Exmark Lawn Mower 4500 367 User Manual

NAVIGATOR®  
For Serial Nos.  
790,000 & Higher  
Part No. 4500-367 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum  
amount of dependability and years of trouble-free  
operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Figure 1  
1. Model and serial number location  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
Model No.  
Serial No.  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Tracking Adjustment..................................... 33  
Contents  
Introduction ........................................................... 3  
Torque Requirements .................................... 15  
Periodic Maintenance ....................................... 22  
Belt Guide Adjustment.................................. 29  
4
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Safety  
• Never let children or untrained people operate  
Safety  
Safety Alert Symbol  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Preparation  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
Figure 2  
1. Safety alert symbol  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
CAUTION  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
This machine produces sound levels in  
excess of 85 dBA at the operator’s ear and  
can cause hearing loss through extended  
periods of exposure.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
Wear hearing protection when operating this  
machine.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
Safe Operating Practices  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
5
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Safety  
DANGER  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
In certain conditions during fueling, static  
electricity can be released causing a spark  
which can ignite gasoline vapors. A fire or  
explosion from gasoline can burn you and  
others and cause property damage.  
A fire or explosion from gasoline can burn  
you, others, and cause property damage.  
• Fill the fuel tank outdoors in an open  
area, when the engine is cold. Wipe up  
any gasoline that spills.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• Do Not fill gasoline containers inside a  
vehicle or on a truck or trailer bed because  
interior carpets or plastic truck bed liners  
may insulate the container and slow the  
loss of any static charge.  
• Do Not fill the fuel tank completely  
full. Add gasoline to the fuel tank until  
the level is 1/4 to 1/2 inch (6–13 mm)  
below the bottom of the filler neck. This  
empty space in the tank allows gasoline  
to expand.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Never smoke when handling gasoline,  
and stay away from an open flame or  
where gasoline fumes may be ignited by  
spark.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Add fuel before starting the engine.  
Never remove the cap of the fuel tank or  
add fuel when engine is running or when  
the engine is hot.  
WARNING  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
6
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Safety  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
WARNING  
Operating a Navigator tractor without an  
approved Exmark front mount attachment  
increases the possibility of operator  
entanglement in drive wheels or forward tip  
over. Entanglement or tip-over could cause  
serious injury or death.  
Operation  
WARNING  
When operating a Navigator tractor  
without an approved Exmark front mount  
attachment, observe the following:  
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.  
• Keep feet and clothing away from tires.  
• Limit operation to minimum required to  
install a different front mount attachment.  
• Allow engine parts, especially the muffler,  
to cool before touching.  
• Minimize speed and use extreme caution.  
• Only operate on a flat level surface.  
• 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.  
• Do not operate up or down a trailer ramp.  
• Avoid sudden acceleration or deceleration.  
• 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.  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can  
kill you.  
• 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.  
Do Not run engine indoors or in a small  
confined area where dangerous carbon  
monoxide fumes can collect.  
• Never mow unless there is a grass collection  
system or mulch kit in place and working properly.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Stop engine, wait for all moving parts to stop,  
remove key and engage parking brake:  
– Before checking, cleaning or working on the  
mower.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
– Before clearing blockages.  
– Whenever you leave the mower.  
7
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Safety  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
DANGER  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. Wheels  
dropping over edges, ditches, steep banks, or  
water can cause rollovers, which may result  
in serious injury, death or drowning.  
– Before refueling.  
– Before dumping the grass catcher.  
WARNING  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
• Do Not mow slopes greater than 15  
degrees.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
• Reduce speed and use extreme caution  
on slopes.  
• Avoid sudden turns or rapid speed  
changes.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
NEVER carry passengers. DO NOT operate  
the mower when people, especially children, or  
pets are in the area.  
• Use a walk behind mower and/or a hand trimmer  
near drop-offs, ditches, steep banks or water.  
(Figure 3).  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
Figure 3  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
1. Safe Zone-Use the mower here on slopes less than 15  
degrees  
2. Danger Zone-Use a walk behind mower and/or hand  
trimmer on slopes greater than 15 degrees, near  
drop-offs and water.  
Slope Operation  
3. Water  
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.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
8
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Safety  
• Avoid sudden starts when mowing downhill.  
Mower may tip forwards.  
• Keep hands and feet away from moving parts.  
If possible, do not make adjustments with the  
engine running.  
• 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.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• Use extreme care with 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  
spark plug wire. Wait for all movement to stop  
before adjusting, cleaning or repairing.  
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.  
• Keep engine, engine area, and pump drive belt  
compartment free from accumulation of grass,  
leaves, excessive grease or oil, and other debris  
which can accumulate in these areas. These  
materials can become combustible and may result  
in a fire.  
• Make sure all hydraulic fluid hoses  
and lines are in good condition and  
all hydraulic connections and fittings  
are tight before applying pressure to  
hydraulic system.  
• Let engine cool before storing and do not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
• Use cardboard or paper, not your hands,  
to find hydraulic leaks.  
• Use jack stands to support components when  
required.  
• 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.  
• Carefully release pressure from components with  
stored energy.  
• Disconnect battery or remove spark plug wire  
before making any repairs. Disconnect the  
negative terminal first and the positive last.  
Reconnect positive first and negative last.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
9
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
1-513747  
103-8444  
65-2690  
98-4361  
103-8451  
103-8495  
98-5954  
103-8611  
103-8425  
10  
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Safety  
103-9034  
109-4638  
103-9724  
109-7318  
109-4273  
116-0404  
11  
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Safety  
116-1175  
Molded in LH Console  
Molded into Front of Hopper  
12  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 790,000 and Higher  
NAV20KC; NAV27KC  
Systems  
Operator Controls  
• Steering and Motion Control:  
Engine  
– Speed Control lever, located on RH console,  
sets maximum forward speed.  
• Engine Specifications: See your Engine Owner’s  
Manual  
• RPM: Full Speed: 3600 ±50 RPM (No Load)  
Idle: 1500 RPM  
– Steering levers, centered in front of the seat,  
control the speed and direction of travel of  
the respective drive wheels.  
– Moving speed control lever rearward to the  
neutral position places the drive system in  
neutral.  
Fuel System  
• Capacity: 7.5 gal. (28 L)  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher.  
• Fuel Filter: In-line 30 Micron Kohler P/N  
2405010.  
• Fuel Shut-Off Valve: 1/4 turn increments in-line  
valve by fuel filter.  
Note: The unit may be moved in reverse  
while the speed control is in the neutral  
position by pulling back on the steering levers.  
• PTO Engagement Lever: Engages drive to PTO  
(mower deck) and blower.  
• Parking Brake Lever: Pull back to engage parking  
brake.  
Electrical System  
• Charging System: Flywheel Alternator  
• Charging Capacity: 15 amps  
• Battery Type: BCI Group U1  
• Battery Voltage: 12 Volt  
• Polarity: Negative Ground  
• Fuses: Two 20 amp and one 30 amp blade type  
• Safety Interlock System:  
Seat  
• Type: Standard seat with high back, foam padded  
(internal suspension).  
• Mounting: Seat is hinged to tilt up for access to  
hydraulic pumps and other components. The seat  
is held in the tilted position with a link.  
• Armrests: None.  
• Seat Safety Switch: Internal to the bottom seat  
cushion, non serviceable. Time delay module  
incorporated into the Safety Interlock System  
eliminates rough ground cut-outs.  
– PTO must be disengaged, brake engaged, and  
speed control lever in neutral position to start  
engine. (It is not necessary for the operator to  
be in the seat to start the engine.)  
– Operator must be in seat when PTO is  
engaged, brake is disengaged, or speed control  
lever is moved out of neutral or engine will  
stop.  
Hydrostatic Ground Drive System  
• Hydrostatic Pumps: Two Hydro Gear variable  
displacement piston pumps.  
• Wheel Motors: Hydro Gear planetary reduction  
motors.  
– Engine will stop in the following conditions:  
◊ If the speed control lever is moved from  
neutral position while brake is engaged.  
◊ If the PTO is engaged while the hopper  
is tilted up.  
• Hydraulic Oil Type: Use Exmark Premium Hydro  
oil.  
• Hydraulic Oil Capacity: 4.0 qt. (3.8 L)  
13  
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Specifications  
• Hydraulic Filter: Replaceable cartridge type.  
– Summer use above 32°F (0°C):  
P/N 109-0071: 25 microns, 10 psi bypass  
– Winter use below 32°F (0°C):  
P/N 1-523541: 40 microns, 18 psi bypass  
• Speeds:  
– Heavy-duty cast iron, spiral bevel gearbox is  
final drive to blades.  
• Deck:  
Full floating deck is attached to out-front support  
frame. Deck design allows for bagging or  
mulching.  
• Deck Depth:  
– 0-7.0 mph (11.3 km/hr) forward.  
– 0-5.5 mph (8.6 km/hr) reverse.  
– 42 inch Deck: 4 5/8 inches (11.7 cm)  
– 48 inch Deck: 4 5/8 inches (11.7 cm)  
• Drive wheel release valves allow machine to be  
moved when engine is not running.  
Dimensions  
Tires & Wheels  
Overall Width:  
Drive  
Front  
Rear Caster  
Caster  
Without Deck  
42 inch Deck  
48 inch Deck  
Pneumatic  
(Air-Filled) Pneumatic  
Semi-  
Semi-  
Pneumatic  
42.6 inches  
(108.2 cm)  
43.2 inches  
(109.7 cm)  
49.2 inches  
(125.0 cm)  
Quantity  
Tread  
2
2
1
“Multi-Trac Smooth  
C/S”  
Smooth  
Overall Length:  
Without Deck  
42 inch Deck  
48 inch Deck  
Size  
18 x  
8 x 3.00-4  
13 x 8.00-6  
10.50-10  
67.3 inches  
(170.9 cm)  
91.8 inches  
(233.2 cm)  
94.5 inches  
(240.0 cm)  
Ply Rating  
Pressure  
4
15 psi (103  
kPa)  
Overall Height:  
Without Deck  
42 inch Deck  
48 inch Deck  
Cutting Deck  
51.2 inches  
(130.0 cm)  
51.2 inches  
(130.0 cm)  
51.2 inches  
(130.0 cm)  
(Sold separately)  
• Model Numbers:  
– CD42CD  
Tread Width: (Center to Center of  
Tires, Widthwise)  
– CD48CD  
42 inch Deck  
48 inch Deck  
• Cutting Width:  
Drive Wheels  
32.7 inches  
(83.1 cm)  
32.7 inches  
(83.1 cm)  
– 42 inch Deck: 42 inch (106.7 cm)  
– 48 inch Deck: 48 inch (121.9 cm)  
• Discharge: Center  
Wheel Base: (Center of Drive Wheel  
to Center of Rear Caster Wheel)  
• Blade Size: (2 ea.)  
– w/42 inch Deck: 22.00 inches (55.9 cm)  
– w/48 inch Deck: 25.00 inches (63.5 cm)  
• Deck Drive:  
42 inch Deck  
48 inch Deck  
44.2 inches (112.3 cm)  
44.2 inches (112.3 cm)  
– Clutching belt on horizontal engine shaft.  
Dual A” section hexagon belt with spring  
tensioned idler to jackshaft and blower.  
14  
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Product Overview  
Curb Weight:  
Product Overview  
42 inch Deck  
48 inch Deck  
850 lb (386 kg)  
1145 lb (519 kg)  
Torque Requirements  
Bolt Location  
Torque  
Blade Mounting Bolt  
Engine Mounting Bolts  
Wheel Lug Nuts  
85-110 ft-lb (115-149 N-m)  
30-35 ft-lb (41-47 N-m)  
90-95 ft-lb (122-129 N-m)  
72-77 ft-lb (98-104 N-m)  
Wheel Motor Mounting  
Bolts  
Wheel Hub Locknut  
210-250 ft-lb  
(285-339 N-m)  
Figure 4  
4. Steering Levers  
1. Speed Control Lever  
2. Controls  
3. Fuel Cap  
5. PTO Engagement Lever  
6. Parking Brake Lever  
15  
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Operation  
Brake Lever  
Operation  
Located on left side of unit, between the seat and  
console.  
Note: Determine the left and right sides of the  
machine from the normal operating position.  
The brake lever engages a parking brake on the drive  
wheels.  
Controls  
Pull the lever up and rearward to engage the brake.  
Push the lever forward and down to disengage the  
brake.  
Steering Levers  
Located in the center in front of the seat.  
The unit must be tied down and brake engaged when  
transporting.  
Pulling back on the steering levers, progressively  
slows, then reverses the direction of travel of the  
respective drive wheels.  
Ignition Switch  
Located on the right hand console.  
By moving both steering levers an equal amount back,  
the machine can be slowed down or travel backward  
in a straight line.  
The ignition switch is used to start and stop the  
engine. The switch has three positions “OFF”, “ON”  
and “START”. Insert key into switch and rotate  
clockwise to the “ON” position. Rotate clockwise to  
the next position to engage the starter (key must be  
held against spring pressure in this position).  
Steering is controlled by varying the position of the  
steering levers relative to each other.  
Speed Control Lever  
Note: Brake must be engaged, speed control lever  
rearward (neutral position) and PTO disengaged to  
start engine. (It is not necessary for the operator to  
be in the seat to start the engine.)  
Located on right hand console.  
The speed control lever sets maximum forward speed.  
Moving speed control lever rearward to the neutral  
position places the drive system in neutral.  
Hour Meter  
Located on the right hand console.  
Choke Control  
The hour meter is connected to a pressure switch  
installed in the engine block and it records the  
number of hours that the engine has run. If the  
ignition switch is left on without engine running,  
hour meter will not run.  
Located on right hand console.  
The choke is used to aid in starting a cold engine.  
Moving the choke lever forward will put the choke in  
the “ON” position and moving the choke lever to the  
rear will put the choke in the “OFF” position. DO  
NOT run a warm engine with choke in the “ON”  
position.  
Note: This switch is not a low oil sensor and will not  
alert the operator if the engine oil is low.  
Fuel Shut-Off Valve  
Throttle Control  
Located in fuel line by fuel tank and fuel filter  
(accessible by raising the hopper).  
Located on right hand console.  
The fuel shut-off valve is used to shut off the fuel  
when the machine will not be used for a few days,  
during transport to and from the jobsite, and when  
parked inside a building.  
The throttle is used to control engine speed. Moving  
throttle lever forward will increase engine speed and  
moving throttle lever to the rear will decrease engine  
speed.  
Rotate the valve 1/4 turn clockwise to shut off the  
fuel. rotate the valve 1/4 turn counterclockwise to  
turn on the fuel.  
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Operation  
Drive Wheel Release Valves  
Pre-Start  
Located on the top left front corner of hydrostatic  
pumps.  
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.  
Drive wheel release valves are used to release the  
hydrostatic drive system to allow the machine to be  
pushed without the engine running. Tilt seat up to  
gain access to pumps.  
Do Not add oil to gasoline.  
With a 7/16 wrench, turn both valves one turn  
counterclockwise to release drive system. Turn  
clockwise to reset system. Do Not overtighten. Do  
Not tow machine.  
Do Not overfill fuel tank. Never fill the fuel tank so  
that the fuel level rises above a level that is 1/2 inch  
(13 mm) below the bottom of the filler neck to allow  
for fuel expansion and prevent fuel spillage.  
Tracking Adjustment Knob  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Located under the seat on the left pump control link.  
Rotating this knob allows fine tuning adjustments so  
that the machine tracks straight with the drive levers  
in the full forward position.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Run unit at 3/4 speed for at least 5 minutes to  
bring hydraulic oil up to operating temperature.  
Stop machine and wait for all moving parts to stop.  
Engage park brake. Tilt seat forward to gain access  
to the tracking knob. Rotate the knob towards the  
right to steer right and rotate towards the left to  
steer left. Adjust in 1/8 turn increments until the  
machine tracks straight. Check that the machine  
does not creep when in neutral with the park brakes  
disengaged.  
Operating Instructions  
Open the Fuel Shut-Off Valve  
The fuel shut-off valve is located on the right side of  
unit in fuel line next to the fuel filter. Raise the hopper  
to access. Rotate the valve 1/4 counterclockwise to  
turn on fuel.  
Important: Do Not rotate the knob too far, as  
this may cause the machine to creep in neutral.  
Refer to the Motion Control Linkage Adjustment  
section in Maintenance.  
Starting the Engine  
1. Move the speed control lever to the neutral  
position.  
2. Pull up and back on the parking brake lever to  
engage the parking brake.  
PTO Engagement Lever  
3. Push the PTO engagement lever down to the  
“STOP” position.  
Located immediately left of the left console.  
Lever must be moved up to the “ROTATE” position  
to engage the PTO and blower drives. Lever is moved  
down to the “STOP” position to stop the drives.  
Note: It is not necessary for the operator to be  
in the seat to start the engine.  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
Engine Oil Temperature Light and  
Buzzer  
5. On a cold engine, push the choke lever forward  
into the “ON” position.  
Located on the right console.  
On a warm engine, leave the choke in the “OFF”  
position.  
The engine oil temperature light monitors the  
temperature of the engine oil. An illuminated engine  
oil temperature light and intermittent buzzing sound  
signals the engine is overheating.  
6. Turn ignition switch to the “START” position.  
Release the switch as soon as the engine starts.  
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Operation  
Important: Do Not crank the engine  
continuously for more than ten seconds at a  
time. If the engine does not start, allow a 60  
second cool-down period between starting  
attempts. Failure to follow these guidelines  
can burn out the starter motor.  
Disengaging the PTO  
1. Set the throttle to the “MIDWAY” position.  
2. Push PTO lever down to the “STOP” position  
stopping the PTO and blower.  
Stopping the Engine  
1. Bring the unit to a full stop.  
7. If the choke is in the “ON” position, gradually  
return choke to the “OFF” position as the engine  
warms up.  
2. Disengage the PTO.  
3. Move speed control lever to the neutral position.  
4. Engage the parking brake.  
Engaging the PTO  
5. 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.  
6. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
7. 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.  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
DANGER  
An uncovered discharge opening will allow  
objects to be thrown in an operator’s or  
bystander’s direction. Also, contact with the  
blower blades could occur. Thrown objects  
or blade contact can cause serious injury or  
death.  
Driving the Machine  
CAUTION  
Machine can spin very rapidly by positioning  
one lever too much ahead of the other.  
Operator may lose control of the machine,  
which may cause damage to the machine  
or injury.  
Never operate the mower with the hopper  
or hopper door raised, removed, or altered  
unless there is a mulch kit in place and  
working properly.  
• Use caution when making turns.  
The PTO lever engages the PTO and blower. Be sure  
that the hopper is down, the hopper door is securely  
closed, and all persons are clear of the mower deck  
and discharge area before engaging PTO.  
• Slow the machine down before making  
sharp turns.  
Important: To begin movement (forward or  
backward) the operator must be in the seat, the  
brake lever must be disengaged (pushed down)  
before the speed control lever can be moved  
forward or the engine will stop.  
Important: Operator must be in seat before the  
PTO can be engaged.  
1. Set the throttle to the “MIDWAY” position.  
2. Pull the PTO lever upward until locked over  
center.  
Driving Forward  
1. Start the engine.  
3. Place the throttle in the “FAST” position to begin  
mowing.  
2. Release the parking brake.  
3. To move forward in a straight line move the speed  
control lever forward.  
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Operation  
To turn left or right, pull one of the steering levers  
back toward neutral in the direction desired.  
The machine will move faster the farther the  
speed control lever is moved away from neutral.  
4. To stop, pull the speed control lever back to the  
neutral position.  
Driving in Reverse  
1. To move rearward in a straight line applying equal  
pressure pull both steering levers rearward.  
Figure 5  
1. Front removable screen 3. Primary screen  
can be rotated and  
stored for wet condtions  
2. Front removable screen 4. Handles.  
To turn left or right, release pressure on the  
steering lever toward the direction desired.  
2. To stop, release the steering levers to the neutral  
position.  
Transporting  
Emptying Hopper  
1. A full hopper is indicated by a buzzer located  
behind the operator in the hopper. Empty hopper  
when buzzer sounds to prevent clogging of the  
blower or deck.  
Transporting a Unit  
Use a heavy-duty trailer or truck to transport the  
machine. Lock brake and block wheels. Securely  
fasten the machine to the trailer or truck with straps,  
chains, cable, or ropes. Be sure that the trailer or truck  
has all necessary lighting and marking as required by  
law. Secure a trailer with a safety chain.  
2. Disengage PTO, move speed control to neutral,  
set park brake and dismount unit to dump hopper.  
3. Make sure unit is on a dry level surface.  
4. Lift the rear door up and allow it to rest on top  
of hopper.  
CAUTION  
This unit does not have proper turn  
5. Dump hopper by firmly grasping one of the  
hopper handles on either side of the unit and  
lifting the hopper.  
signals, lights, reflective markings, or a  
slow moving vehicle emblem. Driving on a  
street or roadway without such equipment  
is dangerous and can lead to accidents  
causing personal injury. Driving on a street  
or roadway without such equipment may also  
be a violation of State laws and the operator  
may be subject to traffic tickets and/or fines.  
Clearing Hopper Screen  
Screen may be removed by firmly lifting screen  
handles (see Figure 5).  
Pull screen towards the back to remove. Gently tap  
debris from the screen as needed.  
Do Not drive a unit on a public street or  
roadway.  
Excessive build-up on the screen can cause the  
blower to plug.  
Note: In conditions where the screen clogs quickly,  
the front removable screen panel can be turned and  
reinstalled under the primary screen to allow free air  
flow from the hopper.  
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Operation  
WARNING  
Loading a unit on a trailer or truck increases  
the possibility of tip-over. Tip-over could  
cause serious injury or death.  
• Use extreme caution when operating a  
unit on a ramp.  
• Use only a single, full width ramp; Do  
Not use individual ramps for each side  
of the unit.  
• If individual ramps must be used, use  
enough ramps to create an unbroken  
ramp surface wider than the unit.  
• Do Not exceed a 15° angle between ramp  
and ground or between ramp and trailer  
or truck.  
• Avoid sudden acceleration while driving  
unit on a ramp.  
Loading a Unit  
Use extreme caution when loading units on trailers  
or trucks. One full width ramp is required. If it is  
not possible to use one full width ramp, use enough  
individual ramps to simulate a full width continuous  
ramp.  
Ramp should be long enough so that the angles  
between the ramp and the ground and the ramp and  
the trailer or truck do not exceed 15°. A steeper angle  
may cause mower deck components to get caught as  
the unit moves from ramp to trailer or truck. Steeper  
angles may also cause the unit to tip. If loading on or  
near a slope, position the trailer or truck so it is on  
the down side of the slope and the ramp extends up  
the slope. This will minimize the ramp angle. The  
trailer or truck should be as level as possible.  
Important: Do Not attempt to turn the unit  
while on the ramp, you may lose control and  
drive off the side.  
Avoid sudden acceleration when driving on a ramp.  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could  
seriously injure you or other bystanders.  
The engine can become very hot. Touching  
a hot engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine  
area.  
Remove the key from the ignition switch,  
engage parking brake, and pull the wire(s)  
off the spark plug(s) before you do any  
maintenance. Also push the wire(s) aside  
so it does not accidentally contact the spark  
plug(s).  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
After the first 100 hours  
After the first 250 hours  
• Check the wheel hub locknuts torque specification.  
• Check the wheel lug nut torque specification.  
• Change the hydraulic filter.  
• Check the engine oil level.  
• Check the safety interlock system.  
• Check for loose hardware.  
Before each use or daily  
• Remove accumulated debris from engine (see Cleaning section.)  
• Clean the grass and debris build-up from the machine.  
• Check the hydraulic oil level.  
• Check the tire pressures.  
• Check the condition of the belts.  
Every 40 hours  
Every 50 hours  
• Service the air cleaner. (May need more often under severe conditions. See the Engine  
Owner’s Manual for additional information.)  
• Remove engine shrouds and clean cooling fins (see Cleaning section.)  
• Change the engine oil. (May need more often under severe conditions.)  
Every 80 hours  
Every 100 hours  
• Lubricate the brake handle pivot.  
• Lubricate the brake rod bushings.  
• Lubricate the steering linkage rod ends.  
• Lubricate hopper actuator  
Every 160 hours  
Every 500 hours  
• Check the spark plugs.  
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)  
• Check the wheel hub locknuts torque specification.  
• Check the wheel lug nut torque specification.  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Check the battery charge.  
Monthly  
Yearly  
• Lubricate grease fittings.  
• Lubricate the caster wheel hubs.  
Periodic Maintenance  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
Check Engine Oil Level  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
2. Check with engine cold.  
3. Raise hopper.  
4. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Remove the dipstick  
and read the oil level.  
5. 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.  
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.  
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).  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
Check Battery Charge  
Service Interval: Monthly  
1 Hour  
16 volts/7  
amps  
12.0–12.2  
11.7–12.0  
25–50%  
0–25%  
2 Hours  
3 Hours  
14.4 volts/4  
amps  
WARNING  
CALIFORNIA  
Proposition 65 Warning  
14.4 volts/4  
amps  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
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.  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
performance and service life. To preserve optimum  
battery performance and life, recharge batteries in  
storage when the open circuit voltage drops to 12.4  
volts.  
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Maintenance  
Check Safety Interlock  
System  
Service Air Cleaner  
Service Interval: Every 50 hours—Service  
the air cleaner. (May  
Service Interval: Before each use or daily  
need more often under  
severe conditions. See  
the Engine Owner’s  
Note: To prevent engine cut-outs on rough terrain  
the seat kill switch has a 1/2 second delay.  
Manual for additional  
information.)  
1. Check starting circuit. Starter should crank with,  
parking brake engaged, PTO disengaged and  
speed control lever in the neutral position. The  
operator does not need to be in the seat to start  
the engine.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Tilt hopper up to gain access to the air cleaner.  
Try to start with operator in seat, parking  
brake disengaged, PTO disengaged and speed  
control lever in the neutral position - starter  
must not crank.  
3. Loosen retaining clips and remove air cleaner  
compartment cover.  
4. Remove paper element. Check the condition  
of the paper element. Replace if dirty, bent or  
damaged.  
Try to start with operator in seat, parking brake  
engaged, PTO engaged and speed control lever  
in the neutral position - starter must not crank.  
5. Check the condition of the inner element. Replace  
whenever it appears dirty, typically every other  
time the paper element is replaced. Clean the base  
around the inner element before removing, so  
dirt does not get into the engine.  
Try to start with operator in seat, parking brake  
engaged, PTO disengaged, and the speed  
control lever forward (out of neutral), starter  
must not crank.  
6. Do Not wash or use pressurized air to clean  
2. Check the kill circuits. Run engine at one-third  
throttle, disengage parking brake and raise off  
of seat (but do not get off of machine) engine  
must initiate shutdown after approximately 1/2  
second has elapsed (seat has time delay kill switch  
to prevent cut-outs on rough terrain).  
paper element or inner element.  
7. Reinstall elements. Position the cover so that the  
rubber dust ejector is pointing downward and  
secure with retaining clips.  
Change Engine Oil  
Service Interval: After the first 5 hours  
Run engine at one-third throttle, engage PTO  
and raise offof seat (but do not get off of  
machine) engine must initiate shutdown after  
1/2 second has elapsed.  
Every 100 hours (May  
need more often under  
severe conditions.)  
Note: If machine does not pass any of these tests,  
do not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
2. Drain oil while engine is warm from operation.  
3. Tilt hopper up to gain access to the engine area.  
4. The oil drain valve is located on right hand side  
of engine at the back of the unit. Remove two  
nuts near right hand drive tire and swing out the  
fuel tank. Install oil drain hose, supplied in the  
literature pack, onto oil drain valve. Place pan  
under machine to catch oil. Open valve to allow  
oil to drain and then close valve  
Check for Loose Hardware  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
5. Replace the oil filter every other oil change. Clean  
around oil filter and unscrew filter to remove.  
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Maintenance  
Before reinstalling new filter, apply a thin coating  
of oil on the surface of the rubber seal. Turn  
filter clockwise until rubber seal contacts the filter  
adapter then tighten filter an additional 1/2 to  
3/4 turn.  
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. Do Not  
overfill.  
6. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
7. Remove drain hose, close fuel tank, and lower  
hopper.  
8. Use oil recommended in engine owner’s manual.  
Do Not overfill. Start the engine and check for  
leaks.  
Check Tire Pressures  
Service Interval: Every 40 hours  
9. Wipe up any spilled oil from engine deck  
mounting surfaces.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Check tire pressure in drive tires.  
Check Hydraulic Oil Level  
3. Inflate drive tires to 15 psi (103 kPa).  
Service Interval: Every 40 hours  
4. The rear caster tire is semi-pneumatic and does  
not need to be inflated.  
WARNING  
Note: Do Not add any type of tire liner or foam  
fill material to the tires. Excessive loads created by  
foam filled tires may cause failures to the hydro drive  
system, frame, and other components. Foam filling  
tires will void the warranty.  
Oil spilled or vented from an overfilled  
hydraulic reservoir onto the PTO brake band  
will cause a longer stopping time for the deck  
and blower rotating components. The deck  
and blower rotating components can cause  
serious injury.  
Check Condition Of Belts  
Service Interval: Every 40 hours  
• Wait for all moving parts to come to a  
complete stop before servicing.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
• Do Not overfill the hydraulic reservoir.  
Carefully fill only to the recommended  
level.  
2. Tilt hopper up and check pump and PTO drive  
belts for wear, cracking, or contamination.  
• Replace the brake band if it becomes  
contaminated with oil.  
3. Belts are spring tensioned and no adjustment is  
necessary unless belts are replaced. See PTO  
Belt Replacement and Pump Drive Belt  
Replacement sections for belt replacement.  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
2. Tilt hopper up.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
3. Clean area around hydraulic reservoir cap and  
remove cap. Oil level should be to the top of the  
baffle inside the tank. If not, add oil. Use only  
Exmark Premium Hydro oil. Replace hydraulic  
reservoir cap and tighten until snug. Do Not  
overtighten. Do Not overfill.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate fittings with one to two pumps of  
NGLI grade #2 multi-purpose gun grease.  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
temperature of the oil. The “HOT” level shows  
Refer to the Lubrication Chart for fitting locations  
and lubrication schedule.  
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Maintenance  
Lubrication Chart  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Fitting  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
Locations  
1. Caster  
Pivot  
*0  
3
1
1
1
*Yearly  
Yearly  
Yearly  
*Yearly  
1
1
2. PTO  
Idler  
3. Pump  
Idler  
4. Rear  
*0  
Caster Hub  
Figure 6  
* See step 3 for special lubrication instructions on  
the front and rear caster pivots and the Lubricate  
Rear Caster Wheel Hubs section for special  
lubrication instructions on the rear caster wheel  
hubs.  
1. Seal guard  
2. Spacer nut with wrench  
flats  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
4. Remove one of the spacer nuts from the axle  
assembly in the caster wheel. Note that thread  
locking adhesive has been applied to lock the  
spacer nuts to the axle. Remove the axle (with  
the other spacer nut still assembled to it) from  
the wheel assembly.  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
7. Insert one bearing, one new seal into the wheel.  
Note: Seals (Exmark PN 103-0063) must be  
replaced.  
8. If the axle assembly has had both spacer nuts  
removed (or broken loose), apply a thread locking  
adhesive to one spacer nut and thread onto the  
axle with the wrench flats facing outward. Do  
Not thread spacer nut all of the way onto the end  
of the axle. Leave approximately 1/8 inch (3 mm)  
from the outer surface of the spacer nut to the  
end of the axle inside the nut.  
Deck shown for reference only. See attachment  
manual for lubrication schedule.  
3. Lubricate caster pivots once a year. Remove hex  
plug and cap. Thread grease zerk in hole and  
pump with grease until it oozes out around top  
bearing. Remove grease zerk and thread plug back  
in. Place cap back on.  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
Lubricate Rear Caster Wheel  
Hubs  
10. With the open end of the wheel facing up, fill  
the area inside the wheel around the axle full of  
NGLI grade #1 multi-purpose grease.  
Service Interval: Yearly  
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Maintenance  
11. Insert the second bearing and new seal into the  
wheel.  
Lubricate Brake Rod  
Bushings  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,  
then re-torque to 20-25 in-lb (2-3 N-m). Make  
sure axle does not extend beyond either nut.  
2. Unhook seat latch and tilt seat up.  
3. Lubricate bronze bushings on each end of brake  
rod shaft with a spray type lubricant or a light oil  
(bushings are located to the inside of the flange  
bearings).  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall caster bolt  
and tighten nut fully.  
Important: To prevent seal and bearing damage,  
check the bearing adjustment often. Spin the  
caster tire. The tire should not spin freely  
(more than 1 or 2 revolutions) or have any side  
play. If the wheel spins freely, adjust torque on  
spacer nut until there is a slight amount of drag.  
Reapply thread locking adhesive.  
Lubricate Steering Linkage  
Rod Ends  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Unhook seat latch and tilt seat up.  
3. Lubricate each end of both steering linkage rods  
with a spray lubricant or a light oil.  
Lubricate Brake Handle Pivot  
Service Interval: Every 160 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Lubricate Hopper Actuator  
Service Interval: Every 160 hours  
2. Lubricate bronze bushings on brake handle  
pivot with a spray type lubricant or light oil (see  
Figure 7).  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Raise hopper and locate actuator on right hand  
side of mainframe.  
3. Lubricate switch actuator rod with a spray  
lubricant or a light oil.  
Check Spark Plugs  
Service Interval: Every 160 hours  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner’s  
Manual.  
Change Fuel Filter  
Service Interval: As required  
Figure 7  
A fuel filter is installed between the fuel tank and the  
engine. Replace when necessary.  
Left Side of Unit Shown  
1. Brake Handle Pivot  
2. PTO Handle Pivot  
3. Spring Arm Pivot  
4. Toggle Pivot  
Replacement Filters  
Kohler  
Kohler P/N 2405010  
26  
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Maintenance  
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.  
Change Hydraulic System  
Filter  
Service Interval: After the first 250 hours  
Every 500 hours/Yearly  
(whichever comes  
first) thereafter  
(Every 250 hours/Yearly if  
using Mobil 1 15W50)  
Note: Use only Exmark Part No. 109-0071 for  
Summer use above 32°F (0°C) or P/N 1-523541  
for Winter use below 32°F (0°C). (Refer to the  
Hydrostatic Ground Drive System section in  
Specifications for filter specifications.)  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Carefully clean area around filter. It is important  
that no dirt or contamination enter hydraulic  
system.  
3. Unscrew filter to remove and allow oil to drain  
from reservoir.  
Important: Before reinstalling new filter, fill  
it with Exmark Premium Hydro oil and apply  
a thin coat of oil on the surface of the rubber  
seal.  
Turn filter clockwise until rubber seal contacts the  
filter adapter, then tighten the filter an additional  
2/3 to 3/4 turn.  
4. Fill reservoir as stated in Check Hydraulic Oil  
Level section.  
Exmark Premium Hydro Oil is recommended.  
Refer to the chart for an acceptable alternative:  
Hydro Oil  
Change Interval  
500 Hours  
Exmark Premium Hydro  
Oil (Preferred)  
250 Hours  
Mobil 1 15W50  
5. Raise the rear of machine up and support with  
jack stands (or equivalent support) just high  
enough to allow drive wheels to turn freely.  
6. Start engine and move throttle control ahead to  
full throttle position. Move the speed control  
levers to the full speed and run for several  
minutes. Shut down machine and recheck oil  
level.  
27  
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Maintenance  
Check Wheel Hub Locknuts  
Service Interval: After the first 100 hours  
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.  
Every 500 hours thereafter  
Torque to 210–250 ft-lb (285–339 N-m).  
PTO Drive Belt Tension  
Check Wheel Lug Nuts  
Self-tensioning - No adjustment necessary.  
Service Interval: After the first 100 hours  
Every 500 hours thereafter  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
Torque to 90–95 ft-lb (122–129 N-m) cross pattern.  
Fuel Tank — Mounting  
Hardware Specifications  
Service Interval: As required  
PTO Belt Replacement  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. With engine “off ”, engage PTO lever, then  
remove the hairpin and clevis pin at the bottom  
of the PTO brake band.  
When installing the nuts on the fuel tank studs, fully  
tighten the nyloc nut and back off 1/2 turn. This  
allows for normal fuel tank expansion and contraction  
with changes in temperature and fuel levels.  
3. Rotate the brake band upwards out of the way of  
the belts keeping clear of the belt drive.  
4. Disengage PTO lever.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
5. Loosen belt guides A” and “B” (See Figure 8).  
6. Remove current belts  
7. Route new belts onto sheaves as shown in the  
decal located on the back of the left drive shield  
(see Figure 8).  
• Pump drive sheave set screws.  
• Square head setscrews on Hydro pump control  
arms.  
• Sheave retaining bolt in the end of engine  
crankshaft, blower shaft and jackshaft.  
• Caster wheel spacer nuts.  
• Fuel tank bulkhead fitting nuts.  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
Figure 8  
1. Idler  
2. Belt Guide “B”  
3. PTO Belt  
5. Engine  
6. Belt Guide “A”  
7. Blower  
Fuel tank studs, where studs are inserted into tank.  
4. Jackshaft  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
8. Engage the PTO lever  
9. Rotate brake band back down into original  
position  
28  
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Maintenance  
10. Re-install clevis pin and hairpin to secure brake  
band.  
11. Engage the PTO lever.  
12. Loosen the jam nuts and adjust linkage until the  
top of the idler arm is aligned with the bottom of  
notch on tension arm as shown in Figure 9.  
Figure 10  
4. Pump  
1. Pump Drive Belt  
2. Pump  
5. Idler  
3. Idler  
6. Engine  
5. Reinstall PTO Belts as stated in the PTO Belt  
Replacement section  
Belt Guide Adjustment  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Figure 9  
1. Tension Arm  
2. Loosen jam nuts  
2. Engage PTO lever.  
3. When PTO is engaged, align top of idler arm with bottom  
of notch on tension arm, as shown.  
4. Idler Arm  
3. Adjust belt guides as shown in Figure 11.  
13. Tighten jam nuts and disengage PTO lever.  
Re-engage PTO lever and check alignment.  
14. Check and adjust belt guides as stated in Belt  
Guide Adjustment section.  
Pump Drive Belt  
Replacement  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Figure 11  
1. 1/8 inch (3 mm)  
4. Rotate wireform guide to  
center belts in guide.  
2. Remove PTO Belts. See PTO Belt Replacement  
2. 7/16 inch (11 mm)  
3. 1/8 inch (3 mm)  
Clearance  
5. 1/4 inch (6 mm)  
6. 5/16 inch (8 mm)  
section for removal instructions.  
3. Pull spring idler or remove spring to relieve pump  
drive belt tension. Remove old belt.  
4. Route new belt onto sheaves as shown in the  
decal located on the back of the left drive shield  
(see Figure 10).  
29  
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Maintenance  
3. The brakes on both sides can be simultaneously  
adjusted by lengthening or shortening the linkage  
shown in Figure 14.  
Adjust Safety Switch  
Adjust all safety switches so plunger extends 3/16  
inch to 1/4 inch (4.8 mm-6.4 mm) from switch body  
when plunger is compressed (see Figure 12).  
Figure 12  
1. 3/16 inch to 1/4 inch (4.8 mm-6.4 mm)  
Figure 14  
Brake Adjustment  
Check to make sure each brake is adjusted properly.  
Brake Adjustment for Both Sides  
(At the same time)  
1. Pull the brake lever up and back to the engaged  
position.  
1. Brake Lever in engaged 3. Rotate yoke  
position  
2. Remove clevis pin  
4. Loosen nut here  
2. A gap must exist between the bottom of the brake  
bolt head and the top surface of the brake swivel  
as shown in Figure 13. If a gap does not exist,  
adjust the linkage to a maximum gap of 1/2 inch  
±1/8 inch (1.3 cm ±0.33 cm) as shown.  
4. If individual adjustment is necessary, loosen the  
jam nut on the brake bolt that is against the clevis  
connected to the brake arm on the wheel motor.  
Turn the brake bolt to achieve proper adjustment.  
5. Tighten the jam nut against the clevis.  
6. Repeat for other side of unit.  
7. Engage and disengage the brakes to check for  
proper engagement and disengagement. Readjust  
if necessary. When the brakes are disengaged,  
there should be free play in the brake linkage with  
no dragging in the brakes.  
Adjust Speed Control Lever  
Tension  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Figure 13  
Brake Adjustment for Each Side (Separately)  
2. Tension in speed control lever can be adjusted  
by adjusting the tightness of the lever pivot bolt,  
which is located under the seat near the speed  
control lever (see Figure 15).  
1. Brake Lever in engaged 4. Brake Bolt  
position  
2. Loosen nut here  
3. 1/2 inch ±1/8 inch (1.3  
cm ±0.33 cm)  
5. Brake Swivel  
3. Set the tension high enough that the speed control  
lever position is maintained during operation and  
30  
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Maintenance  
loose enough to be moved comfortably by the  
operator.  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
• Adjust steering levers  
1. Stop engine and wait for all moving parts to  
stop.  
2. Pull the speed control lever completely back to  
the neutral position. The two steering levers  
should be straight up and down (vertical). If  
necessary, adjust steering levers by changing  
the length of the link between the speed  
control lever and the control arm on the end  
of the steering control shaft (see Figure 16).  
Figure 15  
1. Speed Control Lever  
2. Friction Plate  
3. Spring disc washers  
4. Hex locknut  
Speed Control Linkage  
Adjustment  
WARNING  
Engine must be running and drive  
wheels must be turning so motion control  
adjustment can be performed. Contact with  
moving parts or hot surfaces may cause  
personal injury.  
Keep fingers, hands, and clothing clear of  
rotating components and hot surfaces.  
Figure 16  
1. Loosen jam nuts here to 2. Steering levers should  
adjust linkage  
be vertical  
• Set neutral:  
1. Remove the electrical connection from the  
seat safety switch, located directly in front of  
the seat switch assembly.  
2. The neutral adjustment must be made with  
the drive wheels turning. Raise the frame and  
place on jack stands so that drive wheels can  
rotate freely. Temporarily install a jumper wire  
31  
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Maintenance  
across the terminals in the connector of the  
Set forward stop bolt:  
wiring harness.  
1. Remove seat deck (with seat attached) to obtain  
a clear view of the steering control shaft to  
complete this adjustment.  
3. Start the engine.  
4. Run the unit at least 5 minutes with the  
speed control lever at full forward speed to  
bring hydraulic system oil up to operating  
temperature. Return speed control lever to  
neutral (full rear) position.  
2. Push the speed control lever forward to full  
forward speed position.  
3. If either steering control lever surface does not  
contact the stop bar at the full forward speed  
position, adjust the stop bolt until contact occurs  
(see Figure 18). Once contact occurs, turn the  
stop bolt one more full turn to prevent bottoming  
of the hydraulic pump internal stops.  
5. To obtain the neutral position, adjust the  
left and right pump control rod linkages that  
connect the steering control to the pump  
control arms until the wheels stop, or creep  
slightly in reverse.  
6. Adjust the left pump linkage by rotating the  
tracking adjustment knob.  
7. Adjust the right pump linkage by using  
a wrench to turn the double nuts on the  
assembly (see Figure 17)  
Figure 18  
1. Speed control Lever  
forward stop bolt  
2. Contact must be  
maintained between  
these components at full  
forward speed condition  
Steering Control Lever  
Response Adjustment  
1. Stop engine, wait for all moving parts to stop and  
remove key. Engage parking brake.  
Figure 17  
2. Move the speed control lever to the full forward  
position.  
1. Rotate tracking knob on 2. Rotate double nuts on  
left side  
right side  
3. Lift the seat and locate the pump control springs.  
To increase responsiveness, increase spring  
8. Move the steering levers to the reverse  
position. While applying slight pressure to  
the levers, allow the steering levers to return  
to neutral. The wheels must stop turning (or  
slightly creep in reverse).  
tension by hooking the rear spring anchor directly  
to the anchor bolt. To decrease responsiveness,  
hook the rear spring anchor to the anchor tab.  
Note: Be sure both springs maintain the same  
adjustment.  
9. Stop engine and wait for all moving parts to  
stop. Remove jumper wire from wire harness  
connector and plug connector into seat switch.  
10. Lower from jackstands.  
32  
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Maintenance  
inch to 1/16 inch (0.8-1.6 mm). Use a straight  
edge to align all three surfaces (see Figure 20).  
Figure 19  
Figure 20  
1. To increase steering responsiveness hook  
pump control sprints directly on anchor bolt.  
To decrease steering responsiveness hook pump  
control springs on anchor tabs as shown.  
1. Align three pump drive  
pulley surfaces shown  
with this pattern within  
1/32 inch to 1/16 inch  
(0.8-1.6 mm).  
2. Align three PTO drive  
pulley surfaces shown  
with this pattern within  
1/32 inch to 1/16 inch  
(0.8-1.6 mm).  
Tracking Adjustment  
See Motion Control Linkage Adjustment section  
10. Tighten the four engine mounting bolts and four  
jackshaft mounting bolts. Check alignment after  
tightening.  
PTO Drive Pulley Alignment  
PTO drive pulley alignment is necessary for any of  
the following conditions:  
11. Re-install pump belt tension spring.  
12. Swing fuel tank in and re-install tank mounting  
nuts.  
13. Complete the Pump Drive Pulley Alignment  
• The blower has been removed or replaced.  
section.  
• The engine mounting bolts have been loosened  
or the engine has been moved or replaced.  
Pump Drive Pulley Alignment  
Pump drive pulley alignment is necessary for any of  
the following conditions:  
• The jackshaft mounting bolts have been loosened  
or the jackshaft has been moved or replaced.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
• The engine mounting bolts have been loosened  
or the engine has been moved or replaced.  
2. Move the speed control lever to the neutral  
position.  
• The pump pulleys have been loosened, moved,  
or replaced.  
3. Disengage the PTO lever.  
4. Remove fuel tank mounting nuts and swing out  
fuel tank.  
• The PTO pulley alignment has been performed  
(see PTO Drive Pulley Alignment section).  
5. Verify that the blower is installed and secured  
tightly.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
6. Loosen the 4 engine mounting bolts.  
7. Unhook the pump belt tension spring.  
8. Loosen the 4 jackshaft mounting bolts.  
2. Loosen set screws on both pump pulleys.  
3. Using a straight edge, align each pump pulley with  
the engine pulley by sliding along the pump shaft  
(see Figure 20).  
9. Measuring from the blower pulley as a baseline,  
move the engine and jackshaft until the rear  
surface of all 3 pulleys are aligned within 1/32  
4. Re-tighten pulley set screws and recheck  
alignment.  
33  
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Maintenance  
Rear Caster Pivot Bearings  
Pre-Load Adjustment  
Remove dust cap from caster and tighten nyloc  
nut until washers are flat. Back off 1/4 of a turn  
to properly set the pre-load on the bearings. If  
disassembled, make sure the spring disc washers are  
reinstalled as shown in Figure 21.  
Figure 22  
2. Place a piece of 3/8 inch  
1. Loosen door hinge  
nuts-three per side  
(9.5 mm) rubber on this  
surface  
PTO Brake Spring  
Adjustment  
PTO brake spring adjustment is only necessary if the  
blower has been removed or replaced or if the PTO  
drive idler arm has been disassembled.  
Figure 21  
1. Spring disc washers  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Hopper Door Adjustment  
Door Closing:  
2. Locate the brake spring and thread the two jam  
nuts out to the end of the brake spring rod (see  
Figure 23).  
Loosen six door hinge nuts (see Figure 22).  
3. Tighten jam nuts together at end of brake spring  
rod.  
Open door and place a 3/8 inch rubber strip or 3/8  
inch diameter hose between the hopper and hopper  
door (see Figure 22).  
Close door and push tight against hopper.  
Tighten hinge hardware. Open hopper door and  
remove rubber strip.  
Figure 23  
1. Tighten jam nuts here  
2. PTO Brake spring assembly  
34  
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Maintenance  
Important: Do Not use water to clean engine.  
Use low pressure compressed air. See Engine  
Owner’s Manual.  
Cleaning  
Clean Engine and Exhaust  
System Area  
Clean Debris From Machine  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
conditions.)  
2. Clean off any oil, debris, or grass build-up on the  
machine, especially around the fuel tank, around  
engine and exhaust area.  
CAUTION  
Excessive debris around the engine cooling  
air intake and inside of the pump drive  
belt compartment and damaged or missing  
rubber baffles can cause the engine and  
hydraulic system to overheat which can  
create a fire hazard.  
Waste Disposal  
Motor Oil Disposal  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
recycling center or according to your state and local  
regulations.  
Clean all debris from inside of pump drive  
belt compartment daily.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Battery Disposal  
2. Clean all debris from rotating engine air intake  
screen and from around engine shrouding and  
exhaust system area.  
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.  
3. Clean all debris from around engine, drive belts,  
and exhaust system area.  
Remove Engine Shrouds and  
Clean Cooling Fins  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
Service Interval: Every 80 hours  
• Do Not swallow electrolyte.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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.  
2. Remove cooling shroud clean-out covers from  
engine and clean cooling fins. Also clean dust,  
dirt, and oil from external surfaces of engine,  
which can cause improper cooling.  
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.  
3. Make sure cooling shroud clean-out covers are  
reinstalled. Operating the engine without cooling  
shroud clean-out covers will cause engine damage  
due to overheating.  
4. For 27HP Kohler units: Swing out the fuel tank  
and remove debris from around the oil cooler  
positioned at right front corner of engine.  
35  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused  
by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major  
items or any items that call for special timing or adjustments procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.  
Problem  
Starter does not crank.  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
2. Parking brake is not set.  
2. Set the parking brake.  
3. Speed control lever is not in neutral  
position.  
3. Ensure the speed control lever is in the  
neutral position.  
4. Battery does not have a full charge.  
4. Charge the battery.  
5. Electrical connections are corroded, loose 5. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
6. Fuse is blown.  
6. Replace the blown fuse.  
7. Relay or switch is defective.  
7. Contact an Authorized Service Dealer.  
Engine will not start, starts hard, or fails to  
keep running.  
1. Fuel tank is empty.  
1. Fill the fuel tank.  
2. Fuel shutoff valve is closed.  
3. Oil level in the crankcase is low.  
2. Open the fuel shutoff valve.  
3. Add oil to the crankcase.  
4. The throttle and choke are not in the  
correct position.  
4. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions, and the choke is in the “ON”  
position for a cold engine or the “OFF”  
position for a warm engine.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
7. Air cleaner is dirty.  
7. Clean or replace the air cleaner element.  
8. Electrical connections are corroded, loose 8. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
9. Relay or switch is defective.  
10. Faulty spark plug.  
11. Spark plug wire is not connected.  
9. Contact an Authorized Service Dealer.  
10. Clean, adjust or replace spark plug.  
11. 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.  
36  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Engine overheats.  
1. Engine load is excessive.  
1. Reduce the ground speed.  
2. Oil level in the crankcase is low.  
2. Add oil to the crankcase.  
3. Cooling fins and air passages for the  
engine are plugged.  
3. Remove the obstructions from the cooling  
fins and air passages.  
Mower pulls left or right (with levers fully  
forward).  
1. Tracking needs adjustment.  
1. Adjust the tracking.  
2. Tire pressure in drive tires not correct.  
2. Adjust tire pressure in the drive tires.  
3. Reverse indicator and speed control  
linkage need adjustment.  
3. Adjust the reverse indicator and the speed  
control linkage.  
Machine does not drive.  
1. Bypass valve is not closed tight.  
1. Tighten the bypass valve.  
2. Change the belt.  
2. Drive or pump belt is worn, loose or  
broken.  
3. Drive or pump belt is off a pulley.  
4. Broken or missing idler spring.  
5. Hydraulic fluid level is low or too hot.  
3. Change the belt.  
4. Replace the spring.  
5. Add hydraulic fluid to reservoir or let it  
cool down.  
Abnormal vibration.  
1. Engine mounting bolts are loose.  
1. Tighten the engine mounting bolts.  
2. Tighten the appropriate pulley.  
2. Loose engine pulley, idler pulley, or blade  
pulley.  
3. Engine pulley is damaged.  
4. Belt is damaged.  
3. Contact an Authorized Service Dealer.  
4. Install new belt.  
37  
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Schematics  
Schematics  
Electrical Diagram  
. G R E E N D K  
. G R E E N D K  
W H I T E  
D K . G R E E N  
D K G R E E N  
B L  
B L  
C A K B L  
C A K B L  
C A K  
C A K  
C A K B L  
C A K B L  
C A K S T R I P E O R A N G E / B L  
D K G R N  
. G R D E K E N  
W O Y E L L  
. B T L L U E  
A T N  
. B T L L U E  
W O N R B  
. G R E E N D K  
Y A G R  
. B T L L U E  
W O N R B  
. G R E E N D K  
. G R E E N D K  
. B T L L U E  
. B T L L U E  
. B T L L U E  
C A K B L  
A T N  
C A K B L  
P I N K  
C A K B L  
Y A G R  
C A K B L  
O R A N G E  
O R A N G E  
O R A N G E  
O R A N G E  
P I N K  
W O N R B  
. B T L L U E  
P I N K  
P I N K  
O R A N G E  
O R A N G E  
. B T L L U E  
C A K B L  
P U R P L E  
C A K B L  
G006851  
38  
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Schematics  
Electrical Logic Schematic  
. G R E E N D K  
. G R E E N D K  
. G R E E N D K  
. G R E E N D K  
W H I T E  
C A K B L  
C A K B L  
. G R E E N D K  
C A K  
B L  
C A K  
B L  
C A K B L  
C A K B L  
. G R E E N D K  
. G R D E K E N  
. G R D E K E N  
A T N  
C A K S T R I P E O R A N G E / B L  
W O Y E L L  
. B T L L U E  
. B T L L U E  
. G R E E N D K  
. B T L L U E  
Y A G R  
. G R D E K E N  
. G R D E K E N  
C A K B L  
. B T L L U E  
. B T L L U E  
. B T L L U E  
W O N R  
B
C A K  
C A K  
B L  
B L  
A T N  
Y A G R  
. B T L L U E  
C A K B L  
O R A N G E  
P I N K  
P I N K  
O R A N G E  
P I N K  
C A K B L  
R E D  
P I N K  
O R A N G E  
O R A N G E  
G006949  
39  
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Schematics  
Hydraulic Diagram  
BYPASS VALVE  
BYPASS VALVE  
HIGH PRESSURE  
REVERSE  
HIGH PRESSURE  
FORWARD  
HIGH PRESSURE  
FORWARD  
HIGH PRESSURE  
REVERSE  
G006950  
HIGH PRESSURE  
CHARGE PUMP  
CASE DRAIN  
40  
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Exmark Commercial Turf Equipment  
2Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
Conditions and Products Covered  
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty  
Company, pursuant to an agreement between them, jointly  
warrant on the terms and conditions herein, that we will repair,  
replace or adjust any part on these products and found by us  
(in the exercise of our reasonable discretion) to be defective in  
factory materials or workmanship for a period of two years.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
This warranty applies to Exmark commercial turf equipment  
sold in the U.S. or Canada. This warranty may only be  
assigned or transferred to a second (or third) owner by an  
authorized Exmark dealer. The warranty period commences  
upon the date of the original retail purchase.  
Owner’s Responsibilities  
The Exmark turf equipment, including any defective part,  
must be returned to an authorized Exmark service dealer  
within the warranty period. This warranty extends only to turf  
equipment operated under normal conditions. You must read  
the operator’s manual. You must also properly service and  
maintain your Exmark product as described in the operator’s  
manual. Such routine maintenance, whether performed by a  
dealer or by you, is at your expense.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
2 years*  
• Engine  
* The Engine warranty is covered by the engine manufacturer.  
Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair or replacement of  
defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall be liable for any  
incidental or consequential loss or damage.  
This warranty only includes the cost of parts and labor.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
Such damages include but are not limited to:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charges relating to repairs or  
replacements outside of normal business hours at the place  
of business of the authorized Exmark Service Dealer.  
• Rental of like or similar replacement equipment during the  
period of any warranty, repair or replacement work.  
• Any telephone or telegram charges or travel charges.  
• Loss or damage to person or property other than that  
covered by the terms of this warranty.  
• Any damage or deterioration due to normal use, wear and  
tear, or exposure.  
• Cost of regular maintenance service or parts, such as filters,  
fuel, lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or  
required replacement or repair due to normal wear,  
accidents, or lack of proper maintenance.  
• Any repairs necessary due to use of parts, accessories or  
supplies, including gasoline, oil or lubricants, incompatible  
with the turf equipment or other than as recommended in  
the operator's manual or other operational instructions  
provided by Exmark.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
There are no other express warranties except for engine and  
special emission system coverage.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
All implied warranties of merchantability (that the  
product is fit for ordinary use) and fitness for use (that the  
product is fit for a particular purpose) are limited to the  
duration of the express warranty.  
Instructions for Obtaining Warranty Service  
The product must be registered with original proof of purchase  
by an Exmark Service Dealer before obtaining any warranty  
service.  
Some states do not allow exclusions of incidental or  
consequential damages, or limitations on how long an  
implied warranty lasts, so the above exclusions and  
limitations may not apply to you.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G4500-425  
41  
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42  
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43  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
© 2009 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-367 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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