Exmark Turf Tracer HP 4500-358 User Manual

TURFTRACER®HP

ForSerialNos.
790,000&Higher

PartNo.4500-358Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.

Important:Whenthemowerisusedoroperated
onanyCaliforniaforest,brushorgrasscovered
land,aworkingsparkarrestermustbeattached
tothemufer.Ifnot,theoperatorisviolating
statelaw,Section4442PublicResourceCode.To
acquireasparkarresterforyourunit,seeyour
EngineServiceDealer.

ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada

TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.

Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.

©2008—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

Contactusatwww.Exmark.com.

2

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

3

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.....................10

Specications.......................................................14

ModelNumbers............................................14

Systems.........................................................14

Dimensions...................................................15

TorqueRequirements....................................16

ProductOverview................................................16

Operation.............................................................17

Controls........................................................17

Pre-Start........................................................19

OperatingInstructions..................................19

Transporting.................................................23

Maintenance.........................................................24

RecommendedMaintenanceSchedule(s)...........24

PeriodicMaintenance.......................................25

CheckEngineOilLevel.................................25

CheckBatteryCharge(ElectricStartUnits

Only).........................................................25

CheckMowerBlades.....................................25

CheckSafetyInterlockSystem.......................27

CheckforLooseHardware............................27

ServicePre-CleanerElementandAir

Cleaner......................................................27

ChangeEngineOil........................................28

CheckHydraulicOilLevel.............................28

CheckTirePressures.....................................28

CheckConditionOfBelts..............................28

LubricateGreaseFittings...............................28

CheckSparkPlugs.........................................29

ChangeHydraulicSystemFilter.....................29

WheelHub-SlottedNutTorque

Specication..............................................31

InspectPTOClutchingBeltTension..............31

ThreadLockingAdhesives.............................31

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................32

Copper-BasedAnti-seize...............................32

DielectricGrease...........................................32

Adjustments.....................................................32

DeckLeveling...............................................32

PumpDriveBeltTension...............................32

PTOClutchingBeltTension..........................32

MowerDeckDriveBeltTension....................32

ParkBrakeAdjustment..................................32

HydroDriveLinkageAdjustment..................32

HydroPumpSpringTensionSetting..............35

PTOSafetySwitch........................................35

Cleaning...........................................................36

CleanEngineandExhaustSystem

Area..........................................................36

RemoveEngineShroudsandCleanCooling

Fins...........................................................36

CleanDebrisFromMachine..........................36

CleanGrassBuild-UpUnderDeck................36

WasteDisposal..............................................36

Troubleshooting...................................................38

Schematics...........................................................40

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.

CAUTION

DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Y ellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

5

Safety

DANGER

Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anygasolinethatspills.

•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.

•DoNotllthefueltankcompletely
full.Addgasolinetothefueltankuntil
thelevelis1/4to1/2inch(6–13mm)
belowthebottomofthellerneck.This
emptyspaceinthetankallowsgasoline
toexpand.

•Neversmokewhenhandlinggasoline,
andstayawayfromanopenameor
wheregasolinefumesmaybeignitedby
spark.

•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.

•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

DANGER

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.

•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas
tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly .DoNotoperateunlessthey
arefunctioningproperly.

6

Safety

Operation

WARNING

Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,
tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer
andenginearea.

•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.

DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.

•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly .

•DoNotchangetheenginegovernorsettingor
overspeedtheengine.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting

andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:

–Beforerefueling.
–Beforedumpingthegrasscatcher.
–Beforemakingheightadjustments.

WARNING

Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.

•DONOToperatethemowerwhenpeople,
especiallychildren,orpetsareinthearea.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.

7

Safety

DANGER

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Lossof
controland/orlossofoperator’sfooting
couldresultinafallwithanarmorleg
gettingunderthemowerorenginedeck
whichmayresultinseriousinjury,deathor
drowning.

•Mowacrossslopes,neverupanddown.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan20
degrees.

•Reducespeedanduseextremecaution
onslopes.

•Avoidsuddenturnsorrapidspeed
changes.

•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.

•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.

•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect

sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.

•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.

•Letenginecoolbeforestoringanddonotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.

•Keephandsandfeetawayfrommovingparts.
Ifpossible,donotmakeadjustmentswiththe
enginerunning.

•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

8

WARNING

Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.

•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.

Safety

•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.

9

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

1-303508

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

1-403143

1-303517

1-413206

36inchDecksOnly

1-413214

1-403005

10

1-413327

48inchand52inchDecksOnly

1-413421

Safety

103-1798

1-513747

19HPKawasakiElectricStartOnly

1-553049

98-5954

103-1976

19HPKawasakiElectricStart

11

Safety

103-1977

15HPand17HPKawasakiManualStart

103-2242

103-2076

103-2243

103-2103

103-4935

12

Safety

109-3148

116-0404

13

Specications

Specications

ModelNumbers

SerialNos:790,000andHigher

ManualStartModels:THP15KA363;THP17KA483;THP17KA523;THP17KA363CA;THP17KA483CA

ElectricStartModels:THP19KAE483;THP19KAE523;THP19KAE483CA

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s
Manual

•RPM:FullSpeed:3600±50RPM(NoLoad)

FuelSystem

•Capacity:5.0gal.(18.9L)

•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher.

•FuelFilter:ReplaceableIn-line

•FuelShut-OffValve:1/4turnincrements

ElectricalSystem(ElectricStart)

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:Two20ampbladetype

neutraltoeachdrivewheelformovingforwardor
reverse,stopping,andpowerturning.

Transmission

TwinHydrostaticDrive

•TwoHydroGearvariabledisplacementhigh
efciencypumpsindependentlycoupledtotwo
highefciencyParker/Rosswheeldrivemotors.

•HydraulicOil:UseExmarkPremiumHydroOil.

•HydraulicOilCapacity:2.4qt.(2.2L)

•HydraulicFilterisreplaceablecartridgetype.

P/N109-4180:25microns,10psibypass
(Summeruseabove32°F(0°C))

P/N1-523541:40microns,18psibypass(Winter
usebelow32°F(0°C))

•Speeds:

–0-6.2mph(10.0km/hr)forward.

–0-2.2mph(3.5km/hr)reverse.

•Drivewheelsreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.

SafetyInterlockSystem

•Operatormusthavespeedcontrolleverinneutral,
PTOdisengaged,(andOPCleversdepressedfor
electricstart)tostartengine.ReleaseofOPC
leverswillcausetheenginetostopifspeedcontrol
leverisnotinneutraland/orPTOisengaged.

•Parkbrakemustbeengagedtomovespeed
controloutofneutralorenginewillkill.

OperatorControls

SteeringControl:Fingertipdrivecontrollevers
provideindependentspeedcontrol,brakingand

WheelDriveSystem

DrivewheelsaredirectcoupledtoParkerwheeldrive
motorswith1inch(25.4mm)taperedshaft.

14

Specications

Tires&Wheels

DriveFrontCaster

Pneumatic
(Air-Filled)

3648&52

Quantity

Tread

Size16x6.50–816x7.50–89x3.50-4

PlyRating

Pressure

222

TurfMasterTurfMasterSmooth

44

14psi
(97kPa)

Pneumatic
(Air-Filled)

14psi
(97kPa)

CuttingDeck

•CuttingWidth:

–36inchDeck:35.25inches(89.5cm)

–48inchDeck:47.25inches(120.0cm)

–52inchDeck:52.00inches(132.1cm)

•Discharge:Side

Semi­Pneumatic

AllDecks

Dimensions

OverallWidth:

36inch
Deck

Deector
Up

Deector
Down

36.1inches
(91.7cm)

46.25inches
(117.5cm)

OverallLength:

36inchDeck48inchDeck52inchDeck

77.3inches
(196.3cm)

73.7inches
(187.2cm)

OverallHeight:

36inchDeck48inchDeck52inchDeck

44.1inches
(112.0cm)

44.1inches
(112.0cm)

48inch
Deck

48.1inches
(122.2cm)

58.25inches
(148.0cm)

52inch
Deck

53.0inches
(134.6cm)

62.6inches
(159.0cm)

75.9inches
(192.8cm)

44.1inches
(112.0cm)

•BladeSize:

–36inchDeck:18.00inches(45.7cm)—

Quantity:2

–48inchDeck:16.25inches(41.3cm)—

Quantity:3

–52inchDeck:18.00inches(45.7cm)—

Quantity:3

•DeckDrive:Manualengagementofbeltwith
over-centerlock.Bladebelttensionisadjustable
viaturnbuckle.

•DeckMounting:Fulloatingdeckisattachedto
out-frontsupportframe,removableforservice.

•DeckDepth:

–36inchDeck:5.0inches(12.7cm)

–48inchDeck:5.0inches(12.7cm)

–52inchDeck:5.0inches(12.7cm)

•CuttingHeightAdjustment:

Adjustsfrom11/2inches(3.8cm)to41/2
inches(11.4cm)in1/2inch(1.3cm)increments

TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)

36inchDeck48inchDeck52inchDeck

35.0inches
(88.9cm)

39.4inches
(100.1cm)

39.4inches
(100.1cm)

CurbWeight:

36inchDeck48inchDeck52inchDeck

565lb(211kg)610lb(277kg)644lb(292kg)

Note:Weightswillvaryslightlydependingonengine
andelectricstartoptions.

•MulchingKit:Optional

•Bagger:Optional

15

ProductOverview

TorqueRequirements

BoltLocation

CutterHousingSpindle
Nut

BladeMountingBolt
(lubricatewithanti-seize)

EngineDeck/Mower
DeckSupportMount
Bolts

Anti-ScalpRollerNyloc
NutSeeFigure9

Anti-ScalpRollerWhizlock
NutSeeFigure9

EngineMountingBolts

WheelLugNuts

WheelHubSlottedNutsminimum100ft-lb

WheelMotorMounting
Bolts

Torque

140-145ft-lb
(190-197N-m)

55-60ft-lb(75-81N-m)

30-35ft-lb(41-47N-m)

30-35ft-lb(41-47N-m)

30-35ft-lb(41-47N-m)

15-20ft-lb(20-27N-m)

90-95ft-lb(122-129N-m)

(136N-m)

30-35ft-lb(41-47N-m)

ProductOverview

Figure3

1.ParkBrakeLever

2.Controls4.Height-of-CutPins

3.FuelCap

16

Operation

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

OperatorPresenceControl(OPC)
Levers

Locatedontheupperhandleassemblydirectlyabove
thehandlegrips.

Whentheseleversaredepressed,theOPCsystem
sensesthattheoperatorisinthenormaloperator’s
position.Whentheleversarereleased,theOPC
systemsensesthattheoperatorhasmovedfromthe
normaloperatingpositionandwillkilltheengineif
eitherthespeedcontrolleverisnotintheneutral
positionorthePTOisengaged.

asshowninFigure4,andthedriveleversarereleased,
thedrivewheelsareengagedintheforwarddirection.

Squeezingthelefthandand/orrighthandlever
causesthelefthandand/orrighthanddrivewheel
respectivelytoslowdown,stop,orreverse,depending
onhowfareachdriveleveris“squeezed”.Squeezing
thedriveleversbeyondtheneutralpositioncauses
thedrivewheelstoengageinthereversedirection
regardlessofthepositionoftheneutrallocklatches
andthespeedcontrollever.

NeutralLockLatches

Locatedontheupperhandleassemblyontheends
ofthehandlegrips.

Theselatchesallowtheoperatortolockthedrive
leversina“neutral”positionwherethedrivewheels
arenotengagedineitheraforwardorreverse
direction.

ChokeControl

Figure4

1.OPCLever

2.Rotateneutrallocklatch
downwardforneutral
lockposition

3.NeutralLockLatch

4.DriveLeverinneutral
position

DriveLevers

Locatedoneachsideoftheupperhandleassembly
aheadofandbelowthehandlegrips.

Locatedonthefrontleftcornerofthefueltank
support.

Chokeisusedtoaidinstartingacoldengine.The
chokecontrolispulledouttobeinthe“ON”position
andpushedintobeinthe“OFF”position.DoNot
runawarmenginewithchokeinthe“ON”position.

ThrottleControl

Locatedontherightsideofthecontrolconsole.

Thethrottleisusedtocontrolenginespeed.Moving
thethrottlecontrolforwardwillincreaseengine
speedandmovingittotherearwilldecreaseengine
speed.Movingthethrottleforwardintothedetent
isfullposition.

SpeedControlLever

Locatedinmiddleofthecontrolconsole.

Thespeedcontrollevercontrolsthemaximum
forwardspeedandisinnitelyvariablefromneutral
0–6.2mph(10.0km/hr).

Theseleversindividuallycontrolthespeedand
directionofeachdrivewheel.Whenthespeedcontrol
leverismovedoutoftheneutralpositionandthe
neutrallocklatchesaremovedintothedriveposition,

Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.

17

Operation

ParkBrakeLever

Locatedontheleftsideoftheunitabovethe
hydraulictank.

Thebrakeleverengagestheparkbrakeonthedrive
wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe
brake.

Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
engaged.Theunitmustbetieddownandbrake
engagedwhentransporting.

Theparkbrakemustbedisengagedtomovespeed
controloutofneutralorenginewillkill.

Formanualstartengines:Theparkbrakemustbe
disengagedbeforethePTOisengagedortheengine
willkill.

“Off-Run”Switch(ManualStartOnly)

Locatedontheconsole.

transportationtoandfromthejobsites,andwhen
themachinewillnotbeusedforafewdays.

Rotatevalve1/4turnclockwisetoshutfueloff.
Rotatevalve1/4turncounterclockwisetoturnfuel
on.

DriveWheelReleaseValves

Locatedontheleftrearcornerofthehydrostatic
pumps.

Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
movedbyhandwithouttheenginerunning.

Witha5/8wrench,turnbothvalvesoneturn
counterclockwisetoreleasethedrivesystem.

Turnclockwisetoresetthedrivesystem.DoNot

overtighten.

TrackingAdjustmentKnob

Locatedontheright-handsideoftherearofthefuel
tanksupport.

Turnkeytothe“Run”positiontoallowtheengine
tobestarted.Turnkeytothe“Off”positiontoshut
engineoff.

Operatormusthavespeedcontrolleverinneutral
andthePTOdisengagedtostartengine.

IgnitionSwitch(ElectricStartOnly)

Locatedonthecontrolconsole.

Theignitionswitchisusedtostartandstopthe
engine.Theignitionswitchhasthreepositions,
“Off”,“On”and“Start”.Insertkeyintoswitch
androtateclockwisetothe“On”position.Rotate
clockwisetothenextpositiontoengagethestarter
(keymustbeheldagainstspringpressureinthis
position).Operatormusthavespeedcontrolleverin
neutral,OPCleversdepressedandPTOdisengaged
tostartengine.Whenenginestarts,releasekey.

FuelShut-OffValve

Locatedinthefuellinemidwaybetweenthetank
andengine.

Thefuelshut-offvalveisusedtoshutoffthe
owoffuelwhenparkinginsideabuilding,during

Theknobcanbeadjustedsothatmachinewill
“track”straightaheadwiththedriveleversreleased.

PTOEngagement

Locatedontheleftsideoftheupperhandle.

Toengagetheblades,pushtheleverforward,oraway
fromtheoperator,untilthelinkagelocksover-center.
Todisengagetheblades,pullthelevertotherear,
ortowardstheoperator.

Formanualstartengines:Theparkbrakemustbe
disengagedbeforethePTOisengagedortheengine
willkill.

ColdStartKit(ManualStartOnly)

Locatedbelowthehydrocontrolshield.

Thecoldstartkitisusedtoeasethestartingofthe
unitincoldweatherorwhentheunithasnotbeen
operatedforaperiodoftime.Thecoldstartkit
movestheidlerpulleyawayfromthepumpbelt,
releasingthetensiononthebeltwhichallowsthe
enginetoturnoverwithlessresistance(seeStarting
theEngine(ManualStart)sectioninOperation).

18

Operation

Pre-Start

Fillfueltanks.Forbestresultsuseonlyclean,fresh
regulargradeunleadedgasolinewithanoctanerating
of87orhigher.Regulargradeleadedgasolinemay
alsobeused;however,combustionchamberand
cylinderheadwillrequiremorefrequentservice.See
EngineOwner’sManual.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

thatthefuellevelrisesabovealevelthatis1/2inch
belowthebottomofthellernecktoallowforfuel
expansionandpreventfuelspillage.

Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.

RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.

Note:Afterstartingtheengineandengagingthe
hydrodrive,ifeitherofthedrivewheelsactssluggish
orwillnotrotateatall,stopengineandreferto
theHydraulicSystemAirPurgeProcedurein
Maintenance.

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethevalve1/4turncounterclockwisetoturn
fuelon.

B.Startengine.Refertothefollowing

guidelinesforfurtherstartingsuggestions.

•Toengagepumpdrive(disengagecoldstart
kit):

A.Pullchainstraightoutfromthesideofthe

unituntilthesplitringcanberemoved
fromthebolt.

B.Slowlyreleasetensiononchain.

2.Pulloutthechokecontrol.Placethethrottle
controlmidwaybetweenthe“Slow”and“Fast”
positions.

3.Turnthekeyswitchtothe“Run”position.

4.Pullrecoilropetostartengine.

5.Afterenginewarmsup,graduallypushinthe
chokecontrol.DoNotrunwarmenginewiththe
chokeinthe“ON”position.

Note:Kawasakienginesgenerallyneedtobe
“choked”evenwhenwarm.

StartingtheEngine(ElectricStart)

Note:OperatormusthavePTOdisengaged,speed

controlleverinneutralposition,andOPClevers
depressedwhenstartingtheengine.

1.Lockdriveleversinneutralandengagepark
brake.

2.Pulloutthechokecontrol.Placethethrottle
controlmidwaybetweenthe“Slow”and“Fast”
positions.

StartingtheEngine(ManualStart)

Note:OperatormusthavePTOdisengagedand

speedcontrolleverinneutralpositionwhenstarting
theengine.

1.Lockdriveleversinneutralandengagepark
brake.

Note:Acoldweatherstartingkithasbeenadded
foreaseofstartingineithercoldweatherorwhen
theunithasnotbeenrunforaperiodoftime.

•Tousecoldstartkit:

A.Pullsplitringstraightoutthesideofthe

unit,andhooktheringoverthelowerrear
hydrocontrolshieldbolt.

3.Turntheignitionswitchtothe“Start”position.
Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine
continuouslyformorethantensecondsat
atime.Iftheenginedoesnotstart,allowa
60secondstartercool-downperiodbetween
startingattempts.Failuretofollowthese
guidelinescanburnoutthestartermotor.

4.Afterenginewarmsup,graduallypushinthe
chokecontrol.DoNotrunwarmenginewiththe
chokeinthe“ON”position.

Note:Kawasakienginesgenerallyneedtobe
“choked”evenwhenwarm.

19

Operation

PTOEngagement

DANGER

Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.

DANGER

Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunless
thereisagrasscollectionsystemormulch
kitinplaceandworkingproperly.

ThePTOswitchengagesthecuttingblades.Besure
thatallpersonsareclearofmowerdeckanddischarge
areabeforeengagingthePTO .

5.Engagetheparkingbrake.

6.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.

7.Allowtheenginetorunforaminimumof15
seconds,thenturnthekeytothe“OFF”position
tostoptheengine.

8.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.

9.Closethefuelshut-offvalvewhenthemachine
willnotbeinuseforafewdays,when
transporting,orwhentheunitisparkedinside
abuilding.

DrivingtheMachine

DriveLever/NeutralLockLatchOperation

Tolockthedriveleversin“neutrallock”,squeezethe
driveleverstothe“neutral”position(DoNotsqueeze
thedriveleversallthewaybackasthiswillcausethe
drivewheelstogointofullreversedirection).See
Figure5position1.Placethumbsontheinnerlobe
oftheneutrallocklatchesandrotatethemunder
thedriveleversintothe“neutrallock”position.See
Figure5position2.Releasethedrivelevers.

1.Setthrottleto“MIDW AY”position.

2.PushthePTOengagementarmforwardand
downtoengageblades.

3.Placethethrottleinthe“FAST”positiontobegin
mowing.

Formanualstartengines:Theparkbrakemust
bedisengagedbeforethePTOisengagedorthe
enginewillkill.

DisengagingthePTO

1.Setthrottleto“MIDW AY”position.

2.PullupwardandbackcompletelyonthePTO
engagementarmtodisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Lockdriveleversinneutral.

3.DisengagethePTO.

CAUTION

Iftheneutrallocklatchesarenotcompletely
engagedthedriveleverscouldunexpectedly
slipintotheforwarddriveposition.Ifthe
driveleversslipintothedrivepositionthe
unitcouldlurchforwardandcauseinjuryor
propertydamage.

Besurethedriveleversarepasttherollerand
securelyseatedatthebottomoftheneutral
locklatches.

Toplacethedriveleversinthe“forward”position,
slightlysqueezethedriveleverswhileplacingthumbs
ontheouterthumblobeoftheneutrallocklatches
(ortheindexngeronthefrontlobe)androtatethem
fromunderthedrivelevers.Slowlyandcarefully
releasethedrivelevers.SeeFigure5position3.

Toplacethedriveleversinthe“reverse”position,
squeezethedriveleverspasttheneutralposition.See
Figure5position4.

4.Movespeedcontrollevertoneutral.

20

1.DriveLeverinneutral
position

2.DriveLeverlockedin
neutralposition

Figure5

3.DriveLeverinforward
position

4.DriveLeverinreverse
position

Operation

DrivinginReverse

Tomoverearwardinastraightline,squeezedrive
leversintothereverseposition.

Toturnleftorright,squeezetherighthanddrivelever
toturnleftandthelefthanddrivelevertoturnright.

Tomakea“zeroturn”,squeezeeitherthelefthand
ortherighthanddriveleverbackintothereverse
positionwhiletheoppositedriveleverisinaforward
positionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine,avoid
quick,jerkymovementsofthedrivelevers.Movethe
driveleverssmoothlyanddeliberately.

Tostop,squeezedriveleversbacktothe“neutral”
position.Movetheneutrallocklatchesintothe
“neutrallock”positionandreleasedrivelevers.Move
thespeedcontrollevertotheneutralposition.

DrivingForward

1.Releasetheparkingbrake.

2.Withdriveleverslockedin“neutral”,shiftspeed
controllevertodesiredforwardspeed.

3.Slowlysqueezeandholdbothdriveleversin
theneutralpositionandrotatebothneutrallock
latchesfromtheneutrallockpositiontothe
forwardposition.

Note:DoNotsqueezebothdriveleversallthe
wayback.Thiswillcausethedrivewheelsto
engageinthereversedirection.

4.Tomoveforwardinastraightline,smoothly
releasebothdriveleverstoengagedrivewheels.

Toturnleftorright,squeezetherighthanddrive
levertoturnrightandthelefthanddrivelever
toturnleft.

Tomakea“zeroturn”,squeezeeithertheleft
handortherighthanddriveleverbackintothe
reversepositionwhiletheoppositedriveleverisin
aforwardpositionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine,
avoidquick,jerkymovementsofthedrivelevers.
Movethedriveleverssmoothlyanddeliberately.

Tostop,squeezedriveleversbacktothe“neutral”
position.Movetheneutrallocklatchesintothe
“neutrallock”positionandreleasedrivelevers.
Movethespeedcontrollevertotheneutral
position.

AdjustingtheCuttingHeight

WARNING

Whenthetwofrontsupportrodhairpinsare
removedfromthemowerdeck,theweightof
thetractorsectionmaycausethefrontframe
oftheunittorisesuddenly.Iftheunitrises
suddenly,injurymayoccur.

Securelyholddownthefrontoftheunitwhen
thefrontsupportrodhairpinsareremoved.

Thecuttingheightofthemowerdeckisadjusted
from11/2to41/2inches(3.81cmto11.4cm)in
1/2inch(1.3cm)increments.

1.Stopthemachineandmovethedriveleverstothe
neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Installhairpinclipsintheholesforthedesired
cuttingheight.SeeFigure6.

Important:T omaintaincorrectcutting
heightandrake,checkthefollowingfor
properadjustment.

A.Thefrontandrearhairpinsareinthesame

holeswiththeproperspacersunderthehair
pins.SeeFigure6.

21

Operation

Figure6

1.Decksupportpin

B.ThetirepressuresaresetasdirectedinCheck

TirePressuresintheMaintenancesection.

2.CuttingHeight

Figure7

LeftHandSideShown

C.Thelengthofthereardecksupportlink

assembliesaverage6.89inches(approximately
67/8inches)(175.01mm)fromthecenterof
theballjointtothecenterofthefarthesthole.
SeeFigure7.

Note:Allfourpinsmustequallysupportthe
weightofthedeck.Adjustmentinthelength
ofthereardecksupportassembliesmaybe
necessary.Ifonesideislongerthan6.89
inches(approximately67/8inches)(175.01
mm),thantheoppositesidemustbeshorter
bythesameamount.

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller
positionwhentheheightofcuthaschanged.

1.Stopthemachineandmovethedriveleversto
theneutrallockposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe
anti-scalprollersbyremovingthewhizlocknut
andspringdiscwasher.

6.Adjustanti-scalprollersforNormalOperating
Conditions.Placerollersinoneofthepositions
showninFigure8.Rollerswillmaintain3/4
inches(19mm)clearancetothegroundto
minimizegougingandrollerwearordamage.

Note:ForMaximumDeckFlotation,place
rollersoneholepositionlower.Rollersshould
maintain1/4inch(6.35mm)clearancetoground.
DoNotadjustrollerstosupportthedeck.Be
surerollerboltsareinstalledwiththespringdisc
washerbetweenheadofthenutandmounting
bracket.

22

Figure8

Forcuttingheightsabove3.5inches(38mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller
mountingbracket

2.Cuttingheight

7.Torquethe3/8–16whizlocknutto30-35ft-lb
(41-47N-m)(Figure9).

Operation

Transporting

TransportingaUnit

WARNING

Loadingthemowerontoatrailerwithout
strongenoughorproperlysupportedramps
couldbedangerous.Therampscould
collapsecausingtheunittofall,whichcould
causeinjury.

•Useproperrampsthataresecuredtothe
truckortrailer.

•Keepfeetandlegsoutfromunderthe
unitwhenloadingandunloading.

•Ifnecessary,useassistancewhenloading .

8.Ifthe3/8nylocnuthasbeenremoved,reinstall
andtorqueto30–35ft-lb(41-47N-m)(Figure9).

Figure9

1.Springdiscwasher
(conetowardsnut)

2.Frontrightanti-scalp
bracketshown

3.3/8nyloc-torqueto30-35
ft-lb(41-47N-m)

4.3/8-16whizlocknut
torqueto30-35ft-lb
(41-47N-m)

Besurethefuelshut-offvalveisclosed.

Useaheavydutytrailertotransportthemachine.
Engageneutrallocklatchesandparkbrake,then
blockwheels.

Securelyfastenthemachinetothetrailerwithstraps,
chains,cables,orropes.

DoNotrelysolelyontheparkingbraketoholdthe
machineonthetrailer.

Besurethatthetrailerhasallnecessarylightingand
markingasrequiredbylawanduseasafetychain.

23

Maintenance

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch,
engageparkingbrake,andpullthewire(s)
offthesparkplug(s)beforeyoudoany
maintenance.Alsopushthewire(s)aside
soitdoesnotaccidentallycontactthespark
plug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst2hours

Aftertherst5hours

Aftertherst100hours

MaintenanceProcedure

•InspectPTOclutchingbelttension.Checkevery2hoursfortherst8hoursofoperation.

•Changetheengineoil.

•Checkwheelhub-slottedtorquespecication.

WARNING

Theenginecanbecomeveryhot.Touching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

Aftertherst250hours

Beforeeachuseordaily

Every25hours

Every40hours

Every80hours

Every100hours

Every160hours

•Changethehydrauliclter.

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Greasethecasterwheelbearings.

•Greasecasterpivots.

•Cleantheengineandexhaustsystemarea.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthedeck.

•Servicetheaircleaner.(Mayneedmoreoftenundersevereconditions.SeetheEngine
Owner’smanualforadditionalinformation.)

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethepumpdriveidlerpivot.

•Greasetheclutcharmpivot.

•Greasethepumpcontrolbearings.

•Greasethemowerdeckidlerpivot.

•InspectPTOclutchingbelttension.

•Removeengineshroudsandcleancoolingns.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Checkthesparkplugs.

24

Maintenance

MaintenanceService

Interval

Every500hours

Monthly

MaintenanceProcedure

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Checkwheelhub-slottedtorquespecication.

•Checkthebatterycharge.

•GreasethePTOengagementbellcrank.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstickand
wipeoiloff.Reinsertthedipstickandpushitall
thewaydownintothetube.DoNotscrewinto
place.Removethedipstickandreadtheoillevel.

4.Iftheoillevelislow ,wipeofftheareaaroundthe
oilllcap,removecapandlltothe“FULL”
markonthedipstick.Useoilasspeciedin
EngineOwner’ sManual.DoNotoverll.

Important:DoNotoperatetheenginewiththe
oillevelbelowthe“LOW”(or“ADD”)markon
thedipstick,oroverthe“FULL”mark.

CheckBatteryCharge
(ElectricStartUnitsOnly)

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof
timewithoutrechargingthemwillresultinreduced
performanceandservicelife.Topreserveoptimum
batteryperformanceandlife,rechargebatteriesin

storagewhentheopencircuitvoltagedropsto12.4
volts.

Note:Topreventdamageduetofreezing,battery
shouldbefullychargedbeforeputtingawayfor
winterstorage.

Checkthevoltageofthebatterywithadigital
voltmeter.Locatethevoltagereadingofthebatteryin
thetableandchargethebatteryfortherecommended
timeintervaltobringthechargeuptoafullcharge
of12.6voltsorgreater.

Important:Makesurethenegativebattery
cablesaredisconnectedandthebatterycharger
usedforchargingthebatteryhasanoutputof
16voltsand7ampsorlesstoavoiddamaging
thebattery(seechartforrecommendedcharger
settings).

Voltage
Reading

12.6or
greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent
Charge

100%

0%

Maximum
Charger
Settings

16volts/7
amps

16volts/7
amps

16volts/7
amps

14.4volts/4
amps

14.4volts/4
amps

14.4volts/2
amps

Charging
Interval

No
Charging
Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor
More

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

25

Maintenance

2.Liftdeckandsecureinraisedpositionasstatedin
theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe
followingorder:

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure10

1.Installbushinginbladepriortoinstallingbushingin
spindle.

wrenchonthetopspindlenutthentorquethe
bladeboltsto55-60ft-lb(75-81N-m).

WARNING

Incorrectinstallationofthebladeor
componentsusedtoretainthebladecan
bedangerous.Failuretousealloriginal
componentsandassembledasshowncould
allowabladeorbladecomponenttobe
thrownoutfromunderthedeckresultingin
seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades,
bladebushings,andbladeboltsasshown.

ReplacingtheDischarge
Deector

ServiceInterval:Asrequired

B.Installbushing/bladeassemblyintospindle.

Figure11

1.Usewrenchherefor
bladeinstallation.This
nuthasbeentorquedto
140–145ft-lb(190–197
N-m)

2.Torqueto55-60ft-lb
(75-81N-m)Apply
lubricanttothreads
asneededtoprevent
seizing.Copper-based
anti-seizepreferable.
Greaseacceptable
substitute.

DANGER

Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectsinthe
operator’sorbystander’sdirectionandresult
inseriousinjury.Also,contactwiththeblade
couldoccur.

Neveroperatethelawnmowerunlessyou
installamulchplate,dischargedeector,or
grasscollectionsystem.

1.Toremoveadamagedorworndischarge
deector,liftthelegofthespringwiththeloop
outofthenotchinthedischargedeectorand
slidetherodoutofthedischargedeector
brackets,anddischargedeector.

2.Toinstallnewdischargedeector,orientthe
springontherodasshowninFigure12.Slidethe
rodthroughthefrontdischargedeectorbracket,
dischargedeector,andreardeectorbracket.

C.Applylubricanttothreadsofbladeboltas

neededtopreventseizing.Copper-based
anti-seizepreferable.Greaseacceptable
substitute.Installbladeboltngertight.Place

26

Figure12

1.Rod4.Mowerdeck

2.Spring5.Dischargedeector

3.Dischargedeector

3.Hookthebentendoftherodaroundthefront
dischargedeectorbrackettoretainitfrom
slidingout.Placethelegofthespringwiththe
loopinthenotchinthedischargedeectorto
holdthedischargedeectorinthedownposition
(seeFigure12).

bracket

6.Assembledview

Maintenance

Trytostartwith,OPCleversdepressed,speed
controlleverinanyspeedbutneutralandPTO

disengaged–startermustnotcrank.

TrytostartwithOPCleversdepressed,
speedcontrolleverinneutralandPTO
engaged–startermustnotcrank..

2.ForAllUnits:CheckOPCcircuits.Clearthe
area.Disengagetheparkbrake.Runengineat
one-thirdthrottle,then,withdriveleversand
neutrallocklatchesinneutrallockposition,
movethespeedcontrolleveroutofneutraland
releaseOPClevers–enginemuststop.Again,
runengineatone-thirdthrottle,movethespeed
controllevertoneutral,engagePTOandrelease
OPClevers–enginemuststop.

Note:Parkbrakemustbedisengagedbeforethe
speedcontrolleverismovedoutofneutralorengine
willkill.

ForManualStartEngines:Theparkbrakemustbe
disengagedbeforethePTOisengagedortheengine
willkill.

Note:Ifmachinedoesnotpassanyofthesetests,
donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing.

Important:Thedischargedeectormustbe
springloadedinthedownposition.Liftthe
deectoruptotestthatitsnapstothefull
downposition.

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

1.ForElectricStartUnitsOnly:Checkstarting
circuit.Startershouldcrankwith:Operator
PresenceControlleversdepressed,speedcontrol
leverinneutral,andPTOdisengaged.

TrytostarttheenginewithOPClevers
disengaged,speedcontrolleverinneutraland
PTOdisengaged–startermustnotcrank.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.

ServicePre-CleanerElement
andAirCleaner

ServiceInterval:Every25hours—Service

theaircleaner.(May
needmoreoftenunder
severeconditions.See
theEngineOwner’s
manualforadditional
information.)

27

Maintenance

1.Stopengine,waitforallmovingpartstostop,and
removekeyorsparkplugwire(s).Engageparking
brake.

2.SeetheEngineOwner’ sManualforcleaning
instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May
needmoreoftenunder
severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseassemblyislocatedontheleft
sideoftheengine.

Placepanundermachinetocatchoil.Removeoil
drainplug.Allowoiltodrainandreplaceoildrain
plug.Torqueplugto20-24ft-lb(27-33N-m).

4.ReplacetheoillterpertheEngineOwner’s
Manual.Cleanaroundoillterandunscrewlter
toremove.Beforethenewlterisinstalled,
applyathincoatingofoilonthesurfaceofthe
rubberseal.Turnlterclockwiseuntilrubberseal
contactsthelteradapter,thentightenlteran
additional2/3to3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto
speciedcapacityandreplacecap.

6.Useoilrecommendedinengineowner’smanual.
DoNotoverll.Starttheengineandcheckfor
leaks.Stopengineandrecheckoillevel.

7.Wipeupanyspilledoilfromenginedeck
mountingsurfaces.

CheckHydraulicOilLevel

temperatureoftheoil.The“HOT”levelshows
thelevelofoilwhenitisat225°F(107°C).The
“COLD”levelshowstheleveloftheoilwhen
itisat75°F(24°C).Filltotheappropriatelevel
dependinguponthetemperatureoftheoil.For
example:Iftheoilisabout150°F(65°C),llto
halfwaybetweenthe“HOT”and“COLD”levels.
Iftheoilisatroomtemperature(about75°F
(24°C)),llonlytothe“COLD”level.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto12–16psi(83–110kPa).

4.Inatetirestopressuresstatedabove.Measure
thecircumferenceofeachdrivetire.Adjusttire
pressureswithintheaboverangetotrytomake
tirecircumferencesmatchascloselyaspossible.

5.Semi-pneumaticcastertiresdonotneedtobe
inated.

CheckConditionOfBelts

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removethemowerdeckbeltshieldtocheck
mowerbladedrivebeltcondition.

3.Lookunderenginedecktocheckthepumpdrive
beltcondition.

4.Checkallidlerarmstobesuretheypivotfreely.
Disassemble,cleanandgreasepivotbushingsif
necessary.

ServiceInterval:Every40hours

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.

2.Cleanareaaroundhydraulicreservoircapand
removecap.Oillevelshouldbetothetopofthe
bafeinsidethetank.Ifnot,addoil.UseExmark
PremiumHydrooil.Replacehydraulicreservoir
capandtightenuntilsnug.DoNotovertighten.

Note:Thebafeislabeled“HOT”and
“COLD”.Theoillevelvarieswiththe

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.LubricatettingswithNGLIgrade#2
multi-purposegungrease.

Refertothefollowingchartforttinglocations
andlubricationschedule.

28

Maintenance

LubricationChart

Fitting

Locations

1.Caster
Wheel
Bearings

2.Caster
Pivots

3.PTO
Engagement
Bellcrank

4.Pump
DriveIdler
Pivot

5.Clutch
ArmPivot

6.Pump
Control
Bearings

7.Mower
DeckIdler
Pivots

Initial

Pumps

12222

2222

1111

2111

1111

2222

2111

NumberofPlacesService

36inch

Deck

48inch

Deck

Removesparkplugs,checkconditionandresetgaps,
orreplacewithnewplugs.SeeEngineOwner’s

Interval

52inch

Deck

Daily

Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledinthefuellinebetweenthe

Daily

40hours

Yearly

fueltankandtheengine.Replacewhennecessary.

ChangeHydraulicSystem
Filter

ServiceInterval:Aftertherst250hours

40hours

40hours

Every500hours/Yearly
(whichevercomes
rst)thereafter
(Every250hours/Yearlyif
usingMobil115W50)

Yearly

Note:UseonlyExmarkPartNo.109–4180for
Summeruseabove32°F(0°C)orP/N1-523541for
Winterusebelow32°F(0°C)(RefertoTransmission
sectioninSpecicationsforlterspecications).

1.Stopengine,waitforallmovingpartstostop,and
removekeyorsparkplugwire(s).Engageparking
brake.

2.Carefullycleanareaaroundlter.Itisimportant
thatnodirtorcontaminationenterhydraulic
system.

3.Unscrewltertoremoveandallowoiltodrain
fromreservoir.

Number4IdlerPivot(PumpDrive)Located

underenginedeck.

Number5(ClutchArmPivot)Locatedunder

enginedeck.

3.Lubricatepivotpointswithaspraypenetrating
lubricantasshownintheSprayLubricantChart.

SprayLubricantChart

PivotPoint

1.PTOLever

NumberofPlaces

1

ServiceInterval

40hours

CheckSparkPlugs

ServiceInterval:Every160hours

Important:Beforereinstallingnewlter,ll

itwithExmarkPremiumHydrooilandapply
athincoatofoilonthesurfaceoftherubber
seal.

Turnlterclockwiseuntilrubbersealcontactsthe
lteradapter,thentightenthelteranadditional
2/3to3/4turn.

4.FillreservoirasstatedinCheckHydraulicOil

Level.

ExmarkPremiumHydroOilisrecommended.
Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro
Oil(Preferred)

Mobil115W50

29

ChangeInterval

500Hours

250Hours

Maintenance

5.Loosenlter1/2turnandallowasmallamount
ofoiltoleakfromtheoillter(thisallowsairto
bepurgedfromtheoillterandsupplyhosefrom
thehydraulicreservoir).Turnlterclockwise
untilrubbersealcontactsthelteradapter.Then
tightenthelteranadditional2/3to3/4turn.

6.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely.

7.Ifeitherdrivewheeldoesnotrotate,oneorboth
ofthechargepumps(locatedonthetopofthe
mainpumpasshowninFigure13)mayhavelost
their“prime”.RefertoHydraulicSystemAir
Purgesection.

Note:DoNotchangehydraulicsystemoil(except
forwhatcanbedrainedwhenchanginglter),unless
itisfelttheoilhasbeencontaminatedorbeen
extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic
systembyintroducingcontaminatesintothesystem.

Figure13

1.Chargepumpcap2.Loosen11/2turnsonly

HydraulicSystemAirPurge

ServiceInterval:Asrequired

Airmustbepurgedfromthehydraulicsystem
whenanyhydrauliccomponents,includingoil
lter,areremovedoranyofthehydrauliclinesare
disconnected.

Thecriticalareaforpurgingairfromthehydraulic
systemisbetweentheoilreservoirandeach
chargepumplocatedonthetopofeachvariable
displacementpump(Figure13).Airinotherpartsof
thehydraulicsystemwillbepurgedthroughnormal
operationoncethechargepumpis“primed”.

1.Stopengineandwaitforallmovingpartstostop.
Raisetherearofthemachineupontojackstands
highenoughtoraisethedrivewheelsoffthe
ground.

2.CheckoillevelasstatedinCheckHydraulicOil
Levelsection.

3.Startengineandmovethrottlecontrolaheadto
fullthrottleposition.Movethespeedcontrol
levertothemiddlespeedpositionandplacethe
driveleversinthe“drive”position.

Ifeitherdrivewheeldoesnotrotate,itispossible
toassistthepurgingofthechargepumpby
carefullyrotatingthetireintheforwardposition.

Note:Itisnecessarytolightlytouchthecharge
pumpcapwithyourhandtocheckthepump
temperature.Ifthecapistoohottotouch,turn
offengine.Thepumpsmaybedamagedifthe
pumpbecomestoohot.

Ifeitherdrivewheelstilldoesnotrotatecontinue
withstep4.

4.Thoroughlycleantheareaaroundeachofthe
chargepumphousings.

5.To“prime”chargepump,loosentwohexsocket
headcapscrews(showninFigure13)11/2turns
only.Makesureengineisnotrunning.Lift
thechargepumphousingupwardandwaitfor

30

Maintenance

asteadyowofoiltoowoutfromunderthe
housing.Retightenthecapscrews.Dothisfor
bothpumps.

Note:Hydraulicreservoircanbepressurizedup
to5psitospeedthisprocess.

6.Ifeitherdrivewheelstilldoesnotrotate,stop
andrepeatsteps4and5abovefortherespective
pump.Ifwheelsrotateslowly,thesystemmay
primeafteradditionalrunning.Checkoillevel
asstatedinChecktheHydraulicOilLevel
section.

7.Allowunittorunseveralminutesafterthecharge
pumpsare“primed”withdrivesysteminthefull
speedposition.CheckoillevelasstatedinCheck
theHydraulicOilLevelsection.

8.Checkhydrodrivelinkageadjustmentasstatedin
HydroDriveLinkageAdjustmentsectionin
Adjustments.

WheelHub-SlottedNut

clutchingbelttension.Boltonbladeengagement
linkagebellcrankandindicatorarmshouldalign
within1/16inch(1.6mm)(seeFigure14).Refer
toPTOEngagementLinkageforadjustment.

Figure14

1.Enginedeck3.Alignbolttoindicator
within1/16inch(1.6
mm)

2.Indicator4.Turnbuckle

TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor
taperedshaft:

1.Torquetheslottednutto100ft-lb(136N-m).

2.Furthertightenthenutuntilthenextsetofslots
lineupwiththecrossholeintheshaft.

3.Replacecotterpin.

Note:Donotuseanti-seizecompoundonthewheel
hub.

InspectPTOClutchingBelt
Tension

ServiceInterval:Aftertherst2hours

Checkevery2hours
fortherst8hoursof
operation.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242”
or“Fel-Pro,Pro-LockNutType”areusedonthe
followingfasteners:

•Pumpsheavesetscrews.

•Squareheadsetscrewsonhydropumpcontrol
arms.

•OPCleversetscrews.

•Lowersheaveretainingboltonclutcharm.

•Shoulderboltsinendsofspeedcontrolcrank.

•Sheaveretainingboltinendofenginecrankshaft.

•Fueltankbulkheadttingthreads

Adhesivessuchas“LoctiteRC/609orRC/680”or
“Fel-ProPro-LockRetainingIorRetainingII”are
usedonthefollowing:

•OPCleverhubsandcross-shaft.

Every40hoursthereafter.

1.Stopengineandwaitforallmovingpartstostop.

2.EngagePTOlever.

3.Lookthroughtheroundholeintheleftrear
corneroftheenginedecktoinspectblade

Note:Caremustbeusednottobondthe
bearing,nexttoeachOPChub,tothecross-shaft
whichcouldcausebindingoftheOPCleversand
erraticoperation.

•Fueltankstuds,wherestudsareinsertedintotank.

31

Maintenance

MobilHTSGrease(Or
Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused
inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing
locations:

•OnthreadsofBladeBolts.SeeCheckMower
Bladessection.

•Betweenenginecrankshaftandpumpandblade
drivesheaves.

•Onclutcharmassemblybetweenbearingsand
shaftandbetweenlowersheaveandshaft.

•Betweenpumpshaftsandsheaves.

Adjustments

Note:DisengagePTO,shutoffengine,waitfor
allmovingpartstostop,engageparkingbrake,and
removekeybeforeservicing,cleaning,ormakingany
adjustmentstotheunit.

DeckLeveling

SeeAdjustingtheCuttingHeightsectionin
Operation.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

PTOClutchingBeltTension

SeeInspectPTOClutchingBeltTensionsection.

MowerDeckDriveBelt
Tension

Self-tensioning-Noadjustmentnecessary.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.

ParkBrakeAdjustment

1.Shutoffengineandwaitforallmovingpartsto
stop.

2.Disengagetheparkbrake.

3.Removethehairpinintheparkbrakelinkage.
Turnthelinkageintheyokeuntilthereis3/16
inch(4.8mm)to1/4inch(6.4mm)clearance
betweentheparkbraketirebarsandthetireswith
theparkbrakedisengaged.Re-installthehairpin.

HydroDriveLinkage
Adjustment

•AdjustSpeedControlLinkageandNeutralSafety
Switch:

1.Stopengineandwaitforallmovingpartsto

stop.Engageparkingbrake.Removekeyor
sparkplugwire(s).

2.Movethespeedcontrollever(locatedon

theconsole)tothefullforwardpositionand
checktheorientationofthetabsontheends
ofthespeedcontrolcrank(seeFigure15).
Thesetabsshouldbepointingstraightdown
atthe6o’clockpositionorslightlyforward.

32

Adjustthethreadedyokeatthebottomofthe
speedcontrollinkage(seeFigure15)untilthe
tabsarepositionedcorrectly.

Figure15

ViewedfromLeftSideofUnit

Maintenance

1.NeutralSafetySwitch3.5/16inch(.76cm)

2.ActuatingT abinneutral
position

3.Pullthespeedcontrolleverbacktoneutral.
Checkthattheneutralsafetyswitchactuating
tabhasdepressedtheplungeroftheswitchso
thatthereisabout5/16inch(.79cm)between
thetabandtheswitch(seeFigure15).If
necessary,movetheswitchforeandaft.

•AdjustNeutralControlLinkages:

1.Raisetherearofthemachineupontojack
standshighenoughtoraisethedrivewheels
offoftheground.

2.Starttheengineandmovethethrottleahead
tothefullthrottleposition.Placetheneutral
locklatchesinthe“forward”positionas
showninFigure5.Releasetheparkbrake
andmovethespeedcontrollevertothe
“mid-speed”position.

Note:TheOPCleversmustbehelddown
andtheparkbrakemustbedisengaged
wheneverthespeedcontrolleverismoved
outofneutralortheenginewillkill.

3.Squeezetherespectivedriveleveruntilan
increasedresistanceisfelt,thisiswhere
neutralshouldbe.

Ifthewheelturnswhileholdingthedrive
leverinneutral,theneutralcontrollinkages
needtobeadjusted.Ifthewheelstopsthen
gotostep7.

Figure16

ViewedfromLeftSideofUnit

1.NeutralControlLinkage5.SpeedControlLinkage

2.HydroControlLinkage

3.DriveLeverLinkage7.Loosennut

4.SpeedControlCrank

6.Adjusthere-rotateat
approximately1/4
turnincrementsand
re-check.

8.Yoke

4.Loosenthenutagainsttheneutralcontrol
linkageyokeasshowninFigure16.

5.Adjusttheneutralcontrollinkageuntil
therespectivedrivewheelstopswhenthe
leverispulledagainsttheneutralspring
(neutralposition).Turntheadjustingbolt
approximately1/4turnclockwiseifthe
wheelisturninginreverseorturnthebolt
approximately1/4turncounterclockwiseif
thewheelisturningforward.Releasethe
drivelevertotheforwarddrivepositionand
squeezebackintotheneutralposition.Check
toseeifthewheelstops.Ifnot,repeatthe
aboveadjustmentprocedure.

6.Makethisadjustmentonbothsides.

7.Afteradjustmentsaremadeandthewheels
stopwhenthedriveleversareintheneutral
position,tightenthenutsagainsttheyokes.

•AdjustHydroControlLinkages:

1.Placethespeedcontrolleverinthe“neutral”
position.Thisadjustmentisagainmadewith
rearofmachineonjackstandsandengine
runningatfullthrottle.OPCleverswillhave
tobehelddownandtheparkbrakemustbe

33

Maintenance

disengagedwheneverspeedcontrolleversare
movedoutoftheneutralposition.

Note:Theneutrallocklatchesshouldbe
“unlocked”andintheforwardposition.

2.Loosenthefrontnutonlefthydrocontrol
linkageasshowninFigure16.Turntherear
controllinkageadjustingnutcounterclockwise
untilwheelrotatesforward.Turntherearnut
ofleftcontrollinkageclockwise1/4ofaturn
atatime,stoppingtomovethespeedcontrol
forwardandbacktoneutral,untilleftwheel
stopsrotatingforward.

Turntherearnutanadditional1/2turnand
tightenthefrontnutmakingsurenottoput
abindonthelinkage.Makesureatpartof
linkageisperpendiculartopinpartofswivel
(seeFigure17).

toneutral.Recheckthedrivewheelrotation
toseeiffurtheradjustmentisnecessary.

4.Thespringthatkeepstensionontheknob
shouldnormallynotneedadjustment.
However,ifadjustmentisneeded,adjustto
wherelengthofspringisabout1inch(2.5cm)
betweenthewashers.Adjustspringlengthby
turningnutatfrontofspring.

•DriveLeverLinkageAdjustment:

1.Withrearofmachinestillonjackstandsand
enginerunningatfullthrottle,disengage
theparkbrakeandmovethespeedcontrol
levertothemidwayposition.Movethe
respectivedriveleverupwarduntilitreaches
theneutralpositionandengageneutrallock
latches(Figure18).Ifthetirerotatesineither
direction,thelengthofthedriveleverlinkwill
needtobeadjusted.

Figure17

1.LeftHydroControlLink
(leftsideshown)

2.Frontnut5.Linkageinincorrect

3.Rearnut

4.Linkageisperpendicular
topin(correctposition)

position

6.Endviewofswivel

Afteradjustingthelefthydrocontrollinkage,
movethespeedcontrollevertothemid-speed
positionandthenbacktotheneutralposition.
Rechecktheleftdrivewheelrotationtoseeif
furtheradjustmentisnecessary-besurethe
speedcontrolleverisintheneutralposition.

Note:Ifinconsistentneutraloccurs,
checktobesurebothspringsareproperly
tightenedonthespeedcontrolleverunderthe
console–especiallytherearpivotspring.

Repeataboveadjustmentsifnecessary.

3.Placethespeedcontrolleverinneutral.Adjust
therightsidelinkagebyturningthequicktrack
knobcounterclockwiseuntilthetirebeginsto
rotateforward.Begintoretightentheknob
clockwiseabout1/4turnatatime,stopping
tomovethespeedcontrolforwardandback

Figure18

2.Adjustthelinkagelengthbylooseningthejam
nutsatbothendsofthelinkageandrotating
thelinkageintheballjoints.Lengthenthe
linkageifthetireisturninginreverseand
shortenthelinkageifthetireiscreeping
forward.Tightenthejamnutsatbothends.
Releaseandre-engagetheneutrallocklatch
checkingthatthetirestops.Continuethis
processuntilthetireisatadeadstop.

3.Makethisadjustmentforbothsides.

•TrackingAdjustment:

1.Stopengineandwaitforallmovingpartsto
stop.Engageparkingbrake.Raisetherearof

34

Maintenance

themachine,removejackstandsandcarefully
lowerthemachinetotheground.(Checkthe
drivetirepressureandtirecircumferencesee
ChecktheTirePressuressection.)

2.Runtheunitandobservethetrackingona
level,smooth,hardsurfacesuchasconcrete
orasphalt.

3.Iftheunittrackstoonesideortheother,turn
thequicktrackknob.Turntheknobrightto
“steer”right;turntheknobleftto“steer”left.

HydroPumpSpringTension
Setting

1.Formediumorheavydutydriveconditionssuch
asoperationwithasulkyonsteepslopes,ahigher
springforcemayberequiredonthehydropump
controlarmstopreventthedrivesystemfrom
stalling.

2.Foraheavierdrivesetting,relocatethespring
anchorlinkasshowninFigure13.Thespring
anchorlinksarelocatedundertheenginedeckon
theleftandrighthandsides.

PTOSafetySwitch

Mountedtoatabontheinsideleftsideofthefuel
tanksupport.

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.Removeignitionkeyor
sparkplugwire(s).

2.WithPTOdisengagedandthebellcranktouching
therearoftheslotintheenginedeck,adjustthe
PTOsafetyswitch(ifneeded)untilthebellcrank
armis5/16inch(7.9mm)fromtheswitchbody.

3.BesurethebellcrankDoesNottouchtheswitch
bodyordamagetotheswitchcouldoccur.

4.RetightenPTOswitchmountinghardware.

Note:In“medium”or“heavyduty”positions,
thedriveleverforcesattheupperhandlewillalso
beincreased.

Figure19

1.Heavyduty

2.Mediumduty4.Retainingbolt

3.Standard

35

Maintenance

Cleaning

CleanEngineandExhaust
SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore
oftenindryordirty
conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair
intakeandexhaustsystemareacancause
engine,exhaustarea,andhydraulicsystem
tooverheatwhichcancreatearehazard.

Cleanalldebrisfromengineandexhaust
systemarea.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake
screen,aroundengineshrouding,andexhaust
systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe
engineandexhaustsystemarea

RemoveEngineShroudsand
CleanCoolingFins

ServiceInterval:Every80hours

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Cleanoffanyoil,debris,orgrassbuild-uponthe
machineandcuttingdeck,especiallyunderdeck
beltshields,aroundthefueltank,aroundengine
andexhaustarea.

CleanGrassBuild-UpUnder
Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Raisedecktothetransport(maximumcutting
height)position.Liftthefrontofunitandsupport
unitusingjackstandsorequivalentsupport.

CAUTION

Raisingthemowerdeckforserviceor
maintenancerelyingsolelyonmechanical
orhydraulicjackscouldbedangerous.The
mechanicalorhydraulicjacksmaynotbe
enoughsupportormaymalfunctionallowing
theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removecoolingshroudsfromengineandclean
coolingns.Alsocleandust,dirt,andoilfrom
externalsurfacesofenginewhichcancause
impropercooling.

3.Makesurecoolingshroudsareproperly
reinstalled.Operatingtheenginewithout
coolingshroudswillcauseenginedamagedueto
overheating.

3.Cleanoutanygrassbuild-upfromundersideof
deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto
theenvironment.Disposeofusedoilatacertied
recyclingcenteroraccordingtoyourstateandlocal
regulations.

36

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

Federallawstatesthatbatteriesshouldnotbeplaced
inthegarbage.Managementanddisposalpractices
mustbewithinrelevantfederal,state,orlocallaws.

Ifabatteryisbeingreplacedoriftheunitcontaining
thebatteryisnolongeroperatingandisbeing
scrapped,takethebatterytoalocalcertiedrecycling
center.Ifnolocalrecyclingisavailablereturnthe
batterytoanycertiedbatteryreseller.

Maintenance

37

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused
byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor
itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have
thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank(ElectricStartUnits).

Enginewillnotstart,startshard,orfailsto
keeprunning.

1.PTOisengaged.

2.Speedcontrolleverisarenotinneutral
lockposition.

3.OPCleversarereleased.

4.Batterydoesnothaveafullcharge.4.Chargethebattery.

5.Electricalconnectionsarecorroded,loose
orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Thethrottleandchokearenotinthe
correctposition.

4.Dirtinfuellter.4.Replacethefuellter.

5.Dirt,water,orstalefuelisinthefuel
system.

6.Aircleanerisdirty.

7.Electricalconnectionsarecorroded,loose
orfaulty.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Faultysparkplug.

10.Sparkplugwireisnotconnected.

1.DisengagethePTO.

2.Ensurethespeedcontrolleverisinthe
neutrallockposition.

3.DepressOPClevers.

5.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Besurethethrottlecontrolismidway
betweenthe“SLOW”and“F AST”
positions,andthechokeisinthe“ON”
positionforacoldengineorthe“OFF”
positionforawarmengine.

5.ContactanAuthorizedServiceDealer.

6.Cleanorreplacetheaircleanerelement.

7.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

9.Clean,adjustorreplacesparkplug.

10.Checkthesparkplugwireconnection.

Enginelosespower.

Engineoverheats.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe
engineareplugged.

5.Ventholeinthefuelcapisplugged.

6.Dirtinfuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel
system.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling
nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

2.Addoiltothecrankcase.

38

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Mowerpullsleftorright(withleversfully
forward).

Machinedoesnotdrive.

Unevencuttingheight.

Abnormalvibration.

1.Trackingneedsadjustment.1.Adjustthetrackingbyturningknobonthe

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor
broken.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty .4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

7.Tipsofadjacentbladesareatanuneven
cuttingheight.Bladestipsshouldbeeven
within3/16inchwhichisapproximately
onebladethickness.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade
pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

7.Beltisdamaged.7.Installnewbelt.

righthydrocontrollinkageinthedirection
thatthemowerneedstobeadjustedto.
Turntheknobin1/4turnincrements
untilthemowertrackscorrectly.

2.Changethebelt.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

Bladesdonotrotate.

1.Drivebeltisworn,looseorbroken.1.Checkthebelttension.

2.Drivebeltisoffpulley.2.Checkbeltfordamage;replaceif

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler

5.Brokenormissingidlerspring.

necessary.Installdrivebeltandcheck
adjustingshaftsandbeltguidesforcorrect
position.

pulley,idlerarmandspringforcorrect
positionandfunction.

5.Replacethespring.

39

Schematics

15 & 17 HP KAWASAKI

SAFETY INTERLOCK MODULE

TRANSMISSION

SWITCH

N.O.

PARK BRAKE

SWITCH N.O.

BLADE

SWITCH

N.O.

OPC SWITCH

N.O.

KEY SWITCH

ENGINE

GROUND

ENGINE KILL

CONNECTORS ARE VIEWED FROM WIRE END
N.C. = NORMALLY CLOSED
N.O. = NORMALLY OPEN

GREEN

BLUE

ORANGE

GREEN

YELLOW

RED

BLACK

RED

BLACK

BROWN

A

B

C

D

E

F

G006978

PARK BRAKE

SWITCH N.C.

FUSES

KEY

SWITCH

OPC

SWITCH

N.O.

SAFETY

INTERLOCK

MODULE

NEUTRAL

SWITCH

N.C./N.O.

BLADE

SWITCH

N.O.

SOLENOID

SOLENOID +

ENGINE

ENGINE

GROUND

SOLENOID

ENGINE

VIOLET

YELLOW

RED

WHITE

LT BLUE

BROWN

VIOLET

ORANGE

BLACK

BROWN

ORANGE

BLACK

GREEN

GREEN

WHITE

RED

BLACK

BLACK/WHITE STRIPE

WHITE

BROWN

19 HP KAWASAKI

ELECTRIC START

BATTERY

+

REGULATOR

BATTERY

+

START

BATTERY

+

REGULATOR

GROUND

+

ENGINE KILL

START

ON

OFF

CIRCUIT
"MAKE"

KEY

POSITION

GROUND

REGULATOR

BATTERY

ENGINE KILL

START

CONNECTORS ARE VIEWED FROM WIRE END
N.C. = NORMALLY CLOSED
N.O. = NORMALLY OPEN

G007009

Schematics

ElectricalDiagram

ElectricalDiagram

40

HydraulicDiagram

Schematics

41

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.

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.

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine 2 years*

* 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.

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.

• 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.

There are no other express warranties except for engine and
special emission system coverage.

All warranty work must be performed by an authorized
Exmark Service Dealer using Exmark approved replacement
parts.

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.

Contact any Exmark Service Dealer to arrange service at their
dealership. To locate a dealer convenient to you, access our
website at www.exmark.com. U.S. or Canada customers may
also call 402-223-6375.

If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:

 Exmark Customer Service Department
 The Exmark Warranty Company
 2101 Ashland Avenue
 Beatrice, NE 68310
 402-223-6375 or
 [e-mail]

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.

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.

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 claims for lost revenue, lost profit or additional cost as 
 a result of a claim of breach of warranty.

• Attorney's fees.

No Claim of breach of warranty shall be cause for cancellation
or rescission of the contract of sale of any Exmark mower.

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.

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.

This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-425

42

Notes:

43

Notes:

44

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

454647

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES A ND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

©2008ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-358Rev .A
[phone]
Fax[phone]
PrintedintheUSA

www.exmark.com