Exmark Lawn Mower PHZ19KA343 User Guide

PHAZER  
For Serial Nos.  
790,000 & Higher  
Part No. 4500-335 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum  
amount of dependability and years of trouble-free  
operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Figure 1  
1. Model and serial number location  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
Model No.  
Serial No.  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Contents  
Introduction ........................................................... 3  
Torque Requirements .................................... 15  
Periodic Maintenance ....................................... 22  
4
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Safety  
• Never let children or untrained people operate  
Safety  
Safety Alert Symbol  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Preparation  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
Figure 2  
1. Safety alert symbol  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
CAUTION  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
This machine produces sound levels in  
excess of 85 dBA at the operator’s ear and  
can cause hearing loss through extended  
periods of exposure.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
Wear hearing protection when operating this  
machine.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
Safe Operating Practices  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
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 in an open  
area, when the engine is cold. Wipe up  
any gasoline that spills.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• Do Not fill gasoline containers inside a  
vehicle or on a truck or trailer bed because  
interior carpets or plastic truck bed liners  
may insulate the container and slow the  
loss of any static charge.  
• Do Not fill the fuel tank completely  
full. Add gasoline to the fuel tank until  
the level is 1/4 to 1/2 inch (6–13 mm)  
below the bottom of the filler neck. This  
empty space in the tank allows gasoline  
to expand.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Never smoke when handling gasoline,  
and stay away from an open flame or  
where gasoline fumes may be ignited by  
spark.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Add fuel before starting the engine.  
Never remove the cap of the fuel tank or  
add fuel when engine is running or when  
the engine is hot.  
WARNING  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
6
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Safety  
damage and make repairs before restarting  
Operation  
and operating the mower).  
– Before clearing blockages.  
– Whenever you leave the mower.  
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.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
– Before refueling.  
• Allow engine parts, especially the muffler,  
to cool before touching.  
– Before dumping the grass catcher.  
• Remove accumulated debris from muffler  
and engine area.  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can  
kill you.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
NEVER carry passengers. DO NOT operate  
the mower when people, especially children, or  
pets are in the area.  
Do Not run engine indoors or in a small  
confined area where dangerous carbon  
monoxide fumes can collect.  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
• Stop engine, wait for all moving parts to stop,  
remove key and engage parking brake:  
Slope Operation  
– Before checking, cleaning or working on the  
mower.  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
occur. The operator is responsible for safe operation  
on slopes.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
7
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Safety  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
DANGER  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. Wheels  
dropping over edges, ditches, steep banks, or  
water can cause rollovers, which may result  
in serious injury, death or drowning.  
• 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.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Do Not mow slopes greater than 15  
degrees.  
• Reduce speed and use extreme caution  
on slopes.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
• Avoid sudden turns or rapid speed  
changes.  
Maintenance and Storage  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
• 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.  
• Use a walk behind mower and/or a hand trimmer  
near drop-offs, ditches, steep banks or water.  
(Figure 3).  
• Keep engine, engine area, and pump drive belt  
compartment free from accumulation of grass,  
leaves, excessive grease or oil, and other debris  
which can accumulate in these areas. These  
materials can become combustible and may result  
in a fire.  
• Let engine cool before storing and Do Not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• 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.  
Figure 3  
• Use jack stands to support components when  
required.  
1. Water  
2. Danger Zone-Use a walk behind mower and/or hand  
trimmer on slopes greater than 15 degrees, near  
drop-offs, and water.  
3. Safe Zone-Use the mower here on slopes less than 15  
degrees  
• Carefully release pressure from components with  
stored energy.  
• Disconnect battery or remove spark plug wire  
before making any repairs. Disconnect the  
negative terminal first and the positive last.  
Reconnect positive first and negative last.  
• 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.  
8
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Safety  
• Keep hands and feet away from moving parts.  
If possible, Do Not make adjustments with the  
engine running.  
• Charge batteries in an open well ventilated area,  
away from spark and flames. Unplug charger  
before connecting or disconnecting from battery.  
Wear protective clothing and use insulated tools.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• All replacement parts must be the same as  
or equivalent to the parts supplied as original  
equipment.  
WARNING  
Hydraulic fluid escaping under pressure  
can penetrate skin and cause injury. Fluid  
accidentally injected into the skin must be  
surgically removed within a few hours by a  
doctor familiar with this form of injury or  
gangrene may result.  
• Make sure all hydraulic fluid hoses  
and lines are in good condition and  
all hydraulic connections and fittings  
are tight before applying pressure to  
hydraulic system.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• Use cardboard or paper, not your hands,  
to find hydraulic leaks.  
• Safely relieve all pressure in the hydraulic  
system by placing the motion control  
levers in neutral and shutting off the  
engine before performing any work on  
the hydraulic system.  
9
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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.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
93-8069  
1. Hot surface/burn hazard—stay a safe distance from the  
hot surface.  
1-303508  
98-5954  
1-403005  
1-513747  
103-1077  
109-2356  
1-513748  
1. Fast  
2. Slow  
3. Neutral  
4. Reverse  
10  
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Safety  
109-2463  
109-2862  
109-2465  
109-2467  
109-2992  
116-0950  
109-2490  
109-2539  
11  
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Safety  
109-2494  
12  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 790,000 and Higher  
PHZ19KA343; PHZ19KA343CA  
Systems  
Operator Controls  
• Steering and Motion Control:  
Engine  
Note: Motion control levers are adjustable to  
two heights.  
• Engine Specifications: See your Engine Owner’s  
Manual  
– Separate levers, on each side of the console,  
control speed and direction of travel of the  
respective drive wheels.  
• RPM: Full Speed: 3750 ±100 RPM (No Load)  
Idle: 1400 RPM  
– Steering is controlled by varying the position  
of the levers relative to each other.  
Fuel System  
• Capacity: 7.7 gal. (29.1 L)  
– Moving motion control levers outward (in  
slots) locks the drive system in neutral.  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher.  
• PTO Engagement Switch: Engages electric clutch  
(to drive belt) which engages mower blades.  
• Fuel Filter: In-line Kawasaki P/N 49019–7001  
• Parking Brake Lever: Engages parking brake.  
• Fuel Shut-Off Valve: 1/4 turn increments (“ON”,  
“OFF”)  
• Deck Height Adjustment Lever: Sets cutting  
height to desired position.  
Electrical System  
• Deck Lift Assist Lever: Foot pedal that assists  
in raising the deck.  
• Charging System: Flywheel Alternator  
• Charging Capacity: 13 amps  
• Battery Type: BCI Group U1  
• Battery Voltage: 12 Volt  
Seat  
• Type: Standard seat with high back, foam padded,  
(internal suspension) and armrests.  
• Polarity: Negative Ground  
• Fuses: Two 20 amp blade type  
• Mounting: Hinged to tilt up for access to battery  
and other components. Held in tilted position  
with lanyard. Adjustable fore and aft seat track.  
• Armrests: Standard–foam padded flip-up  
armrests.  
Safety Interlock System  
• PTO must be disengaged, brake engaged, and  
motion control levers out (neutral lock) to start  
engine. (It is not necessary for the operator to be  
in the seat to start the engine.)  
• Seat Safety Switch: Incorporated into the  
Safety Interlock System. Time delay seat switch  
eliminates rough ground cut-outs.  
• Operator must be in seat when PTO is engaged,  
brake is disengaged, or motion control levers are  
moved in or engine will stop.  
Hydrostatic Ground Drive System  
• Hydrostatic Drive: Two Hydro Gear ZT2800  
Integrated drive systems.  
• Engine will stop if either the left, the right, or  
both levers are moved from neutral lock position  
while brake is engaged.  
• Hydraulic Oil Type: Use Exmark Premium Hydro  
Oil.  
13  
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Specifications  
• Speeds:  
The cutting height adjustment handle has a  
transport position and all adjustments can be  
made while the operator remains seated.  
– 0-7.2 mph (11.6 km/hr) forward.  
– 0-4.0 mph (6.4 km/hr) reverse.  
• Mulching Kit: Optional.  
• Drive wheel releases allow machine to be moved  
when engine is not running and brake is off (left  
and right sides of engine).  
Dimensions  
Overall Width:  
Tires & Wheels  
Without Deck  
Deflector Up  
34.5 inches (87.6 cm)  
35.0 inches (89.0 cm)  
44.0 inches (111.8 cm)  
Drive  
Front Caster  
Pneumatic  
(Air-Filled)  
Semi-Pneumatic  
Deflector Down  
Quantity  
Tread  
2
2
Turf Mate  
18 x 7.00-8  
4
Smooth  
11 x 4.00-5  
Overall Length:  
Size  
70.0 inches (177.8 cm)  
Ply Rating  
Pressure  
13 psi (90 kPa)  
Overall Height:  
39.0 inches (99.1 cm)  
Cutting Deck  
• Cutting Width: 34.5 inches (87.6 cm)  
• Discharge: Side  
Tread Width: (Center to Center of  
Tires, Widthwise)  
• Blade Size: (2 ea.) 17.50 inches (44.5 cm)  
Drive Wheels  
Caster Wheels  
26.5 inches (67.3 cm)  
29.0 inches (73.7 cm)  
• Blade Spindles: Solid steel spindles with 1 inch  
(25.4 mm) I.D. bearings.  
• Deck Drive:  
Wheel Base: (Center of Caster Tire to  
Center of Drive Tire)  
– Electric clutch mounted on vertical engine  
shaft.  
45.0 inches (114.3 cm)  
– Blades are driven by one belt  
(w/self-tensioning idler) direct from  
the engine.  
Curb Weight:  
570 lb (258.5 kg)  
• Deck:  
Full floating deck is attached to out-front support  
frame.  
Two optional anti-scalp rollers.  
Deck design allows for bagging, mulching or side  
discharge.  
• Deck Depth: 5.0 inches (12.7 cm)  
• Cutting Height Adjustment:  
Foot operated deck lift lever is used to adjust the  
cutting height from 1 inch (2.5 cm) to 5 inches  
(12.7 cm) in 1/4 inch (6.4 mm) increments.  
14  
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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  
115-120 ft-lb  
(156-163 N-m)  
Anti-Scalp Roller Nyloc  
Nut  
40-45 ft-lb (54-61 N-m)  
Engine Mounting Bolts  
Wheel Lug Nuts  
25-30 ft-lb (34-41 N-m)  
90-95 ft-lb (122-129 N-m)  
55-60 ft-lb (75-81 N-m)  
Clutch Retaining Bolt  
(secured with threadlocker)  
Figure 4  
4. Parking Brake Lever  
5. Height-of-Cut Foot Lever  
1. Fuel Cap  
2. Motion Control Lever  
3. Controls  
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Operation  
The unit must be tied down and brake engaged when  
transporting.  
Operation  
Note: Determine the left and right sides of the  
machine from the normal operating position.  
Ignition Switch  
Located right of center on the console.  
Controls  
The ignition switch is used to start and stop the  
engine. The switch has three positions “OFF”, “ON”  
and “START”. Insert key into switch and rotate  
clockwise to the “ON” position. Rotate clockwise to  
the next position to engage the starter (key must be  
held against spring pressure in this position).  
Motion Control Levers  
The motion control levers located on each side of the  
console control the forward and reverse motion of  
the machine. The levers control the flow of hydraulic  
oil from the hydrostatic pump to the drive wheel  
motor for each side.  
Note: Brake must be engaged, motion control levers  
out (neutral lock position) and PTO switch “OFF” to  
start engine. (It is not necessary for the operator to  
be in the seat to start the engine.)  
Moving the levers forward or backward turns the  
wheel on the same side forward or in reverse. Wheel  
speed is proportional to the amount the lever is  
moved.  
Hour Meter  
Moving the levers outward from the center position  
into the T-slot locks them in the neutral position  
(Figure 5).  
Located right of center on the console (below ignition  
switch).  
The hour meter is connected to a pressure switch  
installed in the engine block and it records the  
number of hours that the engine has run. If the  
ignition switch is left on without engine running,  
hour meter will not run.  
Choke Control  
Located on the center of the console.  
The choke is used to aid in starting a cold engine.  
Moving the choke lever forward will put the choke in  
the “ON” position and moving the choke lever to  
the rear will put the choke in the “OFF” position.  
Do Not run a warm engine with choke in the “ON”  
position.  
Note: This switch is not a low oil sensor and will not  
alert the operator if the engine oil is low.  
Fuel Shut-Off Valve  
The valve is located in the fuel line midway between  
the fuel tank and the engine behind the seat.  
Throttle Control  
Located on the center of the console (to the left side  
of the choke).  
The fuel shut-off valve is used to shut off the fuel  
when the machine will not be used for a few days,  
during transport to and from the jobsite, and when  
parked inside a building.  
The throttle is used to control engine speed. Moving  
the throttle lever forward will increase engine speed  
and moving the throttle lever to the rear will decrease  
engine speed.  
Rotate the valve 1/4 turn clockwise to shut off fuel.  
Rotate the valve 1/4 turn counterclockwise to turn  
on fuel.  
Brake Lever  
Located on left side of the console.  
Drive Wheel Release Levers  
The brake lever engages a parking brake on the drive  
wheels.  
Located at the rear of the mainframe.  
Pull the lever up and rearward to engage the brake.  
Drive wheel release levers are used to release the  
hydrostatic drive system to allow the machine to be  
pushed without the engine running.  
Push the lever forward and down to disengage the  
brake.  
16  
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Operation  
Pull each lever rearward and outward to lock. Pull  
each lever inward and push forward to reset. Do Not  
tow machine.  
Note: It is not necessary for the operator to be  
in the seat to start the engine.  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
PTO Engagement Switch  
5. On a cold engine, push the choke lever forward  
into the “ON” position.  
Located right of center on the console (left side of  
ignition switch).  
On a warm engine, leave the choke in the “OFF”  
position.  
Switch must be pulled out to the “ROTATE”  
position to engage the blades. Switch is pushed in to  
the “STOP” position to stop the blades.  
6. Turn ignition switch to the “START” position.  
Release the switch as soon as the engine starts.  
Important: Do Not crank the engine  
continuously for more than ten seconds at a  
time. If the engine does not start, allow a 60  
second cool-down period between starting  
attempts. Failure to follow these guidelines  
can burn out the starter motor.  
Pre-Start  
Fill fuel tanks. For best results use only clean, fresh  
regular grade unleaded gasoline with an octane rating  
of 87 or higher. Regular grade leaded gasoline may  
also be used; however, combustion chamber and  
cylinder head will require more frequent service. See  
Engine Owner’s Manual.  
7. If the choke is in the “ON” position, gradually  
return choke to the “OFF” position as the engine  
warms up.  
Do Not add oil to gasoline.  
Do Not overfill fuel tank. Never fill the fuel tank so  
that the fuel level rises above a level that is 1/2 inch  
(13 mm) below the bottom of the filler neck to allow  
for fuel expansion and prevent fuel spillage.  
Engaging the PTO  
DANGER  
The rotating blades under the mower deck  
are dangerous. Blade contact can cause  
serious injury or kill you.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Do Not put hands or feet under the mower  
or mower deck when the blades are engaged.  
Operating Instructions  
DANGER  
Open the Fuel Shut-Off Valve  
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.  
The fuel shut off valve is located under the seat in the  
fuel line between the left fuel tank and the engine.  
Rotate the valve 1/4 turn counterclockwise to turn  
on fuel.  
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.  
Starting the Engine  
1. Move the motion control levers out to the neutral  
lock position.  
2. Pull up and back on the parking brake lever to  
engage the parking brake.  
The PTO push-pull switch engages the cutting blades.  
Be sure that all persons are clear of the mower deck  
and discharge area before engaging PTO.  
3. Push in on the PTO switch to the “STOP”  
position.  
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Operation  
Important: Operator must be in seat before the  
PTO can be engaged.  
Important: To begin movement (forward or  
backward) the operator must be in the seat, the  
brake lever must be disengaged (pushed down)  
before the motion control levers can be moved in  
or the engine will stop.  
1. Set the throttle to the “MIDWAY” position.  
2. Pull the PTO switch outward to the “ROTATE”  
position.  
When levers are centered in the T-slot the drive  
system is in the neutral position. With levers moved  
out in the T-slot the drive system is in the neutral lock  
position (Figure 5).  
3. Place the throttle in the “FAST” position to begin  
mowing.  
Disengaging the PTO  
1. Set the throttle to the “MIDWAY” position.  
2. Push the PTO switch in to the “STOP” position  
to disengage the blades.  
Stopping the Engine  
1. Bring the unit to a full stop.  
2. Disengage the PTO.  
3. Move the motion control levers out to the neutral  
lock position.  
4. Engage the parking brake.  
5. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
Figure 5  
1. Handles Out (Neutral  
Lock)  
5. Neutral  
6. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
2. Handles In (Neutral)  
3. Front of Unit  
4. Forward  
6. Reverse  
7. Neutral Lock  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
Driving Forward  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
1. Release the parking brake.  
2. Move the motion control levers inward to the  
center to the neutral unlocked position.  
3. To move forward in a straight line apply equal  
forward pressure to both levers.  
Driving the Machine  
To turn left or right, pull the motion control lever  
back toward neutral in the direction desired.  
CAUTION  
The machine will move faster the farther the  
motion control levers are moved away from  
neutral.  
Machine can spin very rapidly by positioning  
one lever too much ahead of the other.  
Operator may lose control of the machine,  
which may cause damage to the machine  
or injury.  
4. To stop, pull the motion control levers back to  
the neutral position.  
• Use caution when making turns.  
• Slow the machine down before making  
sharp turns.  
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Operation  
The deck can be raised by pushing down on the  
foot operated deck lift assist lever located at the  
front right corner of the floor pan.  
Note: When changing the cutting height  
positions, always come to a complete stop  
and disengage the PTO.  
Figure 7  
1. Transport position and 5 inch (12.7 cm) cutting height  
position  
Figure 6  
4. Insert the height adjustment pin into the hole  
corresponding to the desired cutting height and  
install the hairpin cotter pin.  
1. Handles Out (Neutral  
4. Forward  
Lock)  
2. Handles In (Neutral)  
3. Front of Unit  
5. Reverse  
See the decal on the side of the deck lift plate for  
cut heights.  
5. Move the deck height lever out of the transport  
position (or 5 inch (12.7 cm) cutting height) and  
down onto the height adjustment pin to mow at  
selected height.  
Driving in Reverse  
1. Move the motion control levers inward to the  
center to the neutral unlocked position.  
2. To move rearward in a straight line applying equal  
pressure pull both motion control levers rearward.  
6. To transport, move lever back up to transport (or  
5 inch (12.7 cm) cutting height) position.  
To turn left or right, release pressure on the  
motion control lever toward the direction desired.  
Transporting  
3. To stop, push the motion control levers to the  
neutral position.  
Transporting a Unit  
Use a heavy-duty trailer or truck to transport the  
machine. Lock brake and block wheels. Securely  
fasten the machine to the trailer or truck with straps,  
chains, cable, or ropes. Be sure that the trailer or truck  
has all necessary lighting and marking as required by  
law. Secure a trailer with a safety chain.  
Adjusting the Cutting Height  
The cutting height of the mower deck is adjusted  
from 1 inch to 5 inches (2.5 cm to 12.7 cm) in 1/4  
inch (6.4 mm) increments.  
1. Stop the machine and move the motion control  
levers outward to the neutral locked position.  
2. Disengage the PTO.  
3. Raise the deck height lever to the transport  
position (also the 5 inch (12.7 cm) cutting height  
position)(Figure 7).  
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Operation  
a surface for the frame members to contact if the  
unit starts to tip backward. If it is not possible to use  
one full width ramp, use enough individual ramps to  
simulate a full width continuous ramp.  
CAUTION  
This unit does not have proper turn  
signals, lights, reflective markings, or a  
slow moving vehicle emblem. Driving on a  
street or roadway without such equipment  
is dangerous and can lead to accidents  
causing personal injury. Driving on a street  
or roadway without such equipment may also  
be a violation of State laws and the operator  
may be subject to traffic tickets and/or fines.  
Ramp should be long enough so that the angles  
between the ramp and the ground and the ramp and  
the trailer or truck Do Not exceed 15°. A steeper  
angle may cause mower deck components to get  
caught as the unit moves from ramp to trailer or  
truck. Steeper angles may also cause the unit to tip  
backward. If loading on or near a slope, position  
the trailer or truck so it is on the down side of the  
slope and the ramp extends up the slope. This will  
minimize the ramp angle. The trailer or truck should  
be as level as possible.  
Do Not drive a unit on a public street or  
roadway.  
WARNING  
Important: Do Not attempt to turn the unit  
while on the ramp, you may lose control and  
drive off the side.  
Loading a unit on a trailer or truck increases  
the possibility of backward tip-over.  
Backward tip-over could cause serious injury  
or death.  
Avoid sudden acceleration when driving up a ramp  
and sudden deceleration when backing down a ramp.  
Both maneuvers can cause the unit to tip backward.  
• Use extreme caution when operating a  
unit on a ramp.  
• Use only a single, full width ramp; Do  
Not use individual ramps for each side  
of the unit.  
• If individual ramps must be used, use  
enough ramps to create an unbroken  
ramp surface wider than the unit.  
• Do Not exceed a 15° angle between ramp  
and ground or between ramp and trailer  
or truck.  
• Avoid sudden acceleration while driving  
unit up a ramp to avoid tipping backward.  
• Avoid sudden deceleration while backing  
unit down a ramp to avoid tipping  
backward.  
Loading a Unit  
Use extreme caution when loading units on trailers or  
trucks. One full width ramp that is wide enough to  
extend beyond the rear tires is recommended instead  
of individual ramps for each side of the unit. The  
lower rear section of the tractor frame extends back  
between the rear wheels and serves as a stop for  
tipping backward. Having a full width ramp provides  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could  
seriously injure you or other bystanders.  
The engine can become very hot. Touching  
a hot engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine  
area.  
Remove the key from the ignition switch,  
engage parking brake, and pull the wire(s)  
off the spark plug(s) before you do any  
maintenance. Also push the wire(s) aside  
so it does not accidentally contact the spark  
plug(s).  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
• Change the hydraulic filter.  
After the first 250 hours  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check for loose hardware.  
Before each use or daily  
• Clean the engine air cooling system.  
• Clean the grass build-up from under the deck.  
• Grease the belt idlers.  
Every 25 hours  
Every 40 hours  
• Check the hydraulic oil level.  
• Check the tire pressures.  
• Check the condition of the belts.  
• Grease the deck pivots.  
• Service the air cleaner. (May need more often under severe conditions. See the Engine  
Owner’s Manual for additional information.)  
Every 50 hours  
• Remove engine shrouds and clean cooling fins.  
Every 80 hours  
Every 100 hours  
• Change the engine oil. (May need more often under severe conditions.)  
• Grease the brake handle pivot.  
• Check the spark plugs.  
Every 160 hours  
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)  
• Check the battery charge.  
Every 500 hours  
Monthly  
• Grease the front caster wheel bearings.  
• Grease front caster pivots.  
• Lubricate the caster wheel hubs.  
Yearly  
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Maintenance  
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).  
Periodic Maintenance  
Check Engine Oil Level  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
2. Check with engine cold.  
3. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick. Screw into  
place. Remove the dipstick and read the oil level.  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
4. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Use oil as specified in  
Engine Owner’s Manual. Do Not overfill.  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
1 Hour  
16 volts/7  
amps  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
12.0–12.2  
11.7–12.0  
25–50%  
0–25%  
2 Hours  
3 Hours  
14.4 volts/4  
amps  
14.4 volts/4  
amps  
Check Battery Charge  
Service Interval: Monthly  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
WARNING  
Check Mower Blades  
CALIFORNIA  
Service Interval: Before each use or daily  
Proposition 65 Warning  
Important: Mower blades are sharp. Wrap the  
blade or wear gloves, and use extra caution when  
servicing them.  
Battery posts, terminals, and related  
accessories contain lead and lead  
compounds, chemicals known to the State of  
California to cause cancer and reproductive  
harm. Wash hands after handling.  
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.  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
performance and service life. To preserve optimum  
battery performance and life, recharge batteries in  
storage when the open circuit voltage drops to 12.4  
volts.  
3. Inspect blades and sharpen or replace as required.  
4. Install blade bolt and spring disc washer. Be sure  
the spring disc washer cone is installed towards  
the bolt head. Place a block of wood between  
front or rear baffles and the blade then torque  
the blade bolts to 115–120 ft-lb (156–163 N-m)  
(Figure 8).  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
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.  
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Maintenance  
Try to start with operator in seat, parking brake  
disengaged, PTO disengaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Try to start with operator in seat, parking brake  
engaged, PTO engaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Try to start with operator in seat, parking  
brake engaged, PTO disengaged, and the left  
motion control lever in, starter must not crank,  
repeat again with the right lever in, then with  
both levers in - starter must not crank.  
2. Check the kill circuits. Run engine at one-third  
throttle, disengage parking brake and raise off  
of seat (but do not get off of machine) engine  
must initiate shutdown after approximately 1/2  
second has elapsed (seat has time delay kill switch  
to prevent cut-outs on rough terrain).  
Figure 8  
1. Do Not use wrench here for blade installation. Maintain  
140–145 ft-lb (190–197 N-m)  
2. Use 1 inch wrench here to hold spindle for blade  
replacement.  
3. Cone towards bolt head  
4. Torque to 115–120 ft-lb (156–163 N-m)  
Run engine at one-third throttle, engage PTO  
and raise off of seat (but do not get off of  
machine) engine must initiate shutdown after  
1/2 second has elapsed.  
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.  
Run engine at one-third throttle, with brake  
disengaged, move levers in and raise off seat (but  
do not get off of machine) engine must initiate  
shutdown after 1/2 second has elapsed.  
Again, run engine at one-third throttle, brake  
engaged, and move left motion control lever in  
- engine must initiate shutdown.  
Always install the original Exmark blades,  
spring disc washers, and blade bolts as  
shown.  
Repeat again moving the right lever in, then  
moving both levers in - engine must initiate  
shutdown whether operator is on seat or not.  
Note: If machine does not pass any of these tests,  
Do Not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
Check Safety Interlock  
System  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
Service Interval: Before each use or daily  
Note: To prevent engine cut-outs on rough terrain  
the seat kill switch has a 1/2 second delay.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
1. Check starting circuit. Starter should crank with,  
parking brake engaged, PTO disengaged and  
motion control levers moved out in the neutral  
lock position. The operator does not need to be  
in the seat to start the engine.  
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Maintenance  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
5. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
6. Use oil recommended in engine owner’s manual.  
Do Not overfill. Start the engine and check for  
leaks. Stop engine and recheck oil level.  
Service Air Cleaner  
Check Hydraulic Oil Level  
Service Interval: Every 50 hours—Service  
the air cleaner. (May  
Service Interval: Every 40 hours  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Allow engine to cool.  
need more often under  
severe conditions. See  
the Engine Owner’s  
Manual for additional  
information.)  
2. Clean area around hydraulic expansion reservoir.  
Oil level should be at the FULL COLD line on  
expansion reservoir. If not, add oil. Use only  
Exmark Premium Hydro oil. Replace hydraulic  
reservoir cap and tighten until snug. Do Not  
overtighten. Do Not overfill.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. See Engine Owner’s Manual for cleaning  
instructions.  
Check Tire Pressures  
Service Interval: Every 40 hours  
Change Engine Oil  
Service Interval: After the first 5 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Every 100 hours/Yearly  
(whichever comes first)  
(May need more often  
under severe conditions.)  
2. Check tire pressure in drive tires.  
3. Inflate drive tires to 13 psi (90 kPa).  
4. Semi-pneumatic caster tires do not need to be  
inflated.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Note: Do Not add any type of tire liner or foam  
fill material to the tires. Excessive loads created by  
foam filled tires may cause failures to the hydro drive  
system, frame, and other components. Foam filling  
tires will void the warranty.  
2. Drain oil while engine is warm from operation.  
3. The oil drain is located on right hand side of  
engine. Place pan under machine to catch oil. Fit  
hose in literature pack over oil drain valve. Rotate  
valve 1/4 turn counterclockwise and gently pull  
outward to open valve. Allow oil to drain, then  
close valve by pushing inward and rotating 1/4  
turn clockwise. Remove and retain the hose for  
future use.  
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.  
4. Replace the oil filter every other oil change. Clean  
around oil filter and unscrew filter to remove.  
Before reinstalling new filter, apply a thin coating  
of oil on the surface of the rubber seal. Turn  
filter clockwise until rubber seal contacts the filter  
adapter then tighten filter an additional 1/2 to  
3/4 turn.  
2. Check under engine deck to check pump drive  
belt.  
3. Remove left and right belt shields on deck and lift  
up floor pan to inspect deck drive belt.  
4. For belt adjustment, see the Pump Drive Belt  
and Deck Belt Tension Adjustment sections.  
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Maintenance  
pump with grease until it oozes out around top  
bearing. Remove grease zerk and thread plug back  
in. Place cap back on.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Lubricate Caster Wheel Hubs  
Service Interval: Yearly  
2. Lubricate fittings with one to two pumps of  
NGLI grade #2 multi-purpose gun grease.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Lubrication Chart  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
1
1
2
4
2
25 Hours  
40 Hours  
*Yearly  
1. Belt  
Idlers  
2. Deck  
Pivots  
3. Front  
Caster  
*0  
Figure 9  
Wheel  
Bearings  
1. Seal guard  
2. Spacer nut with wrench  
flats  
4. Front  
Caster  
Pivots  
*0  
1
2
1
*Yearly  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
5. Brake  
Handle  
Pivot  
160 Hours  
4. Remove one of the spacer nuts from the axle  
assembly in the caster wheel. Note that thread  
locking adhesive has been applied to lock the  
spacer nuts to the axle. Remove the axle (with  
the other spacer nut still assembled to it) from  
the wheel assembly.  
* See step 3 for special lubrication instructions on  
the front caster pivots and the Lubricate Caster  
Wheel Hubs section for special lubrication  
instructions on the front casters wheel hubs.  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
7. Insert one bearing, one new seal into the wheel.  
Note: Seals (Exmark P/N 103-0063) must be  
replaced.  
8. If the axle assembly has had both spacer nuts  
removed (or broken loose), apply a thread locking  
adhesive to one spacer nut and thread onto the  
axle with the wrench flats facing outward. Do  
Not thread spacer nut all of the way onto the end  
of the axle. Leave approximately 1/8 inch (3 mm)  
from the outer surface of the spacer nut to the  
end of the axle inside the nut.  
3. Lubricate front caster pivots once a year. Remove  
hex plug and cap. Thread grease zerk in hole and  
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Maintenance  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
Change Hydraulic System  
Filter  
Service Interval: After the first 250 hours  
10. With the open end of the wheel facing up, fill  
the area inside the wheel around the axle full of  
NGLI grade #1 multi-purpose grease.  
Every 500 hours/Yearly  
(whichever comes  
first) thereafter  
(Every 250 hours/Yearly if  
using Mobil 1 15W50)  
11. Insert the second bearing and new seal into the  
wheel.  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Locate the two filters under the transmissions.  
Remove filter guards.  
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,  
then re-torque to 20-25 in-lb (2-3 N-m). Make  
sure axle does not extend beyond either nut.  
3. Carefully clean area around filters. It is important  
that no dirt or contamination enter hydraulic  
system.  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall caster bolt  
and tighten nut fully.  
4. Unscrew filters to remove and allow oil to drain  
from drive system.  
Important: To prevent seal and bearing damage,  
check the bearing adjustment often. Spin the  
caster tire. The tire should not spin freely  
(more than 1 or 2 revolutions) or have any side  
play. If the wheel spins freely, adjust torque on  
spacer nut until there is a slight amount of drag.  
Reapply thread locking adhesive.  
Important: Before reinstalling new filter,  
apply a thin coat of Exmark Premium Hydro  
oil on the surface of the rubber seal.  
Turn the filters clockwise until rubber seal  
contacts the filter adapter then tighten the filter  
an additional 1/2 to 3/4 turn.  
5. Remove the vent plug on each transmission and  
fill through expansion reservoir, when oil comes  
out of vent reinstall plug. Torque plugs to 180  
in-lbs (20 N-m).  
Check Spark Plugs  
Service Interval: Every 160 hours  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner’s  
Manual.  
Change Fuel Filter  
Service Interval: As required  
A fuel filter is installed between the fuel tanks and the  
engine. Replace when necessary.  
Replacement Filters  
Kawasaki  
Kawasaki P/N  
49019–7001  
Figure 10  
Left Side Shown  
1. Left rear tire  
2. Oil filter  
3. Vent plug  
26  
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Maintenance  
6. Add oil until it reaches the FULL COLD line on  
the expansion reservoir.  
Fuel Tank — Mounting  
Hardware Specifications  
Exmark Premium Hydro Oil is recommended.  
Refer to the chart for an acceptable alternative:  
Service Interval: As required  
When installing the nuts on the fuel tank studs, fully  
tighten the nyloc nut and back off 1/2 turn. This  
allows for normal fuel tank expansion and contraction  
with changes in temperature and fuel levels.  
Hydro Oil  
Change Interval  
500 Hours  
Exmark Premium Hydro  
Oil (Preferred)  
250 Hours  
Mobil 1 15W50  
7. Raise the rear of machine up and support with  
jack stands (or equivalent support) just high  
enough to allow drive wheels to turn freely.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
CAUTION  
• Clutch retaining bolt in the end of engine  
crankshaft.  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
• Caster wheel spacer nuts.  
• Cutter housing spindle nut.  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
Fuel tank studs, where studs are inserted into tank.  
8. Start engine and move throttle control ahead to  
1/2 throttle position. Disengage parking brake.  
Mobil HTS Grease (Or  
Food-Grade Anti-seize)  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
A. With the bypass valve open and the engine  
running, slowly move the directional control  
in both forward and reverse (5 or 6 times).  
• Between the cutter housing spindle and bearings.  
• Between the cutter housing spindle and sheave.  
• Under top cutter housing bearing guard.  
B. With the bypass valve closed and the engine  
running, slowly move the directional control  
in both forward and reverse directions (5 to 6  
times).  
C. It may be necessary to repeat steps A and  
B until all the air is completely purged from  
the system. When the transaxle operates at  
normal noise levels and moves smoothly  
forward and reverse at normal speeds, then  
the transaxle is considered purged.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
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.  
27  
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Maintenance  
Motion Control Linkage  
Adjustment  
Note: There are two lever height options available.  
Place the levers in the top two holes to increase  
height of the levers, or in the bottom two holes to  
decrease the height of the levers.  
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  
1. Align the levers front/rear position. With the  
levers in the neutral position, loosen the hardware  
and adjust the levers sliding and/or tilting the  
lever(s) forward or backward until properly  
aligned and tighten hardware (Figure 11).  
1. Position mower on a flat surface.  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Check tire pressure in drive tires. Proper inflation  
pressure for tires is 13 psi (90 kPa). Adjust if  
necessary. Semi-pneumatic caster tires Do Not  
need to be inflated.  
4. Set anti-scalp rollers to top holes (if installed) or  
remove them completely for this adjustment.  
5. Lower the deck to the 1 1/2 inch (3.8 cm) height  
position. Place two 1 1/8 inch (2.9 cm) thick  
blocks under the rear edge of the cutting deck  
skirt; one on each side of the cutting deck.  
6. Place a 1 inch (2.5 cm) block under the center  
front edge, but not under the anti-scalp roller  
brackets.  
Figure 11  
7. Loosen the four bottom chain bolts in slots until  
the deck is supported by the blocks. Take the  
slack out of the chains and retighten the hardware.  
1. Motion control levers  
2. Spring disc washer  
3. 3/8-16 x 1 inch screw  
8. Recheck that blocks fit just snugly under the  
deck skirt and that the tension on all the chains  
is approximately equal. Make sure all chain  
attachment bolts are tight.  
2. If the ends of the levers hit against each other,  
while in the drive position (levers rotated in as  
far as possible), make adjustments by moving the  
levers outwards to the neutral lock position and  
carefully bending them outward. Move them back  
to the drive position and check for clearance.  
Repeat if necessary.  
9. Reposition anti-scalp rollers (if installed) and  
tighten securely.  
Note: When above adjustments have been made,  
the front of the deck will be slightly lower than the  
rear of the deck.  
3. If the machine turns right or left when handles are  
pushed forward together, adjust the stop on the  
side opposite the direction of turn (see Figure 12).  
Move the stop back until the unit drives straight.  
Readjust handles if necessary.  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
Deck Drive Belt Tension  
Self-tensioning – No adjustment necessary.  
Electric Clutch Adjustment  
No adjustment necessary.  
28  
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Maintenance  
Cleaning  
Clean Engine Air Cooling  
System  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
conditions.)  
CAUTION  
Excessive debris can cause the engine and  
hydraulic system to overheat which can  
create a fire hazard.  
Figure 12  
1. Adjust stop  
Clean all debris from around the engine and  
hydraulic pumps daily.  
Adjust Throttle Lever  
Tension  
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. Clean all debris from rotating engine air intake  
screen and from around engine shrouding.  
2. Tension in throttle lever can be adjusted by  
adjusting the tightness of the lever pivot bolt,  
which is located under the console (Figure 13).  
Remove Engine Shrouds and  
Clean Cooling Fins  
Service Interval: Every 80 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.  
Figure 13  
1. Hex bolt  
2. Spring disc washers  
3. Tab washer  
4. Friction washer  
5. Lever  
6. Bracket  
7. Hex locknut  
3. Make sure cooling shrouds are properly  
reinstalled. Operating the engine without  
cooling shrouds will cause engine damage due to  
overheating.  
Clean Grass Build-Up Under  
Deck  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
29  
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Maintenance  
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.  
Federal law states that batteries should not be placed  
in the garbage. Management and disposal practices  
must be within relevant federal, state, or local laws.  
If a battery is being replaced or if the unit containing  
the battery is no longer operating and is being  
scrapped, take the battery to a local certified recycling  
center. If no local recycling is available return the  
battery to any certified battery reseller.  
30  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused  
by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do not attempt to service or replace major  
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.  
Problem  
Starter does not crank  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
2. Parking brake is not engaged.  
2. Set the parking brake.  
3. Drive levers are not in neutral lock  
position.  
3. Ensure the drive levers are in the neutral  
lock position.  
4. Battery does not have a full charge.  
4. Charge the battery.  
5. Electrical connections are corroded, loose 5. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
6. Fuse is blown.  
6. Replace the blown fuse.  
7. Relay or switch is defective.  
7. Contact an Authorized Service Dealer.  
Engine will not start, starts hard, or fails to  
keep running  
1. Fuel tank is empty.  
1. Fill the fuel tank.  
2. Fuel shutoff valve is closed.  
3. Oil level in the crankcase is low.  
2. Open the fuel shutoff valve.  
3. Add oil to the crankcase.  
4. The throttle and choke are not in the  
correct position.  
4. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions, and the choke is in the “ON”  
position for a cold engine or the “OFF”  
position for a warm engine.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
7. Air cleaner is dirty.  
8. Seat switch is not properly adjusted.  
7. Clean or replace the air cleaner element.  
8. Adjust the seat switch.  
9. Electrical connections are corroded, loose 9. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
10. Relay or switch is defective.  
11. Faulty spark plug.  
12. Spark plug wire is not connected.  
10. Contact an Authorized Service Dealer.  
11. Clean, adjust or replace spark plug.  
12. Check the spark plug wire connection.  
Engine 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.  
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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. Tire pressure in drive tires not correct.  
2. Motion control stops need adjustment.  
1. Adjust tire pressure in the drive tires.  
2. Adjust the motion control stops.  
Machine does not drive  
1. Drive wheel release is not closed.  
1. Close the drive wheel release.  
2. Change the belt.  
2. Drive or pump belt is worn, loose or  
broken.  
3. Drive or pump belt is off a pulley.  
4. Broken or missing idler spring.  
5. Hydraulic fluid level is low or too hot.  
3. Change the belt.  
4. Replace the spring.  
5. Add hydraulic fluid to reservoir or let it  
cool down.  
Uneven cutting height.  
1. Blade(s) not sharp.  
1. Sharpen the blade(s).  
2. Install new cutting blade(s).  
3. Level mower deck from side-to-side and  
front-to-rear.  
2. Cutting blade(s) is/are bent.  
3. Mower deck is not level.  
4. Underside of mower is dirty.  
5. Tire pressure in drive tires not correct.  
6. Blade spindle bent.  
4. Clean the underside of the mower.  
5. Adjust tire pressure in the drive tires.  
6. Contact an Authorized Service Dealer.  
7. Tips of adjacent blades are at an uneven  
cutting height. Blades tips should be even  
within 3/16 inch which is approximately  
one blade thickness.  
7. Replace blades, spindles and (or) check  
for damage to mower deck.  
Abnormal vibration  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Engine mounting bolts are loose.  
4. Loose engine pulley, idler pulley, or blade  
pulley.  
2. Tighten the blade mounting bolt.  
3. Tighten the engine mounting bolts.  
4. Tighten the appropriate pulley.  
5. Engine pulley is damaged.  
6. Blade spindle is bent.  
5. Contact an Authorized Service Dealer.  
6. Contact an Authorized Service Dealer.  
Blades do not rotate.  
1. Drive belt is worn, loose or broken.  
2. Drive belt is off pulley.  
1. Check the belt tension.  
2. Install drive belt and check adjusting  
shafts and belt guides for correct position.  
3. Deck belt is worn, loose or broken.  
4. Deck belt is off pulley.  
3. Install new deck belt.  
4. Install deck pulley and check the idler  
pulley, idler arm and spring for correct  
position and function.  
5. Broken or missing idler spring.  
6. PTO clutch does not engage.  
5. Replace the spring.  
6. Contact an Authorized Service Dealer.  
32  
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Schematics  
Schematics  
Electrical Diagram  
N E E R G . D K  
N E E R G . D K  
E P I R T S T H W / N E E R G . D K  
V I O L E T  
W H I T E  
C A K B L  
C A K B L  
K C A B L  
C A K B L  
K C A B L  
N E E R G . D K  
N E E R G . D K  
K C A B L  
K C A B L  
O R A N G E / B L K S T R I P E  
G R E Y  
E P I R T S T H W / N E E R G . D K  
W O Y E L L  
. B T L L U E  
N E E R G . D K  
N E E R G . D K  
A T N  
A T N  
P I N K / B L K S T R I P E  
A T N  
. B T L L U E  
. B T L L U E  
. B T L L U E  
K C A B L  
N E E R G . D K  
. G T R L E E N  
A T N  
A T N  
. G T R L E E N  
. B T L L U E  
. B T L L U E  
G007567  
33  
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Schematics  
Electrical Logic Schematic  
. G R D E K E N  
V I O L E T  
. G R D E K E N  
C A K B L  
C A K B L  
. G R D E K E N / W H T S T R I P E  
C A K B L  
W H I T E  
C A K B L  
C A K B L  
G R E Y  
C A K B L  
C A K B L  
. G R D E K E N  
. G R D E K E N  
A T N  
A T N  
. G R D E K E N / W H T S T R I P E  
O R A N G E / B L K S T R I P E  
W O Y E L L  
. B T L L U E  
. G R D E K E N  
. G R D E K E N  
A T N  
C A K S T R I P E P I N K / B L  
C A K B L  
. B T L L U E  
. G R D E K E N  
. G T R L E E N  
A T N  
A T N  
. G T R L E E N  
. B T L L U E  
. B T L L U E  
G007921  
34  
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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  
The Exmark turf equipment, including any defective part,  
must be returned to an authorized Exmark service dealer  
within the warranty period. This warranty extends only to turf  
equipment operated under normal conditions. You must read  
the operator’s manual. You must also properly service and  
maintain your Exmark product as described in the operator’s  
manual. Such routine maintenance, whether performed by a  
dealer or by you, is at your expense.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
2 years*  
• 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.  
G4500-425  
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Notes:  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
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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.  
© 2008 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-335 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA.  
All Rights Reserved  
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