is adjustable  
via turnbuckle.  
Curb Weight:  
36 inch Deck  
48 inch Deck  
52 inch Deck  
• Deck Mounting: Full floating deck is attached to  
out-front support frame, removable for service.  
634 lb (285 kg)  
775 lb (349 kg)  
774 lb (348 kg)  
• Deck Depth:  
Note: Weights will vary slightly depending on engine  
and electric start options.  
– 36 inch Deck: 5.0 inches (12.7 cm)  
– 48 inch Deck: 5.0 inches (12.7 cm)  
– 52 inch Deck: 5.0 inches (12.7 cm)  
• Cutting Height Adjustment:  
Adjusts from 1 1/2 inches (3.8 cm) to 4 1/2  
inches (11.4 cm) in 1/2 inch (1.3 cm) increments  
• Mulching Kit: Optional  
• Bagger: Optional  
15  
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Product Overview  
Torque Requirements  
Product Overview  
Bolt Location  
Torque  
Cutter Housing Spindle  
Nut  
140-145 ft-lb  
(190-197 N-m)  
Blade Mounting Bolt  
55-60 ft-lb (75-81 N-m)  
(lubricate with anti-seize)  
30-35 ft-lb (41-47 N-m)  
Engine Deck/Mower  
Deck Support Mount  
Bolts  
Anti-Scalp Roller Nyloc  
Nut See Figure 9  
30-35 ft-lb (41-47 N-m)  
Anti-Scalp Roller Whizlock 30-35 ft-lb (41-47 N-m)  
Nut See Figure 9  
Engine Mounting Bolts  
Wheel Lug Nuts  
17-23 ft-lb (23-31 N-m)  
90-95 ft-lb (122-129 N-m)  
Wheel Hub Slotted Nut  
(Style A)  
140-155 ft-lb  
(190-210 N-m)  
Figure 3  
Wheel Hub Slotted Nut  
(Style B)  
minimum 100 ft-lb  
(136 N-m)  
1. Park Brake Lever  
2. Controls  
3. Fuel Cap  
4. Height-of-Cut Pins  
Wheel Motor Mounting  
Bolts  
30-35 ft-lb (41-47 N-m)  
16  
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Operation  
as shown in Figure 4, and the drive levers are released,  
the drive wheels are engaged in the forward direction.  
Operation  
Note: Determine the left and right sides of the  
Squeezing the left hand and/or right hand lever  
causes the left hand and/or right hand drive wheel  
respectively to slow down, stop, or reverse, depending  
on how far each drive lever is “squeezed”. Squeezing  
the drive levers beyond the neutral position causes  
the drive wheels to engage in the reverse direction  
regardless of the position of the neutral lock latches  
and the speed control lever.  
machine from the normal operating position.  
Controls  
Operator Presence Control (OPC)  
Levers  
Located on the upper handle assembly directly above  
the handle grips.  
Neutral Lock Latches  
Located on the upper handle assembly on the ends  
of the handle grips.  
When these levers are depressed, the OPC system  
senses that the operator is in the normal operator’s  
position. When the levers are released, the OPC  
system senses that the operator has moved from the  
normal operating position and will kill the engine if  
either the speed control lever is not in the neutral  
position or the PTO is engaged (see Figure 4).  
These latches allow the operator to lock the drive  
levers in a “neutral” position where the drive wheels  
are not engaged in either a forward or reverse  
direction.  
Choke Control  
Located on the front left corner of the fuel tank  
support.  
Choke is used to aid in starting a cold engine. The  
choke control is pulled out to be in the “ON” position  
and pushed in to be in the “OFF” position. Do Not  
run a warm engine with choke in the “ON” position.  
Throttle Control  
Located on the control console’s right side.  
The throttle is used to control engine speed. Moving  
the throttle control forward will increase engine  
speed and moving it to the rear will decrease engine  
speed. Moving the throttle forward into the detent  
is full position.  
Figure 4  
1. OPC Lever  
3. Neutral Lock Latch  
2. Rotate neutral lock latch 4. Drive Lever in neutral  
downward for neutral  
lock position  
position  
Speed Control Lever  
Located in middle of control console.  
Drive Levers  
The speed control lever controls the maximum  
forward speed and is infinitely variable from neutral  
0–6.2 mph (10.0 km/hr).  
Located on each side of the upper handle assembly  
ahead of and below the handle grips.  
These levers individually control the speed and  
direction of each drive wheel. When the speed control  
lever is moved out of the neutral position and the  
neutral lock latches are moved into the drive position,  
Park brake must be disengaged to move speed control  
out of neutral or engine will kill.  
17  
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Operation  
Park Brake Lever  
transportation to and from the job sites, and when  
the machine will not be used for a few days.  
Located on the left side of the unit above the  
hydraulic tank.  
Rotate valve 1/4 turn clockwise to shut fuel off.  
Rotate valve 1/4 turn counterclockwise to turn fuel  
on.  
The brake lever engages the park brake on the drive  
wheels.  
Pull the lever up and rearward to engage the brake.  
Drive Wheel Release Valves  
Push the lever forward and down to disengage the  
brake.  
Located on the left rear corner of the hydrostatic  
pumps.  
When parking on a steep slope, the wheels must be  
chocked or blocked in addition to the brake being  
engaged. The unit must be tied down and brake  
engaged when transporting.  
Drive wheel release valves are used to release the  
hydrostatic drive system to allow the machine to be  
moved by hand without the engine running.  
With a 5/8 wrench, turn both valves one turn  
counterclockwise to release the drive system.  
The park brake must be disengaged to move speed  
control out of neutral or engine will kill.  
Turn clockwise to reset the drive system. Do Not  
overtighten.  
For manual start engines: The park brake must be  
disengaged before the PTO is engaged or the engine  
will kill.  
Tracking Adjustment Knob  
“Off-Run” Switch (Manual Start Only)  
Located on the right-hand side of the rear of the fuel  
tank support.  
Located on the console.  
The knob can be adjusted so that machine will  
“track” straight ahead with the drive levers released.  
Turn key to the “Run” position to allow the engine  
to be started. Turn key to the “Off ” position to shut  
engine off.  
PTO Engagement  
Operator must have speed control lever in neutral  
and the PTO disengaged to start engine.  
Located on the left side of the upper handle.  
To engage the blades, push the lever forward, or away  
from the operator, until the linkage locks over-center.  
To disengage the blades, pull the lever to the rear,  
or towards the operator.  
Ignition Switch (Electric Start Only)  
Located on the control console.  
The ignition switch is used to start and stop the  
engine. The ignition switch has three positions,  
“Off ”, “On” and “Start”. Insert key into switch  
and rotate clockwise to the “On” position. Rotate  
clockwise to the next position to engage the starter  
(key must be held against spring pressure in this  
position). Operator must have speed control lever in  
neutral, OPC levers depressed and PTO disengaged  
to start engine. When engine starts, release key.  
For manual start engines: The park brake must be  
disengaged before the PTO is engaged or the engine  
will kill.  
Cold Start Kit (Manual Start Only)  
Located below the hydro control shield.  
The cold start kit is used to ease the starting of the  
unit in cold weather or when the unit has not been  
operated for a period of time. The cold start kit  
moves the idler pulley away from the pump belt,  
releasing the tension on the belt which allows the  
engine to turn over with less resistance (see Starting  
the Engine (Manual Start) section in Operation).  
Fuel Shut-Off Valve  
Located in the fuel line midway between the tank  
and engine.  
The fuel shut-off valve is used to shut off the  
flow of fuel when parking inside a building, during  
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Operation  
B. Start engine. Refer to the following  
Pre-Start  
Fill fuel tank on level ground. For best results use  
only clean, fresh regular grade unleaded gasoline with  
an octane rating of 87 or higher.  
guidelines for further starting suggestions.  
• To engage pump drive (disengage cold start  
kit):  
A. Pull chain straight out from the side of the  
unit until the split ring can be removed  
from the bolt.  
Important: Never use methanol, gasoline  
containing methanol, gasohol containing more  
than 10% ethanol, premium gasoline, or white  
gas because the fuel system could be damaged.  
B. Slowly release tension on chain.  
Do Not add oil to gasoline.  
2. Pull out the choke control. Place the throttle  
control midway between the “Slow” and “Fast”  
positions.  
Do Not overfill fuel tank. Fill the fuel tank to the  
bottom of the filler neck. The empty space in the  
tank allows gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine or emission  
system (if equipped).  
3. Turn the key switch to the “Run” position.  
4. Pull recoil rope to start engine.  
5. After engine warms up, gradually push in the  
choke control. Do Not run warm engine with the  
choke in the “ON” position.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Note: Kawasaki engines generally need to be  
“choked” even when warm.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Note: After starting the engine and engaging the  
hydro drive, if either of the drive wheels acts sluggish  
or will not rotate at all, stop engine and refer to  
the Hydraulic System Air Purge Procedure in  
Maintenance.  
Starting the Engine (Electric Start)  
Note: Operator must have PTO disengaged, speed  
control lever in neutral position, and OPC levers  
depressed when starting the engine.  
1. Lock drive levers in neutral and engage park  
brake.  
Operating Instructions  
2. Pull out the choke control. Place the throttle  
control midway between the “Slow” and “Fast”  
positions.  
Open the Fuel Shut-Off Valve  
Rotate the valve 1/4 turn counterclockwise to turn  
fuel on.  
3. Turn the ignition switch to the “Start” position.  
Release the switch as soon as the engine starts.  
Starting the Engine (Manual Start)  
Important: Do Not crank the engine  
continuously for more than ten seconds at  
a time. If the engine does not start, allow a  
60 second starter cool-down period between  
starting attempts. Failure to follow these  
guidelines can burn out the starter motor.  
Note: Operator must have PTO disengaged and  
speed control lever in neutral position when starting  
the engine.  
1. Lock drive levers in neutral and engage park  
brake.  
4. After engine warms up, gradually push in the  
choke control. Do Not run warm engine with the  
choke in the “ON” position.  
Note: A cold weather starting kit has been added  
for ease of starting in either cold weather or when  
the unit has not been run for a period of time.  
Note: Kawasaki engines generally need to be  
“choked” even when warm.  
• To use cold start kit:  
A. Pull split ring straight out the side of the  
unit, and hook the ring over the lower rear  
hydro control shield bolt.  
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Operation  
6. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
PTO Engagement  
DANGER  
The rotating blades under the mower deck are  
dangerous. Blade contact can cause serious  
injury or kill you.  
7. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
8. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
Do Not put hands or feet under the mower or  
mower deck when the blades are engaged.  
9. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
DANGER  
An uncovered discharge opening will allow  
objects to be thrown in an operator’s or  
bystander’s direction. Also, contact with the  
blade could occur. Thrown objects or blade  
contact can cause serious injury or death.  
Driving the Machine  
Drive Lever/Neutral Lock Latch Operation  
To lock the drive levers in “neutral lock”, squeeze the  
drive levers to the “neutral” position (Do Not squeeze  
the drive levers all the way back as this will cause the  
drive wheels to go into full reverse direction). See  
Figure 5 position 1. Place thumbs on the inner lobe  
of the neutral lock latches and rotate them under  
the drive levers into the “neutral lock” position. See  
Figure 5 position 2. Release the drive levers.  
Never operate the mower with the discharge  
deflector raised, removed, or altered unless there  
is a grass collection system or mulch kit in place  
and working properly.  
The PTO switch engages the cutting blades. Be sure  
that all persons are clear of mower deck and discharge  
area before engaging the PTO.  
CAUTION  
1. Set throttle to “MIDWAY” position.  
If the neutral lock latches are not completely  
engaged the drive levers could unexpectedly slip  
into the forward drive position. If the drive levers  
slip into the drive position the unit could lurch  
forward and cause injury or property damage.  
2. Push the PTO engagement arm forward and  
down to engage blades.  
3. Place the throttle in the “FAST” position to begin  
mowing.  
For manual start engines: The park brake must  
be disengaged before the PTO is engaged or the  
engine will kill.  
Be sure the drive levers are past the roller and  
securely seated at the bottom of the neutral lock  
latches.  
Disengaging the PTO  
1. Set throttle to “MIDWAY” position.  
To place the drive levers in the “forward” position,  
slightly squeeze the drive levers while placing thumbs  
on the outer thumb lobe of the neutral lock latches  
(or the index finger on the front lobe) and rotate them  
from under the drive levers. Slowly and carefully  
release the drive levers. See Figure 5 position 3.  
2. Pull upward and back completely on the PTO  
engagement arm to disengage the blades.  
Stopping the Engine  
1. Bring the unit to a full stop.  
2. Lock drive levers in neutral.  
3. Disengage the PTO.  
To place the drive levers in the “reverse” position,  
squeeze the drive levers past the neutral position. See  
Figure 5 position 4.  
4. Move speed control lever to neutral.  
5. Engage the parking brake.  
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Operation  
Driving in Reverse  
To move rearward in a straight line, squeeze drive  
levers into the reverse position.  
To turn left or right, squeeze the right hand drive lever  
to turn left and the left hand drive lever to turn right.  
To make a “zero turn”, squeeze either the left hand  
or the right hand drive lever back into the reverse  
position while the opposite drive lever is in a forward  
position at an equal but opposite speed.  
Note: For smooth operation of this machine, avoid  
quick, jerky movements of the drive levers. Move the  
drive levers smoothly and deliberately.  
Figure 5  
1. Drive Lever in neutral  
3. Drive Lever in forward  
position  
4. Drive Lever in reverse  
position  
To stop, squeeze drive levers back to the “neutral”  
position. Move the neutral lock latches into the  
“neutral lock” position and release drive levers. Move  
the speed control lever to the neutral position.  
position  
2. Drive Lever locked in  
neutral position  
Driving Forward  
Adjusting the Cutting Height  
WARNING  
When the two front support rod hairpins are  
removed from the mower deck, the weight of the  
tractor section may cause the front frame of the  
unit to rise suddenly. If the unit rises suddenly,  
injury may occur.  
1. Release the parking brake.  
2. With drive levers locked in “neutral”, shift speed  
control lever to desired forward speed.  
3. Slowly squeeze and hold both drive levers in  
the neutral position and rotate both neutral lock  
latches from the neutral lock position to the  
forward position.  
Securely hold down the front of the unit when the  
front support rod hairpins are removed.  
Note: Do Not squeeze both drive levers all the  
way back. This will cause the drive wheels to  
engage in the reverse direction.  
The cutting height of the mower deck is adjusted  
from 1 1/2 to 4 1/2 inches (3.81 cm to 11.4 cm) in  
1/2 inch increments.  
4. To move forward in a straight line, smoothly  
release both drive levers to engage drive wheels.  
To turn left or right, squeeze the right hand drive  
lever to turn right and the left hand drive lever  
to turn left.  
1. Stop the machine and move the drive levers to the  
neutral locked position.  
2. Disengage the PTO.  
To make a “zero turn”, squeeze either the left  
hand or the right hand drive lever back into the  
reverse position while the opposite drive lever is in  
a forward position at an equal but opposite speed.  
3. Engage the park brake.  
4. Stop the engine, remove the key and wait for all  
moving parts to stop.  
5. Install hairpin clips in the holes for the desired  
cutting height. See Figure 6.  
Note: For smooth operation of this machine,  
avoid quick, jerky movements of the drive levers.  
Move the drive levers smoothly and deliberately.  
Important: To maintain correct cutting  
height and rake, check the following for  
proper adjustment.  
To stop, squeeze drive levers back to the “neutral”  
position. Move the neutral lock latches into the  
“neutral lock” position and release drive levers.  
Move the speed control lever to the neutral  
position.  
A. The front and rear hairpins are in the same  
holes with the proper spacers under the hair  
pins. See Figure 6.  
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Operation  
Adjusting the Anti-Scalp Rollers  
It is recommended to change the anti-scalp roller  
position when the height of cut has changed.  
1. Stop the machine and move the drive levers to  
the neutral lock position.  
2. Disengage the PTO.  
3. Engage the park brake.  
4. Stop the engine, remove the key and wait for all  
moving parts to stop.  
5. After adjusting the height of cut, adjust the  
anti-scalp rollers by removing the whizlock nut  
and spring disc washer.  
Figure 6  
2. Cutting Height  
1. Deck support pin  
6. Adjust anti-scalp rollers for Normal Operating  
Conditions. Place rollers in one of the positions  
shown in Figure 8. Rollers will maintain 3/4  
inches (19 mm) clearance to the ground to  
minimize gouging and roller wear or damage.  
B. The tire pressures are set as directed in Check  
Tire Pressures in the Maintenance section.  
C. The length of the rear deck support link  
assemblies average 6.89 inches (approximately  
6 7/8 inches) (175.01 mm) from the center of  
the balljoint to the center of the farthest hole.  
See Figure 7.  
Note: For Maximum Deck Flotation, place  
rollers one hole position lower. Rollers should  
maintain 1/4 inch (6.35 mm) clearance to ground.  
Do Not adjust rollers to support the deck. Be  
sure roller bolts are installed with the spring disc  
washer between head of the nut and mounting  
bracket.  
Note: All four pins must equally support the  
weight of the deck. Adjustment in the length  
of the rear deck support assemblies may be  
necessary. If one side is longer than 6.89  
inches (approximately 6 7/8 inches) (175.01  
mm), than the opposite side must be shorter  
by the same amount.  
Figure 8  
For cutting heights above 3.5 inches (38 mm) use the  
bottom hole. The rollers will still be effective against  
scalping.  
1. Anti-scalp roller  
mounting bracket  
2. Cutting height  
7. Torque the 3/8–16 whizlock nut to 30-35 ft-lb  
(41-47 N-m) (Figure 9).  
Figure 7  
Left Hand Side Shown  
8. If the 3/8 nyloc nut has been removed, reinstall  
and torque to 30–35 ft-lb (41-47 N-m) (Figure 9).  
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Operation  
Figure 9  
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)  
Transporting  
Transporting a Unit  
WARNING  
Loading the mower onto a trailer without strong  
enough or properly supported ramps could be  
dangerous. The ramps could collapse causing  
the unit to fall, which could cause injury.  
• Use proper ramps that are secured to the  
truck or trailer.  
• Keep feet and legs out from under the unit  
when loading and unloading.  
• If necessary, use assistance when loading.  
Be sure the fuel shut-off valve is closed.  
Use a heavy duty trailer to transport the machine.  
Engage neutral lock latches and park brake, then  
block wheels.  
Securely fasten the machine to the trailer with straps,  
chains, cables, or ropes.  
Do Not rely solely on the parking brake to hold the  
machine on the trailer.  
Be sure that the trailer has all necessary lighting and  
marking as required by law and use a safety chain.  
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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  
• Inspect PTO clutching belt tension. Check every 2 hours for the first 8 hours of operation.  
• Change the engine oil.  
After the first 2 hours  
After the first 5 hours  
After the first 100 hours  
After the first 250 hours  
• Check wheel hub-slotted torque specification.  
• Change the hydraulic filter.  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check for loose hardware.  
• Grease the caster wheel bearings.  
• Grease caster pivots.  
Before each use or daily  
• Clean the engine and exhaust system area.  
• Clean the grass and debris build-up from the machine and cutting deck.  
• Clean the grass build-up from under the deck.  
• Service the foam element. (May need more often under severe conditions. See the Engine  
Owner’s manual for additional information.)  
Every 25 hours  
Every 40 hours  
• Check the hydraulic oil level.  
• Check the tire pressures.  
• Check the condition of the belts.  
• Grease the pump drive idler pivot.  
• Grease the clutch arm pivot.  
• Grease the pump control bearings.  
• Grease the mower deck idler pivot.  
• Inspect PTO clutching belt tension.  
• Service the paper element. (May need more often under severe conditions. See the Engine  
Owner’s manual for additional information.)  
• Change the engine oil. (May need more often under severe conditions.)  
• Remove engine shrouds and clean cooling fins.  
Every 100 hours  
• Check the spark plugs.  
Every 160 hours  
Every 200 hours  
• Replace the paper element.  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)  
• Replace the emissions air intake filter.  
• Check wheel hub-slotted torque specification.  
Every 500 hours  
Monthly  
• Check the battery charge.  
• Grease the PTO engagement bellcrank.  
Periodic Maintenance  
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  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
2. Check with engine cold.  
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.  
3. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Do Not screw into  
place. Remove the dipstick and read the oil level.  
4. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Exmark 4-Cycle Premium  
Engine Oil is recommended; refer to the Engine  
Owner’s manual for an acceptable alternative. Do  
Not overfill.  
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.  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
Check Battery Charge  
(Electric Start Units Only)  
Service Interval: Monthly  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
1 Hour  
16 volts/7  
amps  
WARNING  
12.0–12.2  
11.7–12.0  
25–50%  
0–25%  
2 Hours  
3 Hours  
14.4 volts/4  
amps  
CALIFORNIA  
Proposition 65 Warning  
Battery posts, terminals, and related  
accessories contain lead and lead  
14.4 volts/4  
amps  
compounds, chemicals known to the State of  
California to cause cancer and reproductive  
harm. Wash hands after handling.  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
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Maintenance  
Recommended Jump  
Starting Procedure (Electric  
Start Units Only)  
WARNING  
Batteries contain acid and produce explosive  
gases.  
• Shield the eyes and face from the batteries  
at all times.  
Service Interval: As required  
1. Check the weak battery for terminal corrosion  
(white, green, or blue “snow”), it must be cleaned  
off prior to jump starting. Clean and tighten  
connections as necessary.  
• Do Not lean over the batteries.  
Note: Be sure the vent caps are tight and level.  
Place a damp cloth, if available, over any vent  
caps on both batteries. Be sure the vehicles do  
not touch and that both electrical systems are  
off and at the same rated system voltage. These  
instructions are for negative ground systems only.  
CAUTION  
Corrosion or loose connections can cause  
unwanted electrical voltage spikes at anytime  
during the jump starting procedure.  
3. Connect the positive (+) cable to the positive (+)  
terminal of the discharged battery that is wired to  
the starter or solenoid as shown in Figure 10.  
Do Not attempt to jump start with loose or  
corroded battery terminals or damage to the  
engine may occur.  
DANGER  
Jump starting a weak battery that is cracked,  
frozen, has low electrolyte level, or an  
open/shorted battery cell, can cause an  
explosion resulting in serious personal injury.  
Do Not jump start a weak battery if these  
conditions exist.  
Figure 10  
2. Make sure the booster is a good and fully charged  
lead acid battery at 12.6 volts or greater. Use  
properly sized jumper cables (4 to 6 AWG) with  
short lengths to reduce voltage drop between  
systems. Make sure the cables are color coded or  
labeled for the correct polarity.  
1. Positive (+) cable on discharged battery  
2. Positive (+) cable on booster battery  
3. Negative (–) cable on the booster battery  
4. Negative (–) cable on the engine block  
5. Booster battery  
6. Discharged battery  
7. Engine block  
CAUTION  
4. Connect the other end of the positive cable to the  
positive terminal of the booster battery.  
Connecting the jumper cables incorrectly  
(wrong polarity) can immediately damage the  
electrical system.  
5. Connect the black negative (–) cable to the other  
terminal (negative) of the booster battery.  
Be certain of battery terminal polarity and  
jumper cable polarity when hooking up  
batteries.  
6. MAKE THE FINAL CONNECTION ON  
THE ENGINE BLOCK OF THE STALLED  
VEHICLE (NOT TO THE NEGATIVE POST)  
AWAY FROM THE BATTERY. STAND BACK.  
Note: The following instructions are adapted  
from the SAE J1494 Rev. Dec. 2001 – Battery  
Booster Cables – Surface Vehicle Recommended  
Practice (SAE – Society of Automotive  
Engineers).  
7. Start the vehicle and remove the cables in the  
reverse order of connection (the engine block  
(black) connection is the first to disconnect).  
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Maintenance  
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).  
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.  
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.  
WARNING  
Incorrect installation of the blade or  
components used to retain the blade can  
be dangerous. Failure to use all original  
components and assembled as shown could  
allow a blade or blade component to be  
thrown out from under the deck resulting in  
serious personal injury or death.  
4. Reinstall the blades (if they were removed) in the  
following order:  
A. Install bushing through blade with bushing  
flange on bottom (grass) side of blade.  
Always install the original Exmark blades,  
blade bushings, and blade bolts as shown.  
Replacing the Discharge  
Deflector  
Figure 11  
Service Interval: As required  
1. Install bushing in blade prior to installing bushing in  
spindle.  
DANGER  
An uncovered discharge opening could allow the  
lawn mower to throw objects in the operator’s or  
bystander’s direction and result in serious injury.  
Also, contact with the blade could occur.  
B. Install bushing/blade assembly into spindle.  
Never operate the lawn mower unless you install  
a mulch plate, discharge deflector, or grass  
collection system.  
1. To remove a damaged or worn discharge  
deflector, lift the leg of the spring with the loop  
out of the notch in the discharge deflector and  
slide the rod out of the discharge deflector  
brackets, and discharge deflector.  
2. To install new discharge deflector, orient the  
spring on the rod as shown in Figure 13. Slide the  
rod through the front discharge deflector bracket,  
discharge deflector, and rear deflector bracket.  
Figure 12  
1. Use wrench here for  
blade installation. This  
nut has been torqued to  
140–145 ft-lb (190–197  
N-m)  
2. Torque to 55-60 ft-lb  
(75-81 N-m) Apply  
lubricant to threads  
as needed to prevent  
seizing. Copper-based  
anti-seize preferable.  
Grease acceptable  
substitute.  
27  
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Maintenance  
Try to start with, OPC levers depressed, speed  
control lever in any speed but neutral and PTO  
disengaged–starter must not crank.  
Try to start with OPC levers depressed,  
speed control lever in neutral and PTO  
engaged–starter must not crank. .  
2. For All Units: Check OPC circuits. Clear the  
area. Disengage the park brake. Run engine at  
one-third throttle, then, with drive levers and  
neutral lock latches in neutral lock position,  
move the speed control lever out of neutral and  
release OPC levers–engine must stop. Again,  
run engine at one-third throttle, move the speed  
control lever to neutral, engage PTO and release  
OPC levers–engine must stop.  
Note: Park brake must be disengaged before the  
speed control lever is moved out of neutral or engine  
will kill.  
Figure 13  
4. Mower deck  
For Manual Start Engines: The park brake must be  
disengaged before the PTO is engaged or the engine  
will kill.  
1. Rod  
2. Spring  
5. Discharge deflector  
bracket  
6. Assembled view  
3. Discharge deflector  
Note: If machine does not pass any of these tests,  
do not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
3. Hook the bent end of the rod around the front  
discharge deflector bracket to retain it from  
sliding out. Place the leg of the spring with the  
loop in the notch in the discharge deflector to  
hold the discharge deflector in the down position  
(see Figure 13).  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Important: The discharge deflector must be  
spring loaded in the down position. Lift the  
deflector up to test that it snaps to the full  
down position.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
Check Safety Interlock  
System  
Service Interval: Before each use or daily  
Service Air Cleaner  
1. For Electric Start Units Only: Check starting  
circuit. Starter should crank with: Operator  
Presence Control levers depressed, speed control  
lever in neutral, and PTO disengaged.  
Service Interval: Every 25 hours—Service  
the foam element. (May  
need more often under  
severe conditions. See  
the Engine Owner’s  
Try to start the engine with OPC levers  
disengaged, speed control lever in neutral and  
PTO disengaged–starter must not crank.  
manual for additional  
information.)  
Every 100 hours—Service  
the paper element. (May  
28  
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Maintenance  
need more often under  
severe conditions. See the  
Engine Owner’s manual  
for additional information.)  
1. Stop engine and wait for all moving parts to stop,  
and remove key. Engage parking brake.  
2. Clean area around hydraulic reservoir cap and  
remove cap. Oil level should be to the top of the  
baffle inside the tank. If not, add oil. Use Exmark  
Premium Hydro Oil. Replace hydraulic reservoir  
cap and tighten until snug. Do Not overtighten.  
Every 200 hours/Yearly  
(whichever comes  
first)—Replace the paper  
element.  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
1. Stop engine, wait for all moving parts to stop, and  
remove key or spark plug wire(s). Engage parking  
brake.  
temperature of the oil. The “HOT” level shows  
the level of oil when it is at 225°F (107°C). The  
“COLD” level shows the level of the oil when  
it is at 75°F (24°C). Fill to the appropriate level  
depending upon the temperature of the oil. For  
example: If the oil is about 150°F (65°C), fill to  
halfway between the “HOT” and “COLD” levels.  
If the oil is at room temperature (about 75°F  
(24°C)), fill only to the “COLD” level.  
2. See the Engine Owner’s Manual for maintenance  
instructions.  
Change Engine Oil  
Service Interval: After the first 5 hours  
Every 100 hours (May  
need more often under  
severe conditions.)  
Check Tire Pressures  
Service Interval: Every 40 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Drain oil while engine is warm from operation.  
2. Check tire pressure in drive tires.  
3. Inflate drive tires to 12–16 psi (83–110 kPa).  
3. The oil drain hose assembly is located on the left  
side of the engine.  
4. Inflate tires to pressures stated above. Measure  
the circumference of each drive tire. Adjust tire  
pressures within the above range to try to make  
tire circumferences match as closely as possible.  
Place pan under machine to catch oil. Remove oil  
drain plug. Allow oil to drain and replace oil drain  
plug. Torque plug to 20-24 ft-lb (27-33 N-m).  
5. Semi-pneumatic caster tires do not need to be  
inflated.  
4. Replace the oil filter per the Engine Owner’s  
Manual. Clean around oil filter and unscrew filter  
to remove. Before the new filter is installed,  
apply a thin coating of Exmark 4–Cycle Premium  
Engine Oil on the surface of the rubber seal.  
Turn filter clockwise until rubber seal contacts  
the filter adapter, then tighten filter an additional  
2/3 to 3/4 turn.  
Check Condition Of Belts  
Service Interval: Every 40 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove the mower deck belt shield to check  
mower blade drive belt condition.  
3. Look under engine deck to check the pump drive  
belt condition.  
4. Check all idler arms to be sure they pivot freely.  
Disassemble, clean and grease pivot bushings if  
necessary.  
5. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
6. Use oil recommended in the Check Engine Oil  
Level section. Do Not overfill. Start the engine  
and check for leaks. Stop engine and recheck oil  
level.  
Check Hydraulic Oil Level  
Service Interval: Every 40 hours  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
29  
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Maintenance  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Spray Lubricant Chart (cont'd.)  
Pivot Point  
Service Interval  
40 hours  
Number of Places  
1
2. Lubricate fittings with NGLI grade #2  
multi-purpose gun grease.  
1. PTO Lever  
Refer to the following chart for fitting locations  
and lubrication schedule.  
Check Spark Plugs  
Service Interval: Every 160 hours  
Lubrication Chart  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner’s  
Manual.  
Fitting  
Locations Pumps  
Initial  
Number of Places  
Service  
Interval  
36 inch 48 inch 52 inch  
Deck  
Deck  
Deck  
1. Caster  
Wheel  
Bearings  
12  
2
2
2
Daily  
Change Fuel Filter  
Service Interval: As required  
2. Caster  
Pivots  
2
1
2
1
2
1
2
1
Daily  
A fuel filter is installed in the fuel line between the  
fuel tank and the engine. Replace when necessary.  
3. PTO  
Engagement  
Bellcrank  
40 hours  
Change Hydraulic System  
Filter  
4. Pump  
Drive Idler  
Pivot  
2
1
1
1
Yearly  
Service Interval: After the first 250 hours  
1
2
1
2
1
2
1
2
5. Clutch  
Arm Pivot  
40 hours  
40 hours  
Every 500 hours/Yearly  
(whichever comes  
first) thereafter  
(Every 250 hours/Yearly if  
using Mobil 1 15W50)  
6. Pump  
Control  
Bearings  
7. Mower  
Deck Idler  
Pivots  
2
1
1
1
Yearly  
Note: Use only Exmark Part No. 109-4180 for  
Summer use above 32°F (0°C) or P/N 1-523541 for  
Winter use below 32°F (0°C) (Refer to Transmission  
section in Specifications for filter specifications).  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Carefully clean area around filter. It is important  
that no dirt or contamination enter hydraulic  
system.  
3. Unscrew filter to remove and allow oil to drain  
from reservoir.  
Important: Before reinstalling new filter,  
fill it with Exmark Premium Hydro Oil and  
apply a thin coat of oil on the surface of the  
rubber seal.  
Number 4 Idler Pivot (Pump Drive) Located  
under engine deck.  
Number 5 (Clutch Arm Pivot) Located under  
engine deck.  
Turn filter clockwise until rubber seal contacts the  
filter adapter, then tighten the filter an additional  
2/3 to 3/4 turn.  
3. Lubricate pivot points with a spray penetrating  
lubricant as shown in the Spray Lubricant Chart.  
4. Fill reservoir as stated in Check Hydraulic Oil  
Spray Lubricant Chart  
Level.  
30  
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Maintenance  
Exmark Premium Hydro Oil is recommended.  
Refer to the chart for an acceptable alternative:  
The critical area for purging air from the hydraulic  
system is between the oil reservoir and each  
charge pump located on the top of each variable  
displacement pump (Figure 14). Air in other parts of  
the hydraulic system will be purged through normal  
operation once the charge pump is “primed”.  
Hydro Oil  
Change Interval  
500 Hours  
Exmark Premium Hydro  
Oil (Preferred)  
250 Hours  
Mobil 1 15W50  
5. Loosen filter 1/2 turn and allow a small amount  
of oil to leak from the oil filter (this allows air to  
be purged from the oil filter and supply hose from  
the hydraulic reservoir). Turn filter clockwise  
until rubber seal contacts the filter adapter. Then  
tighten the filter an additional 2/3 to 3/4 turn.  
6. Raise the rear of machine up and support with  
jack stands (or equivalent support) just high  
enough to allow drive wheels to turn freely.  
CAUTION  
Raising the mower for service or maintenance  
relying solely on mechanical or hydraulic  
jacks could be dangerous. The mechanical or  
hydraulic jacks may not be enough support  
or may malfunction allowing the unit to fall,  
which could cause injury.  
Figure 14  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
1. Charge pump cap  
2. Loosen 1 1/2 turns only  
1. Stop engine and wait for all moving parts to stop.  
Raise the rear of the machine up onto jack stands  
high enough to raise the drive wheels off the  
ground.  
7. If either drive wheel does not rotate, one or both  
of the charge pumps (located on the top of the  
main pump as shown in Figure 14) may have lost  
their “prime”. Refer to Hydraulic System Air  
Purge section.  
2. Check oil level as stated in Check Hydraulic Oil  
Level section.  
3. Start engine and move throttle control ahead to  
full throttle position. Move the speed control  
lever to the middle speed position and place the  
drive levers in the “drive” position.  
Note: Do Not change hydraulic system oil (except  
for what can be drained when changing filter), unless  
it is felt the oil has been contaminated or been  
extremely hot.  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminates into the system.  
If either drive wheel does not rotate, it is possible  
to assist the purging of the charge pump by  
carefully rotating the tire in the forward position.  
Note: It is necessary to lightly touch the charge  
pump cap with your hand to check the pump  
temperature. If the cap is too hot to touch, turn  
off engine. The pumps may be damaged if the  
pump becomes too hot.  
Hydraulic System Air Purge  
Service Interval: As required  
Air must be purged from the hydraulic system  
when any hydraulic components, including oil  
filter, are removed or any of the hydraulic lines are  
disconnected.  
If either drive wheel still does not rotate continue  
with step 4.  
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Maintenance  
4. Thoroughly clean the area around each of the  
charge pump housings.  
5. To “prime” charge pump, loosen two hex socket  
head capscrews (shown in Figure 14) 1 1/2 turns  
only. Make sure engine is not running. Lift  
the charge pump housing upward and wait for  
a steady flow of oil to flow out from under the  
housing. Retighten the capscrews. Do this for  
both pumps.  
Figure 15  
1. Style A (black finish)  
3. Style B (yellow zinc)  
4. .24 inch (6 mm)  
2. .03 inch (.76 mm)  
Note: Hydraulic reservoir can be pressurized up  
to 5 psi to speed this process.  
Style A (black finish):  
Torque the slotted nut to 140-155 ft-lb (190-210  
N-m).  
6. If either drive wheel still does not rotate, stop  
and repeat steps 4 and 5 above for the respective  
pump. If wheels rotate slowly, the system may  
prime after additional running. Check oil level  
as stated in Check the Hydraulic Oil Level  
section.  
Note: Do Not use anti-seize on wheel hub.  
Style B (yellow zinc):  
1. Remove and discard the cotter pin.  
2. Torque the slotted nut to 100 ft-lb (136 N-m).  
7. Allow unit to run several minutes after the charge  
pumps are “primed” with drive system in the full  
speed position. Check oil level as stated in Check  
the Hydraulic Oil Level section.  
3. Check distance from bottom of slot in nut to  
inside edge of hole. Two threads (0.1 inch) or  
less should be showing.  
8. Check hydro drive linkage adjustment as stated in  
Hydro Drive Linkage Adjustment section in  
Adjustments.  
Replace Emissions Air Intake  
Filter  
Service Interval: Every 500 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key or spark plug wire(s). Engage parking  
brake.  
Figure 16  
1. 0.1 inch max  
2. No more than two  
threads (0.1 inch max)  
should be showing here.  
2. Remove the filter from the vent hose.  
3. Insert a new filter into the end of the vent hose.  
4. If more than two threads (0.1 inch) are  
showing remove nut and install washer (P/N  
1-523157) between hub and nut.  
Wheel Hub-Slotted Nut  
Torque Specification  
5. Torque the slotted nut to 100 ft-lb (136 N-m).  
Service Interval: After the first 100 hours  
6. Then tighten nut until the next set of slots line  
up with the cross hole in shaft. Do Not loosen  
nut to align the slot. If required, tighten to  
the next set of slots.  
Every 500 hours thereafter  
See Figure 15 to determine which slotted nut has  
been installed on the unit.  
7. Install new cotter pin (P/N 1-806800).  
Note: Do Not use anti-seize on wheel hub.  
32  
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Maintenance  
• Sheave retaining bolt in end of engine crankshaft.  
• Fuel tank bulkhead fitting threads  
Inspect PTO Clutching Belt  
Tension  
Service Interval: After the first 2 hours  
Check every 2 hours  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
for the first 8 hours of  
operation.  
• OPC lever hubs and cross-shaft.  
Every 40 hours thereafter.  
1. Stop engine and wait for all moving parts to stop.  
2. Engage PTO lever.  
Note: Care must be used not to bond the  
bearing, next to each OPC hub, to the cross-shaft  
which could cause binding of the OPC levers and  
erratic operation.  
3. Look through the round hole in the left rear  
corner of the engine deck to inspect blade  
• Fuel tank studs, where studs are inserted into tank.  
clutching belt tension. Bolt on blade engagement  
linkage bellcrank and indicator arm should align  
within 1/16 inch (1.6 mm) (see Figure 17). Refer  
to PTO Engagement Linkage for adjustment.  
Mobil HTS Grease (Or  
Food-Grade Anti-seize)  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
• Between the cutter housing spindle and bearings.  
• Between the cutter housing spindle and sheave.  
• Under top cutter housing bearing guard.  
Copper-Based Anti-seize  
Copper-based anti-seize is used in the following  
locations:  
• On threads of Blade Bolts. See Check Mower  
Blades section.  
Figure 17  
1. Engine deck  
2. Indicator  
3. Align bolt to indicator  
within 1/16 inch (1.6  
mm)  
• Between engine crankshaft and pump and blade  
drive sheaves.  
4. Turnbuckle  
• On clutch arm assembly between bearings and  
shaft and between lower sheave and shaft.  
• Between pump shafts and sheaves.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
• Pump sheave setscrews.  
• Square head setscrews on hydro pump control  
arms.  
• OPC lever setscrews.  
• Lower sheave retaining bolt on clutch arm.  
• Shoulder bolts in ends of speed control crank.  
33  
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Maintenance  
Adjust the threaded yoke at the bottom of the  
speed control linkage (see Figure 18) until the  
tabs are positioned correctly.  
Adjustments  
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.  
Deck Leveling  
See Adjusting the Cutting Height section in  
Operation.  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
Figure 18  
Viewed from Left Side of Unit  
1. Neutral Safety Switch  
3. 5/16 inch (7.9 mm)  
PTO Clutching Belt Tension  
See Inspect PTO Clutching Belt Tension section.  
2. Actuating Tab in neutral  
position  
3. Pull the speed control lever back to neutral.  
Check that the neutral safety switch actuating  
tab has depressed the plunger of the switch  
so that there is about 5/16 inch (7.9 mm)  
between the tab and the switch (see Figure 18).  
If necessary, move the switch fore and aft.  
Deck Belt Tension  
Self-tensioning - No adjustment necessary.  
Park Brake Adjustment  
1. Shut off engine and wait for all moving parts to  
stop.  
Adjust Neutral Control Linkages:  
1. Raise the rear of the machine up onto jack  
stands high enough to raise the drive wheels  
off of the ground.  
2. Disengage the park brake.  
3. Remove the hairpin in the park brake linkage.  
Turn the linkage in the yoke until there is 3/16  
inch (4.8 mm) to 1/4 inch (6.4 mm) clearance  
between the park brake tire bars and the tires with  
the park brake disengaged. Re-install the hairpin.  
2. Start the engine and move the throttle ahead  
to the full throttle position. Place the neutral  
lock latches in the “forward” position as  
shown in Figure 4. Release the park brake  
and move the speed control lever to the  
“mid-speed” position.  
Hydro Drive Linkage  
Adjustment  
Note: The OPC levers must be held down  
and the park brake must be disengaged  
whenever the speed control lever is moved  
out of neutral or the engine will kill.  
Adjust Speed Control Linkage and Neutral  
Safety Switch:  
1. Stop engine and wait for all moving parts to  
stop. Engage parking brake. Remove key or  
spark plug wire(s).  
3. Squeeze the respective drive lever until an  
increased resistance is felt, this is where  
neutral should be.  
2. Move the speed control lever (located on  
the console) to the full forward position and  
check the orientation of the tabs on the ends  
of the speed control crank (see Figure 18).  
These tabs should be pointing straight down  
at the 6 o’clock position or slightly forward.  
If the wheel turns while holding the drive  
lever in neutral, the neutral control linkages  
need to be adjusted. If the wheel stops then  
go to step 7.  
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Maintenance  
disengaged whenever speed control levers are  
moved out of the neutral position.  
Note: The neutral lock latches should be  
“unlocked” and in the forward position.  
2. Loosen the front nut on left hydro control  
linkage as shown in Figure 19. Turn the rear  
control linkage adjusting nut counterclockwise  
until wheel rotates forward. Turn the rear nut  
of left control linkage clockwise 1/4 of a turn  
at a time, stopping to move the speed control  
forward and back to neutral, until left wheel  
stops rotating forward.  
Turn the rear nut an additional 1/2 turn and  
tighten the front nut making sure not to put  
a bind on the linkage. Make sure flat part of  
linkage is perpendicular to pin part of swivel  
(see Figure 20).  
Figure 19  
Viewed from Left Side of Unit  
1. Neutral Control Linkage 5. Speed Control Linkage  
2. Hydro Control Linkage  
6. Adjust here-rotate at  
approximately 1/4  
turn increments and  
re-check.  
7. Loosen nut  
8. Yoke  
3. Drive Lever Linkage  
4. Speed Control Crank  
Figure 20  
4. Loosen the nut against the neutral control  
linkage yoke as shown in Figure 19.  
1. Left Hydro Control Link  
(left side shown)  
4. Linkage is perpendicular  
to pin (correct position)  
5. Adjust the neutral control linkage until  
the respective drive wheel stops when the  
lever is pulled against the neutral spring  
(neutral position). Turn the adjusting bolt  
approximately 1/4 turn clockwise if the  
wheel is turning in reverse or turn the bolt  
approximately 1/4 turn counterclockwise if  
the wheel is turning forward. Release the  
drive lever to the forward drive position and  
squeeze back into the neutral position. Check  
to see if the wheel stops. If not, repeat the  
above adjustment procedure.  
2. Front nut  
5. Linkage in incorrect  
position  
6. End view of swivel  
3. Rear nut  
After adjusting the left hydro control linkage,  
move the speed control lever to the mid-speed  
position and then back to the neutral position.  
Recheck the left drive wheel rotation to see if  
further adjustment is necessary - be sure the  
speed control lever is in the neutral position.  
Important: If inconsistent neutral occurs,  
check to be sure both springs are properly  
tightened on the speed control lever under  
the console–especially the rear pivot  
spring.  
6. Make this adjustment on both sides.  
7. After adjustments are made and the wheels  
stop when the drive levers are in the neutral  
position, tighten the nuts against the yokes.  
Repeat above adjustments if necessary.  
Adjust Hydro Control Linkages:  
3. Place the speed control lever in neutral. Adjust  
the right side linkage by turning the quick track  
knob counterclockwise until the tire begins to  
rotate forward. Begin to retighten the knob  
clockwise about 1/4 turn at a time, stopping  
to move the speed control forward and back  
1. Place the speed control lever in the “neutral”  
position. This adjustment is again made with  
rear of machine on jack stands and engine  
running at full throttle. OPC levers will have  
to be held down and the park brake must be  
35  
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Maintenance  
to neutral. Recheck the drive wheel rotation  
to see if further adjustment is necessary.  
Tracking Adjustment  
1. Stop engine and wait for all moving parts to stop.  
4. The spring that keeps tension on the knob  
should normally not need adjustment.  
However, if adjustment is needed, adjust to  
where length of spring is about 1 inch (2.5 cm)  
between the washers. Adjust spring length by  
turning nut at front of spring.  
2. Check the drive tire pressures and tire  
circumferences as stated in Check the Tire  
Pressures section in Maintenance.  
3. Run the unit and observe the tracking on a level,  
smooth, hard surface such as concrete or asphalt.  
Drive Lever Linkage Adjustment:  
4. If the unit tracks to one side or the other, turn the  
quick track knob. Turn the knob right to “steer”  
right, turn the knob left to “steer” left.  
1. With rear of machine still on jack stands and  
engine running at full throttle, disengage  
the park brake and move the speed control  
lever to the midway position. Move the  
respective drive lever upward until it reaches  
the neutral position and engage neutral lock  
latches (Figure 21). If the tire rotates in either  
direction, the length of the drive lever link will  
need to be adjusted.  
Hydro Pump Spring Tension  
Setting  
1. For medium or heavy duty drive conditions such  
as operation with a sulky on steep slopes, a higher  
spring force may be required on the hydro pump  
control arms to prevent the drive system from  
stalling.  
2. For a heavier drive setting, relocate the spring  
anchor link as shown in Figure 13. The spring  
anchor links are located under the engine deck on  
the left and right hand sides.  
Note: In “medium” or “heavy duty” positions,  
the drive lever forces at the upper handle will also  
be increased.  
Figure 21  
2. Adjust the linkage length by loosening the jam  
nuts at both ends of the linkage and rotating  
the linkage in the ball joints. Lengthen the  
linkage if the tire is turning in reverse and  
shorten the linkage if the tire is creeping  
forward. Tighten the jam nuts at both ends.  
Release and re-engage the neutral lock latch  
checking that the tire stops. Continue this  
process until the tire is at a dead stop.  
Figure 22  
3. Make this adjustment for both sides.  
1. Heavy duty  
3. Standard  
4. Stop engine and wait for all moving parts  
to stop. Raise rear of machine, remove jack  
stands, and carefully lower machine to the  
ground.  
2. Medium duty  
4. Retaining bolt  
36  
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Maintenance  
PTO Safety Switch  
Mounted to a tab on the inside left side of the fuel  
tank support.  
Cleaning  
Clean Engine and Exhaust  
System Area  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove ignition key or  
spark plug wire(s).  
2. With PTO disengaged and the bellcrank touching  
the rear of the slot in the engine deck, adjust the  
PTO safety switch (if needed) until the bellcrank  
arm is 5/16 inch (7.9 mm) from the switch body.  
conditions.)  
CAUTION  
3. Be sure the bellcrank Does Not touch the switch  
body or damage to the switch could occur.  
Excessive debris around engine cooling air  
intake and exhaust system area can cause engine,  
exhaust area, and hydraulic system to overheat  
which can create a fire hazard.  
4. Retighten PTO switch mounting hardware.  
Clean all debris from engine and exhaust system  
area.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean all debris from rotating engine air intake  
screen, around engine shrouding, and exhaust  
system area.  
3. Wipe up any excessive grease or oil around the  
engine and exhaust system area  
Remove Engine Shrouds and  
Clean Cooling Fins  
Service Interval: Every 100 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove cooling shrouds from engine and clean  
cooling fins. Also clean dust, dirt, and oil from  
external surfaces of engine which can cause  
improper cooling.  
3. Make sure cooling shrouds are properly  
reinstalled. Operating the engine without  
cooling shrouds will cause engine damage due to  
overheating.  
37  
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Maintenance  
If a battery is being replaced or if the unit containing  
the battery is no longer operating and is being  
scrapped, take the battery to a local certified recycling  
center. If no local recycling is available return the  
battery to any certified battery reseller.  
Clean Debris From Machine  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean off any oil, debris, or grass build-up on the  
machine and cutting deck, especially under deck  
belt shields, around the fuel tank, around engine  
and exhaust area.  
Clean Grass Build-Up Under  
Deck  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Raise deck to the transport (maximum cutting  
height) position. Lift the front of unit and support  
unit using jack stands or equivalent support.  
3. Clean out any grass build-up from underside of  
deck and in discharge chute.  
Waste Disposal  
Motor Oil Disposal  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
recycling center or according to your state and local  
regulations.  
Battery Disposal  
DANGER  
Battery electrolyte contains sulfuric acid, which  
is poisonous and can cause severe burns.  
Swallowing electrolyte can be fatal or if it touches  
skin can cause severe burns.  
• Wear safety glasses to shield eyes, and rubber  
gloves to protect skin and clothing when  
handling electrolyte.  
• Do Not swallow electrolyte.  
• In the event of an accident, flush with water  
and call a doctor immediately.  
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.  
38  
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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  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
Starter does not crank (Electric Start Units).  
2. Speed control lever is are not in neutral  
lock position.  
2. Ensure the speed control lever is in the  
neutral lock position.  
3. OPC levers are released.  
3. Depress OPC levers.  
4. Battery does not have a full charge.  
4. Charge the battery. See Check  
Battery Charge and Recommended  
Jump Starting Procedure sections in  
Maintenance.  
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.  
2. Open the fuel shutoff valve.  
3. The throttle and choke are not in the  
correct position.  
3. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions, and the choke is in the “ON”  
position for a cold engine or the “OFF”  
position for a warm engine.  
4. Dirt in fuel filter.  
4. Replace the fuel filter.  
5. Dirt, water, or stale fuel is in the fuel  
system.  
5. Contact an Authorized Service Dealer.  
6. Air cleaner is dirty.  
6. Clean or replace the air cleaner element.  
7. Electrical connections are corroded, loose 7. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
8. Relay or switch is defective.  
9. Faulty spark plug.  
10. Spark plug wire is not connected.  
8. Contact an Authorized Service Dealer.  
9. Clean, adjust or replace spark plug.  
10. Check the spark plug wire connection.  
Engine loses 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.  
39  
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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 by turning knob on the  
right hydro control linkage in the direction  
that the mower needs to be adjusted to.  
Turn the knob in 1/4 turn increments  
until the mower tracks correctly.  
2. Tire pressure in drive tires not correct.  
1. Bypass valve is not closed tight.  
2. Adjust tire pressure in the drive tires.  
Machine does not drive.  
Uneven cutting height.  
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.  
3. Change the belt.  
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.  
7. Belt is damaged.  
5. Contact an Authorized Service Dealer.  
6. Contact an Authorized Service Dealer.  
7. Install new belt.  
Blades do not rotate.  
1. Drive belt is worn, loose or broken.  
2. Drive belt is off pulley.  
1. Check the belt tension.  
2. Check belt for damage; replace if  
necessary. 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.  
6. PTO clutch does not engage.  
5. Replace the spring.  
6. Contact an Authorized Service Dealer.  
40  
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Schematics  
Schematics  
Electrical Diagram  
41  
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Schematics  
Electrical Diagram  
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Schematics  
Hydraulic Diagram  
43  
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Exmark Commercial Turf Equipment  
2Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
Conditions and Products Covered  
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty  
Company, pursuant to an agreement between them, jointly  
warrant on the terms and conditions herein, that we will repair,  
replace or adjust any part on these products and found by us  
(in the exercise of our reasonable discretion) to be defective in  
factory materials or workmanship for a period of two years.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
This warranty applies to Exmark commercial turf equipment  
sold in the U.S. or Canada. This warranty may only be  
assigned or transferred to a second (or third) owner by an  
authorized Exmark dealer. The warranty period commences  
upon the date of the original retail purchase.  
Owner’s Responsibilities  
If your product requires warranty service it must be returned  
to an authorized Exmark service dealer within the warranty  
period. This warranty extends only to turf equipment operated  
under normal conditions. You must read the operator’s  
manual. You must also properly service and maintain your  
Exmark product as described in the operator’s manual. Such  
routine maintenance, whether performed by a dealer or by  
you, is at your expense.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
*
• Engine  
* The Engine warranty is covered by the engine manufacturer.  
Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair or replacement of  
defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall be liable for any  
incidental or consequential loss or damage.  
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.  
Such damages include but are not limited to:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charges relating to repairs or  
replacements outside of normal business hours at the place  
of business of the authorized Exmark Service Dealer.  
• Rental of like or similar replacement equipment during the  
period of any warranty, repair or replacement work.  
• Any telephone or telegram charges or travel charges.  
• Loss or damage to person or property other than that  
covered by the terms of this warranty.  
• Any 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.  
• 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.  
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.  
All implied warranties of merchantability (that the  
product is fit for ordinary use) and fitness for use (that the  
product is fit for a particular purpose) are limited to the  
duration of the express warranty.  
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.  
Some states do not allow exclusions of incidental or  
consequential damages, or limitations on how long an  
implied warranty lasts, so the above exclusions and  
limitations may not apply to you.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G4500-589_C  
44  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
45  
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Figure 23  
This page may be copied for personal use.  
1. The maximum slope you can safely operate the machine on is 20 degrees. Use the slope indicator to determine the  
degree of slope of hills before operating. Do Not operate this machine on a slope greater than 20 degrees. Fold  
along the appropriate line to match the recommended slope.  
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.  
3. Example of how to compare slope with folded edge.  
47  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
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.  
©2010 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-696 Rev. B  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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