Exmark Lawn Mower TT23KAEP User Guide

TURF TRACER®  
TT23KAEP MODEL ONLY  
For Serial Nos.  
790,000 & Higher  
Part No. 4500-382 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.  
Figure 1  
1. Model and serial number location  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Model No.  
Serial No.  
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.  
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..................................... 31  
Contents  
Introduction ........................................................... 3  
Torque Requirements .................................... 14  
Periodic Maintenance ....................................... 22  
4
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Safety  
• Never let children or untrained people operate  
Safety  
Safety Alert Symbol  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Preparation  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
Figure 2  
1. Safety alert symbol  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
CAUTION  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
This machine produces sound levels in  
excess of 85 dBA at the operator’s ear and  
can cause hearing loss through extended  
periods of exposure.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
Wear hearing protection when operating this  
machine.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
Safe Operating Practices  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
5
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Safety  
DANGER  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
In certain conditions during fueling, static  
electricity can be released causing a spark  
which can ignite gasoline vapors. A fire or  
explosion from gasoline can burn you and  
others and cause property damage.  
A fire or explosion from gasoline can burn  
you, others, and cause property damage.  
• Fill the fuel tank outdoors in an open  
area, when the engine is cold. Wipe up  
any gasoline that spills.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• Do Not fill gasoline containers inside a  
vehicle or on a truck or trailer bed because  
interior carpets or plastic truck bed liners  
may insulate the container and slow the  
loss of any static charge.  
• Do Not fill the fuel tank completely  
full. Add gasoline to the fuel tank until  
the level is 1/4 to 1/2 inch (6–13 mm)  
below the bottom of the filler neck. This  
empty space in the tank allows gasoline  
to expand.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Never smoke when handling gasoline,  
and stay away from an open flame or  
where gasoline fumes may be ignited by  
spark.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Add fuel before starting the engine.  
Never remove the cap of the fuel tank or  
add fuel when engine is running or when  
the engine is hot.  
WARNING  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
6
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Safety  
– 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
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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
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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
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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.  
1–303102  
103-2076  
1-303517  
103-5354  
1-403143  
1-413214  
1-513747  
10  
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Safety  
103-2432  
103-4935  
116-0404  
11  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 790,000 and Higher  
TT23KAEP  
Systems  
Operator Controls  
Steering Control: Fingertip drive control levers  
provide independent speed control, braking and  
neutral to each drive wheel for moving forward or  
reverse, stopping, and power turning.  
Engine  
• Engine Specifications: See your Engine Owner’s  
Manual  
• RPM: Full Speed: 3600 (No Load)  
Transmission  
• Two Hydro Gear variable displacement piston  
pumps independently coupled to two high  
efficiency Parker wheel drive motors.  
Fuel System  
• Capacity: 5.0 gal. (18.9 L)  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher.  
• Hydraulic Oil: Use Exmark Premium Hydro Oil.  
• Hydraulic Oil Capacity: 2.4 qt. (2.2 L)  
• Fuel Filter: Replaceable In-line  
• Hydraulic Filter is replaceable cartridge type.  
• Fuel Shut-Off Valve: 1/4 turn increments  
P/N 109–4180: 25 microns, 10 psi bypass  
(Summer use above 32°F (0°C))  
Electrical System  
P/N 1–523541: 40 microns, 18 psi bypass (Winter  
use below 32°F (0°C))  
• Charging System: Flywheel Alternator  
• Charging Capacity: 15 amps  
• Battery Type: BCI Group U1 235 amps 0°F  
• Battery Voltage: 12 Volt  
• Speeds:  
– 0-6.75 mph (10.9 km/hr) forward.  
– 0-2.25 mph (3.6 km/hr) reverse.  
• Polarity: Negative Ground  
• Drive wheel release valves allow machine to be  
moved when engine is not running.  
• Fuses: Two blade type, 20 amp to charging circuit;  
20 amp to electric clutch  
Wheel Drive System  
Safety Interlock System:  
Drive wheels are direct coupled to Parker wheel drive  
motors with 1 inch (25.4 mm) tapered shaft.  
• Operator must have OPC (Operator Presence  
Control) levers held in contact with handle  
grips, speed control lever in neutral, and PTO  
disengaged to start engine. Release of OPC levers  
will cause the engine to stop if speed control lever  
is not in neutral and/or PTO is engaged.  
• Park brake must be engaged to move speed  
control out of neutral or engine will kill.  
12  
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Specifications  
Tires & Wheels  
Dimensions  
Drive  
Front Caster  
Overall Width:  
Pneumatic  
(Air-Filled)  
Semi-Pneumatic  
52 inch Deck  
53.4 inches  
(135.6 cm)  
60 inch Deck  
Quantity  
Tread  
2
2
Deflector Up  
61.4 inches  
(156.0 cm)  
Turf Master  
18 x 8.50-8  
4
Smooth  
11 x 4.00-5  
Size  
Deflector Down 64.8 inches  
(164.6 cm)  
73.0 inches  
(185.4 cm)  
Ply Rating  
Pressure  
14 psi (96 kPa)  
Overall Length:  
52 inch Deck  
60 inch Deck  
Cutting Deck  
83.4 inches (211.8 cm)  
83.4 inches (211.8 cm)  
• Model Numbers:  
– FMD524  
Overall Height:  
– FMD604  
• Cutting Width:  
– 52 inch (132.1 cm)  
– 60 inch (152.4 cm)  
• Discharge: Side  
• Blade Size: (3 ea.)  
52 inch Deck  
60 inch Deck  
45 inches (114.3 cm)  
45 inches (114.3 cm)  
Tread Width: (Outside to Outside of  
Tires, Widthwise)  
– 52 inch Deck: 18.00 inches (45.7 cm)  
– 60 inch Deck: 20.50 inches (52.1 cm)  
52 inch Deck  
60 inch Deck  
45.8 inches (116.3 cm)  
45.8 inches (116.3 cm)  
• Blade Spindles: Solid steel spindles with 1 3/4  
inch (4.45 cm) I.D. bearings.  
Wheel Base: (Center of Caster Tire to  
Center of Drive Tire)  
• Deck Drive:  
– Electric clutch mounted on engine shaft.  
52 inch Deck  
60 inch Deck  
– Blades driven by two belts (w/self-tensioning  
idlers).  
43.3 inches (110.0 cm)  
43.3 inches (110.0 cm)  
• Deck:  
Curb Weight:  
Full floating deck is attached to out-front support  
frame, removable for service. Six anti-scalp rollers  
provide maximum turf protection. Deck design  
allows for bagging, mulching or side discharge.  
52 inch Deck  
60 inch Deck  
720 lb (327 kg)  
760 lb (345 kg)  
• Deck Depth:  
– 52 inch Deck: 5.5 inches (14.0 cm)  
– 60 inch Deck: 5.5 inches (14.0 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  
13  
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Product Overview  
Torque Requirements  
Product Overview  
Bolt Location  
Torque  
Cutter Housing Spindle  
Nut  
140–145 ft-lb (190–197  
N-m)  
Blade Mounting Bolt  
55-60 ft-lb (75-81 N-m)  
(lubricate with anti-seize)  
30-35 ft-lb (41-47 N-m)  
Engine Deck/Mower  
Deck Support Mount  
Bolts  
Type 1 Hardware  
–Anti-Scalp Roller  
Whizlock Nut See Figure 8  
40-45 ft-lb (54-61 N-m)  
30-35 ft-lb (41-47 N-m)  
Type 2  
Hardware–Anti-Scalp  
Roller Nyloc Nut See  
Figure 8  
Type 2 & 3 Hardware  
–Anti-Scalp Roller Hex  
Capscrew See Figure 8  
50-55 ft-lb (68-75 N-m)  
30-35 ft-lb (41-47 N-m)  
Figure 3  
1. Controls  
2. Fuel Cap  
3. Park Brake Lever  
4. Height-of-Cut Pins  
Type 3  
Hardware–Anti-Scalp  
Roller Flanged Nyloc Nut  
See Figure 8  
Type 4  
30-35 ft-lb (41-47 N-m)  
30-35 ft-lb (41-47 N-m)  
Hardware–Anti-Scalp  
Roller Whizlock Nut See  
Figure 8  
Type 4  
Hardware–Anti-Scalp  
Roller Nyloc Nut See  
Figure 8  
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)  
Clutch Retaining Bolt  
55-60 ft-lb (75-81 N-m)  
(secured with threadlocker)  
Wheel Motor Mounting  
Bolts  
30-35 ft-lb (41-47 N-m)  
14  
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Operation  
lever is moved out of the neutral position and the  
neutral lock latches are moved into the drive position,  
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  
machine from the normal operating position.  
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.  
Controls  
Operator Presence Control (OPC)  
Levers  
Located on the upper handle assembly directly above  
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.  
Neutral Lock Latches  
Located directly above the drive levers.  
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, see Figure 4.  
Choke Control  
Located on the control console right hand side.  
Choke is used to aid in starting a cold engine. The  
choke control is pulled out to be in the “ON” position  
and pushed in to be in the “OFF” position. Do Not  
run a warm engine with choke in the “ON” position.  
Throttle Control  
Located on the control console’s right side.  
The throttle is used to control engine speed. Moving  
the throttle control forward will increase engine speed  
and moving it to the rear will decrease engine speed.  
Figure 4  
1. Latch is in the drive  
position  
5. Neutral-hold in this  
position  
Speed Control Lever  
2. Rotate back for neutral  
lock position  
6. Forward-release drive  
lever  
Located in middle of control console.  
3. Neutral  
7. Reverse-squeeze drive  
lever  
The speed control lever controls the maximum  
forward speed and is infinitely variable from neutral  
0–6.75 mph (10.9 km/hr).  
4. Full speed forward  
Park brake must be disengaged to move speed control  
out of neutral or engine will kill.  
Drive Levers  
Located on each side of the upper handle assembly  
directly below the handle grips.  
Brake Lever  
These levers individually control the speed and  
direction of each drive wheel. When the speed control  
Located on the left side of the unit above the  
hydraulic tank.  
15  
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Operation  
The brake lever engages the park brake on the drive  
wheels.  
Drive Wheel Release Valves  
Located on the left rear corner of the hydrostatic  
pumps.  
Pull the lever up and rearward to engage the brake.  
Push the lever forward and down to disengage the  
brake.  
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.  
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.  
With a 5/8 wrench, turn both valves one turn  
counterclockwise to release the drive system.  
Turn clockwise to reset the drive system. Do Not  
overtighten.  
Park brake must be disengaged to move speed control  
out of neutral or engine will kill.  
Tracking Adjustment Knob  
Ignition Switch  
Located on the right-hand side of the rear of the fuel  
tank support.  
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.  
The knob can be adjusted so that machine will  
“track” straight ahead with the drive levers released.  
PTO Engagement Switch  
Switch is located on left side of control console.  
The switch must be pulled out to the “Rotate”  
position to engage the blades. The switch is pushed  
in to the “Stop” position to stop the blades. Operator  
must have operator presence control levers depressed  
when PTO is engaged or engine will stop.  
Hour Meter  
Located on the left hand side of console just above  
the PTO switch.  
The hour meter is connected to a pressure switch  
installed in the engine block and it records the  
number of hours that the engine has run. If ignition  
switch is left on without engine running, hour meter  
will not run.  
Pre-Start  
Fill fuel tanks. For best results use only clean, fresh  
regular grade unleaded gasoline with an octane rating  
of 87 or higher. Regular grade leaded gasoline may  
also be used; however, combustion chamber and  
cylinder head will require more frequent service. See  
Engine Owner’s Manual.  
Note: This switch is not a low oil sensor and will not  
alert the operator if the engine oil is low.  
Do Not add oil to gasoline.  
Fuel Shut-Off Valve  
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.  
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  
transportation to and from the job sites, and when  
the machine will not be used for a few days.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Rotate valve 1/4 turn clockwise to shut fuel off.  
Rotate valve 1/4 turn counterclockwise to turn fuel  
on.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
16  
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Operation  
Operating Instructions  
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.  
Open the Fuel Shut-Off Valve  
Rotate the valve 1/4 turn counterclockwise to turn  
fuel on.  
Starting the Engine  
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.  
1. On a cold engine, place the throttle midway  
between the “Slow” and “Fast” positions and  
place the choke in the “On” position. On a warm  
engine, place the throttle lever midway between  
“Slow” and “Fast” positions and leave the choke  
in the “Off ” position.  
The PTO switch engages the cutting blades. Be sure  
that all persons are clear of mower deck and discharge  
area before engaging the PTO.  
2. Turn ignition switch to “Start” position. Release  
the switch as soon as the engine starts.  
1. Set throttle to “MIDWAY” position.  
3. On a cold engine, gradually return choke to the  
“Off ” position after engine starts and warms up.  
2. Pull the PTO switch outward to the “ROTATE”  
position to engage the blades.  
Important: Do not crank the engine  
continuously for more than ten seconds at  
a time. If the engine does not start, allow a  
60 second starter cool-down period between  
starting attempts. Failure to follow these  
guidelines can burn out the starter motor.  
3. Place the throttle in the “FAST” position to begin  
mowing.  
Disengaging the PTO  
1. Set throttle to “MIDWAY” position.  
2. Push in on the switch to the “STOP” position  
to disengage the blades.  
Note: It is helpful to have the left and right  
neutral lock latches locked in neutral when  
starting the engine. Refer to Neutral Lock  
Latches section in Controls.  
Stopping the Engine  
1. Bring the unit to a full stop.  
2. Lock drive levers in neutral.  
3. Disengage the PTO.  
PTO Engagement  
DANGER  
The rotating blades under the mower deck  
are dangerous. Blade contact can cause  
serious injury or kill you.  
4. Move speed control lever to neutral.  
5. Engage the parking brake.  
6. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
Do Not put hands or feet under the mower  
or mower deck when the blades are engaged.  
7. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
8. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
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.  
17  
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Operation  
Driving the Machine  
reverse position while the opposite drive lever is in  
a forward position at an equal but opposite speed.  
Drive Lever/Neutral Lock Latch Operation  
Note: For smooth operation of this machine,  
avoid quick, jerky movements of the drive levers.  
Move the drive levers smoothly and deliberately.  
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 4. Place thumbs on the upper  
portion of the neutral lock latches and move them to  
the rear. See Figure 4. Release the drive levers.  
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.  
Driving in Reverse  
CAUTION  
To move rearward in a straight line, squeeze drive  
levers into the reverse position.  
If the neutral lock latches are not completely  
engaged the drive levers could unexpectedly  
slip into the forward drive position. If the  
drive levers slip into the drive position the  
unit could lurch forward and cause injury or  
property damage.  
To turn left or right, squeeze the right hand drive lever  
to turn right and the left hand drive lever to turn left.  
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.  
Be sure the pins protruding through the slots  
of each neutral lock latch are completely  
engaged in the rear slot of each latch.  
Adjusting the Cutting Height  
To place the drive levers in the “forward” position,  
firmly hold the drive levers, place thumbs on the  
upper portion of the neutral lock latches and move  
them forward to release the drive levers. Slowly and  
smoothly release the drive levers.  
WARNING  
When the two front support rod hairpins are  
removed from the mower deck, the weight of  
the tractor section may cause the front frame  
of the unit to rise suddenly. If the unit rises  
suddenly, injury may occur.  
Driving Forward  
1. Release the parking brake.  
Securely hold down the front of the unit when  
the front support rod hairpins are removed.  
2. With drive levers locked in “neutral”, shift speed  
control lever to desired forward speed.  
3. Slowly squeeze and hold both drive levers in  
the neutral position and rotate both neutral lock  
latches from the neutral lock position to the  
forward position.  
The cutting height of the mower deck is adjusted  
from 1 1/2 to 4 1/2 inches (3.81 cm to 11.4 cm) in  
1/2 inch increments.  
1. Stop the machine and move the drive levers to the  
neutral locked position.  
2. Disengage the PTO.  
3. Engage the park brake.  
Note: Do Not squeeze both drive levers all the  
way back. This will cause the drive wheels to  
engage in the reverse direction.  
4. To move forward in a straight line, smoothly  
release both drive levers to engage drive wheels.  
4. Stop the engine, remove the key and wait for all  
moving parts to stop.  
To turn left or right, squeeze the right hand drive  
lever to turn right and the left hand drive lever  
to turn left.  
5. Install hairpin clips in the holes for the desired  
cutting height. See Figure 5.  
Important: To maintain correct cutting  
height and rake, check the following for  
proper adjustment.  
To make a “zero turn”, squeeze either the left  
hand or the right hand drive lever back into the  
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Operation  
A. The front and rear hairpins are in the same  
holes with the proper spacers under the hair  
pins. See Figure 5.  
Figure 6  
Left Hand Side Shown  
Figure 5  
1. Deck support pin  
2. Cutting Height  
B. The tire pressures are set as directed in Check  
Tire Pressures in the Maintenance section.  
Adjusting the Anti-Scalp Rollers  
It is recommended to change the anti-scalp roller  
position, when the height of cut has changed.  
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 6.  
1. Stop the machine and move the drive levers to the  
neutral locked position.  
2. Disengage the PTO.  
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.  
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 spring disc  
washer and bolt (see step 7).  
6. Adjust anti-scalp rollers for Normal Operating  
Conditions. Place rollers in one of the positions  
shown in Figure 7. 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 (6.4 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 bolt and mounting  
bracket.  
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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 7  
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. Four types of anti-scalp roller assemblies are  
available. See Figure 8 to determine which  
assembly has been installed on the unit. Torque  
hardware as specified, or loss of roller may result.  
See Figure 8.  
• If necessary, use assistance when loading.  
Be sure the fuel shut-off valve is closed.  
Use a heavy duty trailer to transport the machine.  
Engage neutral lock latches and park brake, then  
block wheels.  
Securely fasten the machine to the trailer with straps,  
chains, cables, or ropes.  
Do Not rely solely on the parking brake to hold the  
machine on the trailer.  
Be sure that the trailer has all necessary lighting and  
marking as required by law and use a safety chain.  
Figure 8  
Front left anti-scalp bracket shown  
1. Type 1 hardware  
2. Type 2 hardware  
3. Type 3 hardware  
4. Type 4 hardware  
5. (Type 1) 3/8–16 x 4 hex screw  
6. (Type 2 & 3) 3/8–24 x 2 hex screw — Torque to 50–55  
ft-lb (68–75 N-m)  
7. (Type 4) 3/8 whizlock nut — Torque to 30–35 ft-lb  
(41– 47 N-m)  
8. Spring disc washer (cone towards bolt head)  
9. (Type 1) 3/8 whizlock nut and heavy flat washer —  
Torque to 40–45 ft-lb (54–61 N-m)  
10. (Type 2) 3/8 nyloc nut and heavy flat washer — Torque  
to 30–35 ft-lb (41–47 N-m)  
11. (Type 3) 3/8 flanged nyloc nut without washer — Torque  
to 30–35 ft-lb (41– 47 N-m)  
12. (Type 4) 3/8 nyloc nut —Torque to 30–35 ft-lb  
(41– 47 N-m).  
20  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could  
seriously injure you or other bystanders.  
The engine can become very hot. Touching  
a hot engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine  
area.  
Remove the key from the ignition switch,  
engage parking brake, and pull the wire(s)  
off the spark plug(s) before you do any  
maintenance. Also push the wire(s) aside  
so it does not accidentally contact the spark  
plug(s).  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
After the first 100 hours  
After the first 250 hours  
• Check the wheel hub slotted nut torque specifications.  
• Change the hydraulic filter.  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check for loose hardware.  
Before each use or daily  
• Clean the grass build-up from under the deck.  
• Check the hydraulic oil level.  
• Check the tire pressures.  
• Check the condition of the belts.  
• Grease the hydro control arm support bushings.  
Every 40 hours  
Every 50 hours  
• Service the air cleaner. (May need more often under severe conditions. See the Engine  
manual for additional information.)  
• Remove engine shrouds and clean cooling fins.  
Every 80 hours  
Every 100 hours  
Every 160 hours  
Every 500 hours  
• Change the engine oil. (May need more often under severe conditions.)  
• Check the spark plugs.  
• Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)  
• Replace the air cleaner elements. (May need more often under severe conditions. See the  
Engine manual for additional information.)  
Every 600 hours  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Check the battery charge.  
Monthly  
• Grease the front caster wheel hubs.  
• Grease front caster pivots.  
• Grease the idler pivots (Mower Deck).  
• Grease the idler pivot (Pump Drive).  
• Lubricate the caster wheel hubs.  
Yearly  
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  
Service Interval: Monthly  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
WARNING  
CALIFORNIA  
Proposition 65 Warning  
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  
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.  
14.4 volts/4  
amps  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
performance and service life. To preserve optimum  
battery performance and life, recharge batteries in  
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Maintenance  
anti-seize preferable. Grease acceptable  
Check Mower Blades  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
substitute. Install blade bolt finger tight. Place  
wrench on the top spindle nut then torque the  
blade bolts to 55-60 ft-lb (75-81 N-m).  
2. Lift deck and secure in raised position as stated  
in the Clean Grass Build-Up Under Deck  
procedure.  
WARNING  
Incorrect installation of the blade or  
components used to retain the blade can  
be dangerous. Failure to use all original  
components and assembled as shown could  
allow a blade or blade component to be  
thrown out from under the deck resulting in  
serious personal injury or death.  
3. Inspect blades and sharpen or replace as required.  
4. Reinstall blades (if they were removed) in the  
following order:  
A. Install bushing through blade with bushing  
flange on bottom (grass) side of blade.  
Always install the original Exmark blades,  
blade bushings, and blade bolts as shown.  
Check Safety Interlock  
System  
Figure 9  
Service Interval: Before each use or daily  
1. Install bushing in blade prior to installing bushing in  
spindle.  
1. Check starting circuit. Starter should crank with:  
Operator Presence Control levers depressed,  
speed control lever in neutral, and PTO  
disengaged.  
B. Install bushing/blade combo into spindle.  
Try to start the engine with OPC levers  
disengaged, speed control lever in neutral and  
PTO disengaged-starter must not crank.  
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. Check OPC circuits. Clear the area. 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.  
Figure 10  
1. Use wrench here for  
blade installation. This  
nut has been torqued to  
90–110 ft-lb (122–149  
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.  
Note: Park brake must be disengaged before the  
speed control lever is moved out of neutral or engine  
will kill.  
C. Apply lubricant to threads of blade bolt as  
needed to prevent seizing. Copper-based  
23  
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Maintenance  
Note: If machine does not pass any of these tests,  
do not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
Change Engine Oil  
Service Interval: After the first 5 hours  
Every 100 hours (May  
need more often under  
severe conditions.)  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
2. Drain oil while engine is warm from operation.  
3. The oil drain hose is located on right hand side  
of engine. Place pan under machine to catch oil.  
Remove plug from end of drain hose. Allow oil  
to drain and replace oil drain plug. Torque plug  
to 20-24 ft-lb.  
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.  
4. Replace the oil filter every other oil change. Clean  
around oil filter and unscrew filter to remove.  
Before reinstalling new filter, apply a thin coating  
of oil on the surface of the rubber seal. Turn  
filter clockwise until rubber seal contacts the filter  
adapter then tighten filter an additional 1/2 to  
3/4 turn.  
Service Air Cleaner  
Service Interval: Every 50 hours—Service  
the air cleaner. (May  
need more often under  
severe conditions. See  
the Engine manual for  
additional information.)  
5. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
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.  
Every 600 hours— Replace  
the air cleaner elements.  
(May need more often  
under severe conditions.  
See the Engine manual for  
additional information.)  
Check Hydraulic Oil Level  
Service Interval: Every 40 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
2. Loosen retaining clips and remove air cleaner  
compartment cover.  
2. Clean area around hydraulic reservoir cap and  
remove cap. Oil level should be to the top of the  
baffle inside the tank. If not, add oil. Use only  
Exmark Premium Hydro oil. Replace hydraulic  
reservoir cap and tighten until snug. Do Not  
overtighten.  
3. Remove paper element. Check the condition  
of the paper element. Replace if dirty, bent or  
damaged.  
4. 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.  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
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.  
5. Do Not wash or use pressurized air to clean  
paper element or inner element.  
6. Reinstall elements. Position the cover so that the  
rubber dust ejector is pointing downward and  
secure with retaining clips.  
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Maintenance  
If the oil is at room temperature (about 75°F  
(24°C)), fill only to the “COLD” level.  
2. Lubricate fittings with one to two pumps of  
NGLI grade #2 multi-purpose gun grease.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
Check Tire Pressures  
Service Interval: Every 40 hours  
Lubrication Chart  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
1. Front  
Caster  
Wheel Hubs  
*0  
*0  
1
2
2
2
*Yearly  
*Yearly  
Yearly  
2. Check tire pressure in drive tires.  
3. Inflate drive tires to 12–14 psi (83–97 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.  
2. Front  
Caster  
Pivots  
3. Idler  
Pivots  
(Mower  
Deck)  
5. For Serial Nos. 599,999 and Lower: Check the  
tire pressure in the pneumatic front caster tires.  
Adjust the tire pressure to 16 psi (110 kPa).  
2
2
1
2
4. Idler  
Pivot (Pump  
Drive)  
Yearly  
Note: Front caster tires have permanent tire  
sealant installed.  
For Serial Nos. 600,000 and Higher:  
Semi-pneumatic caster tires do not need to be  
inflated.  
40 Hours  
5. Hydro  
Control  
Arm  
Support  
Bushings  
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.  
* See step 3 for special lubrication instructions on  
the front caster pivots and the Lubricate Caster  
Wheel Hubs section for special lubrication  
instructions on the front casters wheel hubs.  
Check Condition Of Belts  
Service Interval: Every 40 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove the three mower deck belt shields  
to check mower primary and secondary belt  
condition.  
3. Look under engine deck to check the pump drive  
belt condition.  
Number 4 (Idler Pivot (Pump Drive) Located  
Under Engine Deck  
4. Check all idler arms to be sure they pivot freely.  
3. Lubricate front caster pivots once a year. Remove  
hex plug and cap. Thread grease zerk in hole and  
pump with grease until it oozes out around top  
bearing. Remove grease zerk and thread plug back  
in. Place cap back on.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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Maintenance  
11. Insert the second bearing and new seal into the  
wheel.  
Lubricate Caster Wheel Hubs  
Service Interval: Yearly  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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.  
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.  
Figure 11  
1. Seal guard  
2. Spacer nut with wrench  
flats  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
Remove Engine Shrouds and  
Clean Cooling Fins  
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.  
Service Interval: Every 80 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove cooling shrouds from engine and clean  
cooling fins. Also clean dust, dirt, and oil from  
external surfaces of engine which can cause  
improper cooling.  
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.  
3. Make sure cooling shrouds are properly  
reinstalled. Operating the engine without  
cooling shrouds will cause engine damage due to  
overheating.  
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.  
Check Spark Plugs  
Service Interval: Every 160 hours  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owners  
Manual.  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
Change Fuel Filter  
Service Interval: As required  
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.  
A fuel filter is installed in the fuel line between the  
fuel tank and the engine. Replace when necessary.  
26  
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Maintenance  
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.  
Replacement Filters  
Kawasaki  
Kawasaki P/N  
49019–7001  
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 12) may have lost  
their “prime”. Refer to Hydraulic System Air  
Purge section.  
Change Hydraulic System  
Filter  
Service Interval: After the first 250 hours  
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.  
Every 500 hours/Yearly  
(whichever comes  
first) thereafter  
(Every 250 hours/Yearly if  
using Mobil 1 15W50)  
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).  
Hydraulic System Air Purge  
Service Interval: As required  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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. Carefully clean area around filter. It is important  
that no dirt or contamination enter hydraulic  
system.  
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 12). Air in other parts of  
the hydraulic system will be purged through normal  
operation once the charge pump is “primed”.  
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.  
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. 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.  
27  
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Maintenance  
a steady flow of oil to flow out from under the  
housing. Retighten the capscrews. Do this for  
both pumps.  
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 Engine 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 Engine Oil Level section.  
8. Check hydro drive linkage adjustment as stated in  
Hydro Drive Linkage Adjustment section in  
Adjustments.  
Figure 12  
2. Loosen 1 1/2 turns only  
Wheel Hub - Slotted Nut  
Torque Specification  
1. Charge pump cap  
Service Interval: After the first 100 hours  
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.  
When tightening the slotted nut on the wheel motor  
tapered shaft:  
1. Torque the slotted nut to 100 ft-lb (136 N-m).  
2. Further tighten the nut until the next set of slots  
line up with the cross hole in the shaft.  
2. Check oil level as stated in Check Engine 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.  
3. Replace cotter pin.  
Note: Do Not use anti-seize on wheel hub.  
Fuel Tank — Mounting  
Hardware Specifications  
Service Interval: As required  
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.  
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.  
If either drive wheel still does not rotate continue  
with step 4.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
• Pump drive sheave set screws.  
• Square head setscrews on Hydro pump control  
arms.  
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 12) 1 1/2 turns  
only. Make sure engine is not running. Lift  
the charge pump housing upward and wait for  
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Maintenance  
• Shoulder bolts in ends of speed control crank.  
• OPC lever setscrews.  
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.  
• Electric clutch retaining bolt.  
• Pump drive idler pivot bolt.  
• Thumb latch screw threads on handles.  
• Caster wheel spacer nuts.  
Deck Leveling  
See Adjusting the Cutting Height section in  
• 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:  
Operation.  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
• OPC lever hubs and cross-shaft  
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 Deck Belt Tension  
erratic operation.  
Self-tensioning - No adjustment necessary.  
• Fuel tank studs, where studs are inserted into tank.  
Blade Drive Belt Tension  
Mobil HTS Grease (Or  
Self-tensioning - No adjustment necessary.  
Food-Grade Anti-seize)  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
Brake Adjustment  
1. Shut off engine and wait for all moving parts to  
• Between the cutter housing spindle and bearings.  
stop.  
• Between the cutter housing spindle and sheave.  
2. Disengage the park brake.  
• Under top cutter housing bearing guard.  
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  
Copper-Based Anti-seize  
Copper-based anti-seize is used in the following  
locations:  
the park brake disengaged. Re-install the hairpin.  
On threads of Blade Bolts Serial Nos. 540,000 and  
Higher. See Check Mower Blades section for  
instructions.  
Speed Control Linkage  
and Neutral Safety Switch  
Adjustment  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
2. Move speed control lever (located on console) to  
the full forward position and check orientation of  
tabs on the ends of the speed control crank, see  
Figure 13. These tabs should be pointing straight  
down at the 6 o’clock position or slightly forward.  
Adjust threaded yoke at the bottom of speed  
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Maintenance  
control linkage until tabs are positioned correctly.  
See Figure 13.  
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.  
3. Pull speed control lever back to neutral. Check  
that the neutral safety switch actuating tab has  
depressed the plunger of the switch so that there  
is about 5/16 inch (7.9 mm) between the tab and  
the switch as shown in Figure 13. If necessary,  
move the switch fore and aft.  
6. Make this adjustment on both sides.  
7. After adjustments are made and the wheels stop  
when the drive lever is in the neutral position,  
tighten the nut against the yokes.  
Figure 13  
Viewed from left side of unit  
1. Neutral Safety Switch  
3. 5/16 inch (7.9 mm)  
2. Actuating Tab in neutral  
position  
Neutral Control Linkages  
Adjustment  
1. Raise the rear of the machine up onto jack stands  
high enough to raise the drive wheels off of the  
ground.  
Figure 14  
1. Neutral Control Linkage 5. Adjust here; rotate at  
approximately 1/4 turn  
2. Start the engine and move the throttle ahead to  
the full throttle position. Place the neutral lock  
latches in the “forward” position as shown in  
Figure 4 and move the speed control lever to the  
“mid-speed” position.  
increments  
6. Loosen nut  
2. Hydro Control Linkage  
3. Drive Lever Linkage  
7. Yoke  
4. Speed Control Linkage  
Note: The park brake must be disengaged and  
the OPC levers must be held down whenever the  
speed control lever is out of the neutral position  
or the engine will kill.  
Hydro Control Linkage  
Adjustment  
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 whenever speed control lever is moved out  
of neutral position.  
3. Squeeze the respective drive lever until an  
increased resistance is felt; this is where neutral  
should be.  
If the wheel turns while holding the drive lever in  
neutral, the neutral control linkages need to be  
adjusted. If wheels stop then go to step 7.  
4. Loosen the nut against the neutral control linkage  
yoke as shown in Figure 14.  
Note: The neutral lock latches should still be  
“unlocked” and in the “forward” position.  
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Maintenance  
2. Loosen the front nut on left hydro control link  
as shown in Figure 15. Turn the rear control  
linkage adjusting nut counterclockwise until wheel  
rotates forward. Turn the rear nut of left control  
link clockwise 1/4 of a turn at a time, stopping  
to move the speed control forward and back to  
neutral, until left wheel stops rotating forward.  
Turn the nut an additional 1/2 turn and tighten  
the front jam 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 15.  
Drive Lever Linkage  
Adjustment  
1. With rear of machine still on jack stands and  
engine running at full throttle, 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  
see Figure 16. If the tire rotates in either direction,  
the length of the drive lever linkage will need to  
be adjusted.  
Figure 15  
1. Left Hydro Control Link  
(left side shown)  
4. Linkage is perpendicular  
to pin (correct position)  
Figure 16  
2. Front nut  
5. Linkage in incorrect  
position  
3. Rear nut  
6. End view of swivel  
2. Adjust the linkage length by releasing the drive  
lever and removing clevis pin and rotating the  
linkage in the lower swivel. Lengthen the linkage  
if the tire is turning in reverse and shorten the  
linkage if the tire is creeping forward. Rotate the  
linkage several turns if the tire is rotating fairly  
fast. But as the adjustment gets closer, adjust  
the linkage in 1/2 turn increments. Release and  
re-engage neutral lock latch checking that the tire  
stops. Continue these process until the tire is at a  
dead stop.  
After adjusting the left hydro control linkage,  
move the speed control lever to the mid-speed  
position and then back to the neutral position.  
Recheck the left drive wheel rotation to see if  
further adjustment is necessary - be sure the speed  
control lever is in the neutral position.  
Important: If inconsistent neutral occurs,  
check to be sure both springs are properly  
tightened on the speed control lever under the  
console–especially the rear pivot spring.  
Replace the hairpin back into each clevis pin.  
3. Make this adjustment for both sides.  
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 to  
neutral. Recheck the drive wheel rotation to see if  
further adjustment is necessary.  
Tracking Adjustment  
1. Stop engine and wait for all moving parts to stop.  
Raise rear of machine, remove jack stands, and  
carefully lower machine to the ground.  
2. Check the drive tire pressures and tire  
circumferences as stated in Check the Tire  
Pressures section in Maintenance.  
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 washers.  
Adjust spring length by turning nut at front of  
spring.  
3. Run the unit and observe the tracking on a level,  
smooth, hard surface such as concrete or asphalt.  
4. If the unit tracks to one side or the other, turn the  
quick track knob. Turn the knob right to “steer”  
right, turn the knob left to “steer” left.  
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Maintenance  
Hydro Pump Spring Tension  
Setting  
1. For medium or heavy duty drive conditions such  
as operation with a sulky on steep slopes, a higher  
spring force may be required on the hydro pump  
control arms to prevent the drive system from  
stalling.  
Cleaning  
Clean Grass Build-Up Under  
Deck  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. 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.  
2. Raise deck to the transport (maximum cutting  
height) position. Lift the front of unit and support  
unit using jack stands or equivalent support.  
Note: In “medium” or “heavy duty” positions,  
the drive lever forces at the upper handle will also  
be increased.  
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.  
3. Clean out any grass build-up from underside of  
deck and in discharge chute.  
Waste Disposal  
Figure 17  
1. Heavy duty  
2. Medium duty  
3. Standard  
4. Retaining bolt  
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.  
Electric Clutch Adjustment  
No adjustment necessary.  
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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.  
33  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused  
by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major  
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.  
Problem  
Starter does not crank.  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
2. 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.  
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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. By pass valve is not closed tight.  
2. Adjust tire pressure in the drive tires.  
Machine does not drive.  
Uneven cutting height.  
1. Tighten the by pass 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.  
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Schematics  
Schematics  
Electrical Diagram  
C A K B L  
C A K / W B H L I T E  
C A K B L  
C A K B L  
C A K B L  
W O Y E L L  
W O Y E L L  
K C A W O / B L Y E L L  
N W O R B  
C A K B L  
W O Y E L L  
O R A N G E  
O R A N G E  
C A K B L  
G R E Y  
C A K / W B H L I T E  
C A K  
W H I T E / B L  
R E D  
C A K / W B H L I T E  
. B T L L U E  
N W O R B  
W O Y E L L  
G006174  
36  
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Schematics  
Hydraulic Diagram  
37  
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Exmark Commercial Turf Equipment  
2Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
Conditions and Products Covered  
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty  
Company, pursuant to an agreement between them, jointly  
warrant on the terms and conditions herein, that we will repair,  
replace or adjust any part on these products and found by us  
(in the exercise of our reasonable discretion) to be defective in  
factory materials or workmanship for a period of two years.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
This warranty applies to Exmark commercial turf equipment  
sold in the U.S. or Canada. This warranty may only be  
assigned or transferred to a second (or third) owner by an  
authorized Exmark dealer. The warranty period commences  
upon the date of the original retail purchase.  
Owner’s Responsibilities  
The Exmark turf equipment, including any defective part,  
must be returned to an authorized Exmark service dealer  
within the warranty period. This warranty extends only to turf  
equipment operated under normal conditions. You must read  
the operator’s manual. You must also properly service and  
maintain your Exmark product as described in the operator’s  
manual. Such routine maintenance, whether performed by a  
dealer or by you, is at your expense.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
2 years*  
• Engine  
* The Engine warranty is covered by the engine manufacturer.  
Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair or replacement of  
defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall be liable for any  
incidental or consequential loss or damage.  
This warranty only includes the cost of parts and labor.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
Such damages include but are not limited to:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charges relating to repairs or  
replacements outside of normal business hours at the place  
of business of the authorized Exmark Service Dealer.  
• Rental of like or similar replacement equipment during the  
period of any warranty, repair or replacement work.  
• Any telephone or telegram charges or travel charges.  
• Loss or damage to person or property other than that  
covered by the terms of this warranty.  
• Any damage or deterioration due to normal use, wear and  
tear, or exposure.  
• Cost of regular maintenance service or parts, such as filters,  
fuel, lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or  
required replacement or repair due to normal wear,  
accidents, or lack of proper maintenance.  
• Any repairs necessary due to use of parts, accessories or  
supplies, including gasoline, oil or lubricants, incompatible  
with the turf equipment or other than as recommended in  
the operator's manual or other operational instructions  
provided by Exmark.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
There are no other express warranties except for engine and  
special emission system coverage.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
All implied warranties of merchantability (that the  
product is fit for ordinary use) and fitness for use (that the  
product is fit for a particular purpose) are limited to the  
duration of the express warranty.  
Instructions for Obtaining Warranty Service  
The product must be registered with original proof of purchase  
by an Exmark Service Dealer before obtaining any warranty  
service.  
Some states do not allow exclusions of incidental or  
consequential damages, or limitations on how long an  
implied warranty lasts, so the above exclusions and  
limitations may not apply to you.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G4500-425  
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Notes:  
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Notes:  
40  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
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.  
© 2008 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-382 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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