Exmark Lawn Mower 4500 358 User Manual

TURF TRACER® HP  
For Serial Nos.  
790,000 & Higher  
Part No. 4500-358 Rev. A  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
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.  
Figure 1  
1. Model and serial number location  
Model No.  
Serial No.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Contents  
Introduction ........................................................... 3  
Torque Requirements .................................... 16  
Periodic Maintenance ....................................... 25  
Service Pre-Cleaner Element and Air  
Wheel Hub-Slotted Nut Torque  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
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
Download from Www.Somanuals.com. All Manuals Search And Download.  
       
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
Download from Www.Somanuals.com. All Manuals Search And Download.  
Safety  
– After striking a foreign object or abnormal  
Operation  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating 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.  
– Before clearing blockages.  
– Whenever you leave the mower.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
• Allow engine parts, especially the muffler,  
to cool before touching.  
– Before refueling.  
– 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  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can  
kill you.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
Do Not run engine indoors or in a small  
confined area where dangerous carbon  
monoxide fumes can collect.  
DO NOT operate the mower when people,  
especially children, or pets are in the area.  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine.  
• Never raise deck with blades running.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
• Do Not change the engine governor setting or  
overspeed the engine.  
Slope Operation  
• Stop engine, wait for all moving parts to stop,  
remove key and engage parking brake:  
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.  
– Before checking, cleaning or working on the  
mower.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
Safety  
spark plug wire. Wait for all movement to stop  
before adjusting, cleaning or repairing.  
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.  
• 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.  
• 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.  
• 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.  
• Do Not mow slopes greater than 20  
degrees.  
• 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.  
• 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.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
• 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.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check all bolts frequently to maintain proper  
tightness.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
• All replacement parts must be the same as  
or equivalent to the parts supplied as original  
equipment.  
Maintenance and Storage  
• Disengage drives, lower implement, set parking  
brake, stop engine and remove key or disconnect  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
Safety  
WARNING  
Hydraulic fluid escaping under pressure  
can penetrate skin and cause injury. Fluid  
accidentally injected into the skin must be  
surgically removed within a few hours by a  
doctor familiar with this form of injury or  
gangrene may result.  
• 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
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Safety  
1-413327  
48 inch and 52 inch Decks Only  
103-1798  
1-413421  
1-513747  
19 HP Kawasaki Electric Start Only  
103-1976  
19 HP Kawasaki Electric Start  
1-553049  
98-5954  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Safety  
103-1977  
15 HP and 17 HP Kawasaki Manual Start  
103-2242  
103-2076  
103-2243  
103-2103  
103-4935  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Safety  
109-3148  
116-0404  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Specifications  
Specifications  
Model Numbers  
Serial Nos: 790,000 and Higher  
Manual Start Models: THP15KA363; THP17KA483; THP17KA523; THP17KA363CA; THP17KA483CA  
Electric Start Models: THP19KAE483; THP19KAE523; THP19KAE483CA  
Systems  
neutral to each drive wheel for moving forward or  
reverse, stopping, and power turning.  
Engine  
Transmission  
• Engine Specifications: See your Engine Owner’s  
Manual  
Twin Hydrostatic Drive  
• RPM: Full Speed: 3600 ±50 RPM (No Load)  
• 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.  
• 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 speed control lever in neutral,  
PTO disengaged, (and OPC levers depressed for  
electric start) 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 engaged to move speed  
control out of neutral or engine will kill.  
Operator Controls  
Steering Control: Fingertip drive control levers  
provide independent speed control, braking and  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
Specifications  
Tires & Wheels  
Drive  
Dimensions  
Front Caster  
Pneumatic Semi-  
Overall Width:  
Pneumatic  
(Air-Filled) (Air-Filled) Pneumatic  
36 inch  
Deck  
48 inch  
Deck  
52 inch  
Deck  
36  
2
48 & 52  
2
All Decks  
2
Deflector  
Up  
36.1 inches 48.1 inches 53.0 inches  
(91.7 cm) (122.2 cm) (134.6 cm)  
Quantity  
Tread  
Turf Master Turf Master Smooth  
16 x 6.50–8 16 x 7.50–8 9 x 3.50-4  
Deflector  
Down  
46.25 inches 58.25 inches 62.6 inches  
(117.5 cm) (148.0 cm) (159.0 cm)  
Size  
Ply Rating  
Pressure  
4
4
14 psi  
14 psi  
Overall Length:  
(97 kPa)  
(97 kPa)  
36 inch Deck  
48 inch Deck  
52 inch Deck  
77.3 inches  
(196.3 cm)  
73.7 inches  
(187.2 cm)  
75.9 inches  
(192.8 cm)  
Cutting Deck  
• 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  
44.1 inches  
(112.0 cm)  
44.1 inches  
(112.0 cm)  
44.1 inches  
(112.0 cm)  
• Blade Size:  
Tread Width: (Outside to Outside of  
Tires, Widthwise)  
– 36 inch Deck: 18.00 inches (45.7 cm)—  
Quantity: 2  
36 inch Deck  
48 inch Deck  
52 inch Deck  
– 48 inch Deck: 16.25 inches (41.3 cm)—  
Quantity: 3  
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  
Curb Weight:  
• Deck Drive: Manual engagement of belt with  
over-center lock. Blade belt tension is adjustable  
via turnbuckle.  
36 inch Deck  
48 inch Deck  
52 inch Deck  
565 lb (211 kg)  
610 lb (277 kg)  
644 lb (292 kg)  
• Deck Mounting: Full floating deck is attached to  
out-front support frame, removable for service.  
Note: Weights will vary slightly depending on engine  
and electric start options.  
• Deck Depth:  
– 36 inch Deck: 5.0 inches (12.7 cm)  
– 48 inch Deck: 5.0 inches (12.7 cm)  
– 52 inch Deck: 5.0 inches (12.7 cm)  
• Cutting Height Adjustment:  
Adjusts from 1 1/2 inches (3.8 cm) to 4 1/2  
inches (11.4 cm) in 1/2 inch (1.3 cm) increments  
• Mulching Kit: Optional  
• Bagger: Optional  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
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  
15-20 ft-lb (20-27 N-m)  
90-95 ft-lb (122-129 N-m)  
Wheel Hub Slotted Nuts  
minimum 100 ft-lb  
(136 N-m)  
Wheel Motor Mounting  
Bolts  
30-35 ft-lb (41-47 N-m)  
Figure 3  
1. Park Brake Lever  
2. Controls  
3. Fuel Cap  
4. Height-of-Cut Pins  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
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.  
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 right side of the control console.  
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 the 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
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  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Operation  
B. Start engine. Refer to the following  
Pre-Start  
guidelines for further starting suggestions.  
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.  
• 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.  
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. Never fill the fuel tank so  
that the fuel level rises above a level that is 1/2 inch  
below the bottom of the filler neck to allow for fuel  
expansion and prevent fuel spillage.  
3. Turn the key switch to the “Run” position.  
4. Pull recoil rope to start engine.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
5. After engine warms up, gradually push in the  
choke control. Do Not run warm engine with the  
choke in the “ON” position.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Note: Kawasaki engines generally need to be  
“choked” even when warm.  
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.  
Operating Instructions  
1. Lock drive levers in neutral and engage park  
brake.  
Open the Fuel Shut-Off Valve  
2. Pull out the choke control. Place the throttle  
control midway between the “Slow” and “Fast”  
positions.  
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)  
Note: Operator must have PTO disengaged and  
speed control lever in neutral position when starting  
the engine.  
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.  
1. Lock drive levers in neutral and engage park  
brake.  
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.  
4. After engine warms up, gradually push in the  
choke control. Do Not run warm engine with the  
choke in the “ON” position.  
• To use cold start kit:  
Note: Kawasaki engines generally need to be  
“choked” even when warm.  
A. Pull split ring straight out the side of the  
unit, and hook the ring over the lower rear  
hydro control shield bolt.  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Operation  
5. Engage the parking brake.  
PTO Engagement  
6. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
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 key 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.  
1. Set throttle to “MIDWAY” position.  
CAUTION  
2. Push the PTO engagement arm forward and  
down to engage blades.  
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.  
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.  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
1. Release the parking brake.  
WARNING  
2. With drive levers locked in “neutral”, shift speed  
control lever to desired forward speed.  
When the two front support rod hairpins are  
removed from the mower deck, the weight of  
the tractor section may cause the front frame  
of the unit to rise suddenly. If the unit rises  
suddenly, injury may occur.  
3. Slowly squeeze and hold both drive levers in  
the neutral position and rotate both neutral lock  
latches from the neutral lock position to the  
forward position.  
Note: Do Not squeeze both drive levers all the  
way back. This will cause the drive wheels to  
engage in the reverse direction.  
Securely hold down the front of the unit when  
the front support rod hairpins are removed.  
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 (1.3 cm) 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.  
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Operation  
Figure 6  
2. Cutting Height  
1. Deck support pin  
Figure 7  
Left Hand Side Shown  
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.  
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.  
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.  
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.  
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.  
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.  
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Operation  
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.  
Figure 8  
For cutting heights above 3.5 inches (38 mm) use the  
bottom hole. The rollers will still be effective against  
scalping.  
• Use proper ramps that are secured to the  
truck or trailer.  
1. Anti-scalp roller  
mounting bracket  
2. Cutting height  
• Keep feet and legs out from under the  
unit when loading and unloading.  
7. Torque the 3/8–16 whizlock nut to 30-35 ft-lb  
(41-47 N-m) (Figure 9).  
• If necessary, use assistance when loading.  
8. If the 3/8 nyloc nut has been removed, reinstall  
and torque to 30–35 ft-lb (41-47 N-m) (Figure 9).  
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.  
Figure 9  
1. Spring disc washer  
(cone towards nut )  
3. 3/8 nyloc-torque to 30-35  
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)  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
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 air cleaner. (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.  
• Remove engine shrouds and clean cooling fins.  
• Change the engine oil. (May need more often under severe conditions.)  
• Check the spark plugs.  
Every 80 hours  
Every 100 hours  
Every 160 hours  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)  
• Check wheel hub-slotted torque specification.  
Every 500 hours  
Monthly  
• Check the battery charge.  
• Grease the PTO engagement bellcrank.  
Periodic Maintenance  
storage when the open circuit voltage drops to 12.4  
volts.  
Check Engine Oil Level  
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.  
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.  
2. Check with engine cold.  
3. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Do Not screw into  
place. Remove the dipstick and read the oil level.  
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).  
4. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Use oil as specified in  
Engine Owner’s Manual. Do Not overfill.  
Important: 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  
CALIFORNIA  
Proposition 65 Warning  
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  
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.  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
Check Mower Blades  
Service Interval: Before each use or daily  
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  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
       
Maintenance  
2. Lift deck and secure in raised position as stated in  
wrench on the top spindle nut then torque the  
blade bolts to 55-60 ft-lb (75-81 N-m).  
the Clean Grass Build-Up Under Deck section.  
3. Inspect blades and sharpen or replace as required.  
WARNING  
4. Reinstall the blades (if they were removed) in the  
following order:  
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.  
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 10  
1. Install bushing in blade prior to installing bushing in  
spindle.  
Service Interval: As required  
B. Install bushing/blade assembly into 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.  
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.  
Figure 11  
2. To install new discharge deflector, orient the  
spring on the rod as shown in Figure 12. Slide the  
rod through the front discharge deflector bracket,  
discharge deflector, and rear deflector bracket.  
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.  
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  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 12  
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 12).  
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  
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.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
Check Safety Interlock  
System  
Service Interval: Before each use or daily  
Service Pre-Cleaner Element  
and Air Cleaner  
Service Interval: Every 25 hours—Service  
the air cleaner. (May  
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.  
need more often under  
severe conditions. See  
the Engine Owner’s  
manual for additional  
information.)  
Try to start the engine with OPC levers  
disengaged, speed control lever in neutral and  
PTO disengaged–starter must not crank.  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
       
Maintenance  
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 cleaning  
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. The oil drain hose assembly is located on the left  
side of the engine.  
3. Inflate drive tires to 12–16 psi (83–110 kPa).  
4. Inflate tires to pressures stated above. Measure  
the circumference of each drive tire. Adjust tire  
pressures within the above range to try to make  
tire circumferences match as closely as possible.  
Place pan under machine to catch oil. Remove oil  
drain plug. Allow oil to drain and replace oil drain  
plug. Torque plug to 20-24 ft-lb (27-33 N-m).  
4. Replace the oil filter per the Engine Owner’s  
Manual. Clean around oil filter and unscrew filter  
to remove. Before the new filter is installed,  
apply a thin coating of oil on the surface of the  
rubber seal. Turn filter clockwise until rubber seal  
contacts the filter adapter, then tighten filter an  
additional 2/3 to 3/4 turn.  
5. Semi-pneumatic caster tires do not need to be  
inflated.  
Check Condition Of Belts  
Service Interval: Every 40 hours  
5. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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.  
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.  
7. Wipe up any spilled oil from engine deck  
mounting surfaces.  
4. Check all idler arms to be sure they pivot freely.  
Disassemble, clean and grease pivot bushings if  
necessary.  
Check Hydraulic Oil Level  
Service Interval: Every 40 hours  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
2. Clean area around hydraulic reservoir cap and  
remove cap. Oil level should be to the top of the  
baffle inside the tank. If not, add oil. Use Exmark  
Premium Hydro oil. Replace hydraulic reservoir  
cap and tighten until snug. Do Not overtighten.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate fittings with NGLI grade #2  
multi-purpose gun grease.  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
Refer to the following chart for fitting locations  
and lubrication schedule.  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
         
Maintenance  
Lubrication Chart  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner’s  
Manual.  
Fitting  
Initial  
Number of Places  
Service  
Interval  
Locations Pumps  
36 inch 48 inch 52 inch  
Change Fuel Filter  
Service Interval: As required  
Deck  
Deck  
Deck  
1. Caster  
Wheel  
12  
2
2
2
Daily  
Bearings  
A fuel filter is installed in the fuel line between the  
fuel tank and the engine. Replace when necessary.  
2. Caster  
Pivots  
2
1
2
1
2
1
2
1
Daily  
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  
Every 500 hours/Yearly  
(whichever comes  
first) thereafter  
(Every 250 hours/Yearly if  
using Mobil 1 15W50)  
1
2
1
2
1
2
1
2
5. Clutch  
Arm Pivot  
40 hours  
40 hours  
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 or spark plug wire(s). 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  
Level.  
Spray Lubricant Chart  
Exmark Premium Hydro Oil is recommended.  
Refer to the chart for an acceptable alternative:  
Pivot Point  
Service Interval  
40 hours  
Number of Places  
1
1. PTO Lever  
Hydro Oil  
Change Interval  
500 Hours  
Exmark Premium Hydro  
Oil (Preferred)  
Check Spark Plugs  
Service Interval: Every 160 hours  
250 Hours  
Mobil 1 15W50  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Maintenance  
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.  
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 13) may have lost  
their “prime”. Refer to Hydraulic System Air  
Purge section.  
Note: Do Not change hydraulic system oil (except  
for what can be drained when changing filter), unless  
it is felt the oil has been contaminated or been  
extremely hot.  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminates into the system.  
Figure 13  
2. Loosen 1 1/2 turns only  
1. Charge pump cap  
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.  
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.  
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.  
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 13). Air in other parts of  
the hydraulic system will be purged through normal  
operation once the charge pump is “primed”.  
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.  
If either drive wheel still does not rotate continue  
with step 4.  
4. Thoroughly clean the area around each of the  
charge pump housings.  
5. To “prime” charge pump, loosen two hex socket  
head capscrews (shown in Figure 13) 1 1/2 turns  
only. Make sure engine is not running. Lift  
the charge pump housing upward and wait for  
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
Maintenance  
a steady flow of oil to flow out from under the  
housing. Retighten the capscrews. Do this for  
both pumps.  
clutching belt tension. Bolt on blade engagement  
linkage bellcrank and indicator arm should align  
within 1/16 inch (1.6 mm) (see Figure 14). Refer  
to PTO Engagement Linkage for adjustment.  
Note: Hydraulic reservoir can be pressurized up  
to 5 psi to speed this process.  
6. If either drive wheel still does not rotate, stop  
and repeat steps 4 and 5 above for the respective  
pump. If wheels rotate slowly, the system may  
prime after additional running. Check oil level  
as stated in Check the Hydraulic Oil Level  
section.  
7. Allow unit to run several minutes after the charge  
pumps are “primed” with drive system in the full  
speed position. Check oil level as stated in Check  
the Hydraulic Oil Level section.  
8. Check hydro drive linkage adjustment as stated in  
Hydro Drive Linkage Adjustment section in  
Adjustments.  
Figure 14  
1. Engine deck  
2. Indicator  
3. Align bolt to indicator  
within 1/16 inch (1.6  
mm)  
4. Turnbuckle  
Wheel Hub-Slotted Nut  
Torque Specification  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
Service Interval: After the first 100 hours  
Every 500 hours thereafter  
When tightening the slotted nut on the wheel motor  
tapered shaft:  
• Pump sheave setscrews.  
1. Torque the slotted nut to 100 ft-lb (136 N-m).  
• Square head setscrews on hydro pump control  
arms.  
2. Further tighten the nut until the next set of slots  
line up with the cross hole in the shaft.  
3. Replace cotter pin.  
• OPC lever setscrews.  
• Lower sheave retaining bolt on clutch arm.  
• Shoulder bolts in ends of speed control crank.  
• Sheave retaining bolt in end of engine crankshaft.  
• Fuel tank bulkhead fitting threads  
Note: Do not use anti-seize compound on the wheel  
hub.  
Inspect PTO Clutching Belt  
Tension  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
Service Interval: After the first 2 hours  
Check every 2 hours  
for the first 8 hours of  
operation.  
• 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.  
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
       
Maintenance  
Mobil HTS Grease (Or  
Food-Grade Anti-seize)  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
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.  
• Between the cutter housing spindle and bearings.  
• Between the cutter housing spindle and sheave.  
• Under top cutter housing bearing guard.  
Deck Leveling  
See Adjusting the Cutting Height section in  
Operation.  
Copper-Based Anti-seize  
Copper-based anti-seize is used in the following  
locations:  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
• On threads of Blade Bolts. See Check Mower  
Blades section.  
PTO Clutching Belt Tension  
See Inspect PTO Clutching Belt Tension section.  
• Between engine crankshaft and pump and blade  
drive sheaves.  
Mower Deck Drive Belt  
Tension  
• On clutch arm assembly between bearings and  
shaft and between lower sheave and shaft.  
• Between pump shafts and sheaves.  
Self-tensioning - No adjustment necessary.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
Park Brake Adjustment  
1. Shut off engine and wait for all moving parts to  
stop.  
2. Disengage the park brake.  
3. Remove the hairpin in the park brake linkage.  
Turn the linkage in the yoke until there is 3/16  
inch (4.8 mm) to 1/4 inch (6.4 mm) clearance  
between the park brake tire bars and the tires with  
the park brake disengaged. Re-install the hairpin.  
Hydro Drive Linkage  
Adjustment  
• Adjust Speed Control Linkage and Neutral Safety  
Switch:  
1. Stop engine and wait for all moving parts to  
stop. Engage parking brake. Remove key or  
spark plug wire(s).  
2. Move the speed control lever (located on  
the console) to the full forward position and  
check the orientation of the tabs on the ends  
of the speed control crank (see Figure 15).  
These tabs should be pointing straight down  
at the 6 o’clock position or slightly forward.  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
                   
Maintenance  
Adjust the threaded yoke at the bottom of the  
speed control linkage (see Figure 15) until the  
tabs are positioned correctly.  
Figure 15  
Viewed from Left Side of Unit  
Figure 16  
1. Neutral Safety Switch  
3. 5/16 inch (.76 cm)  
2. Actuating Tab in neutral  
position  
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. 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 (.79 cm) between  
the tab and the switch (see Figure 15). If  
necessary, move the switch fore and aft.  
3. Drive Lever Linkage  
4. Speed Control Crank  
4. Loosen the nut against the neutral control  
linkage yoke as shown in Figure 16.  
• Adjust Neutral Control Linkages:  
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.  
1. Raise the rear of the machine up onto jack  
stands high enough to raise the drive wheels  
off of the ground.  
2. Start the engine and move the throttle ahead  
to the full throttle position. Place the neutral  
lock latches in the “forward” position as  
shown in Figure 5. Release the park brake  
and move the speed control lever to the  
“mid-speed” position.  
Note: The OPC levers must be held down  
and the park brake must be disengaged  
whenever the speed control lever is moved  
out of neutral or the engine will kill.  
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.  
3. Squeeze the respective drive lever until an  
increased resistance is felt, this is where  
neutral should be.  
• Adjust Hydro Control Linkages:  
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.  
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  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
     
Maintenance  
disengaged whenever speed control levers are  
moved out of the neutral position.  
to neutral. Recheck the drive wheel rotation  
to see if further adjustment is necessary.  
4. The spring that keeps tension on the knob  
should normally not need adjustment.  
However, if adjustment is needed, adjust to  
where length of spring is about 1 inch (2.5 cm)  
between the washers. Adjust spring length by  
turning nut at front of spring.  
Note: The neutral lock latches should be  
“unlocked” and in the forward position.  
2. Loosen the front nut on left hydro control  
linkage as shown in Figure 16. Turn the rear  
control linkage adjusting nut counterclockwise  
until wheel rotates forward. Turn the rear nut  
of left control linkage clockwise 1/4 of a turn  
at a time, stopping to move the speed control  
forward and back to neutral, until left wheel  
stops rotating forward.  
• Drive Lever Linkage Adjustment:  
1. With rear of machine still on jack stands and  
engine running at full throttle, disengage  
the park brake and move the speed control  
lever to the midway position. Move the  
respective drive lever upward until it reaches  
the neutral position and engage neutral lock  
latches (Figure 18). If the tire rotates in either  
direction, the length of the drive lever link will  
need to be adjusted.  
Turn the rear nut an additional 1/2 turn and  
tighten the front nut making sure not to put  
a bind on the linkage. Make sure flat part of  
linkage is perpendicular to pin part of swivel  
(see Figure 17).  
Figure 17  
1. Left Hydro Control Link  
(left side shown)  
4. Linkage is perpendicular  
to pin (correct position)  
2. Front nut  
5. Linkage in incorrect  
position  
3. Rear nut  
6. End view of swivel  
After adjusting the left hydro control linkage,  
move the speed control lever to the mid-speed  
position and then back to the neutral position.  
Recheck the left drive wheel rotation to see if  
further adjustment is necessary - be sure the  
speed control lever is in the neutral position.  
Figure 18  
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.  
Note: If inconsistent neutral occurs,  
check to be sure both springs are properly  
tightened on the speed control lever under the  
console–especially the rear pivot spring.  
Repeat above adjustments if necessary.  
3. Place the speed control lever in neutral. Adjust  
the right side linkage by turning the quick track  
knob counterclockwise until the tire begins to  
rotate forward. Begin to retighten the knob  
clockwise about 1/4 turn at a time, stopping  
to move the speed control forward and back  
3. Make this adjustment for both sides.  
• Tracking Adjustment:  
1. Stop engine and wait for all moving parts to  
stop. Engage parking brake. Raise the rear of  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Maintenance  
the machine, remove jack stands and carefully  
lower the machine to the ground. (Check the  
drive tire pressure and tire circumference see  
Check the Tire Pressures section.)  
PTO Safety Switch  
Mounted to a tab on the inside left side of the fuel  
tank support.  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove ignition key or  
spark plug wire(s).  
2. Run the unit and observe the tracking on a  
level, smooth, hard surface such as concrete  
or asphalt.  
2. With PTO disengaged and the bellcrank touching  
the rear of the slot in the engine deck, adjust the  
PTO safety switch (if needed) until the bellcrank  
arm is 5/16 inch (7.9 mm) from the switch body.  
3. If the unit tracks to one side or the other, turn  
the quick track knob. Turn the knob right to  
“steer” right; turn the knob left to “steer” left.  
3. Be sure the bellcrank Does Not touch the switch  
body or damage to the switch could occur.  
Hydro Pump Spring Tension  
Setting  
4. Retighten PTO switch mounting hardware.  
1. For medium or heavy duty drive conditions such  
as operation with a sulky on steep slopes, a higher  
spring force may be required on the hydro pump  
control arms to prevent the drive system from  
stalling.  
2. For a heavier drive setting, relocate the spring  
anchor link as shown in Figure 13. The spring  
anchor links are located under the engine deck on  
the left and right hand sides.  
Note: In “medium” or “heavy duty” positions,  
the drive lever forces at the upper handle will also  
be increased.  
Figure 19  
1. Heavy duty  
3. Standard  
2. Medium duty  
4. Retaining bolt  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
   
Maintenance  
Clean Debris From Machine  
Service Interval: Before each use or daily  
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, 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.  
conditions.)  
Clean Grass Build-Up Under  
Deck  
CAUTION  
Excessive debris around engine cooling air  
intake and exhaust system area can cause  
engine, exhaust area, and hydraulic system  
to overheat which can create a fire hazard.  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Clean all debris from engine and exhaust  
system area.  
2. Raise deck to the transport (maximum cutting  
height) position. Lift the front of unit and support  
unit using jack stands or equivalent support.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
CAUTION  
2. Clean all debris from rotating engine air intake  
screen, around engine shrouding, and exhaust  
system area.  
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.  
3. Wipe up any excessive grease or oil around the  
engine and exhaust system area  
Remove Engine Shrouds and  
Clean Cooling Fins  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
Service Interval: Every 80 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Clean out any grass build-up from underside of  
deck and in discharge chute.  
2. 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.  
Waste Disposal  
Motor Oil Disposal  
3. Make sure cooling shrouds are properly  
reinstalled. Operating the engine without  
cooling shrouds will cause engine damage due to  
overheating.  
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.  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
           
Maintenance  
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.  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
4. Battery does not have a full charge.  
3. Depress OPC levers.  
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.  
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.  
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.  
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
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.  
5. Replace the spring.  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Schematics  
Schematics  
Electrical Diagram  
TRANSMISSION  
SWITCH  
N.O.  
15 & 17 HP KAWASAKI  
PARK BRAKE  
SWITCH N.O.  
BLADE  
SWITCH  
N.O.  
SAFETY INTERLOCK MODULE  
BLUE  
ORANGE  
YELLOW  
RED  
GREEN  
RED  
OPC SWITCH  
N.O.  
BLACK  
BROWN  
BLACK  
CONNECTORS ARE VIEWED FROM WIRE END  
N.C. = NORMALLY CLOSED  
KEY SWITCH  
ENGINE KILL  
GROUND  
N.O. = NORMALLY OPEN  
G006978  
ENGINE  
Electrical Diagram  
SAFETY  
INTERLOCK  
MODULE  
19 HP KAWASAKI  
ELECTRIC START  
BLADE  
SWITCH  
N.O.  
NEUTRAL  
SWITCH  
N.C./N.O.  
PARK BRAKE  
SWITCH N.C.  
OPC  
SWITCH  
N.O.  
GREEN  
KEY  
SWITCH  
GREEN  
BLACK/WHITE STRIPE  
BLACK  
BLACK  
BLACK  
ENGINE  
SOLENOID  
ORANGE  
ORANGE  
VIOLET  
BROWN  
ENGINE  
WHITE  
RED  
LT BLUE  
YELLOW  
GROUND  
WHITE  
SOLENOID +  
SOLENOID  
RED  
VIOLET  
ENGINE  
REGULATOR  
ENGINE KILL  
KEY  
CIRCUIT  
START  
BATTERY  
GROUND  
POSITION "MAKE"  
CONNECTORS ARE VIEWED FROM WIRE END  
N.C. = NORMALLY CLOSED  
GROUND  
+
OFF  
ON  
ENGINE KILL  
BATTERY  
N.O. = NORMALLY OPEN  
+
REGULATOR  
G007009  
BATTERY  
BATTERY  
+
START  
+
REGULATOR  
START  
FUSES  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
Schematics  
Hydraulic Diagram  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Notes:  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Notes:  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Service Record  
Date:  
Description of Work Done:  
Service Done By:  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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. 4500-358 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Eclipse Fujitsu Ten Car Video System CD3000 User Manual
Edelbrock Automobile Parts 9629 User Manual
Eton Exercise Bike FR250 User Manual
Frymaster Fryer D160G User Manual
GE Microwave Oven REM25 User Manual
Gemini Industries Microphone UX 1600 User Manual
Gemini Musical Instrument MM 01 4U 19 User Manual
GE Monogram Double Oven ZET857WBWW User Manual
GE Monogram Switch Zenith Controls User Manual
Global Machinery Company Saw LS250TS2000W User Manual