Exmark VH15KA483, VH15KA362 User Manual

r

For Serial Nos.

670,000 & Highe

Part No. 109-6455 Rev A.

WARNING

POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating pr actices can result in serious

operator injury or even death.
HOW TO AVOID THE HAZARD
♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condit ion.
♦ Stop engine, wait for all moving part s t o stop and engage parking

brake. Remove spark plug wire(s) or r em ove k ey before

adjusting, servicing, or performing maintenance.
♦ If mower deck becomes clogg ed, stop engine, wait for all moving

parts to stop and engage parking brake. Remove spark plug

wire(s) or remove key before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts .
♦ Keep off mower unless seat platf o r m is pr ovided.
♦ Keep others off mower.

WARNING

POTENTIAL HAZARD
♦ Gasoline is harmful or f at a l if swallowed. Long-term exposure to

vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN
♦ Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD

♦ 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.

IMPORTANT

When the mower is used or oper ated on any California forest, brush or grass covered land, a working
spark arrester must be at t ached t o the muffler. If not, the operator is violating stat e law, Section 4442
Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.

This spark ignition system complies with Canadian ICES-002
Ce système d’allumage par ètincelle de vèhicule est conform e à la norme NMB-002 du Canada

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and the California Emission Control Regulation of
emission systems, maintenance and warranty.

Keep this engine Owner’s M anual with your unit. Should this engine O wner’s Manual become
damaged or illegible, replace immediately. Replacements may be ordered through the engine
manufacturer.

Exmark reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products manufactured previously. Exmark, or its
distributors and dealers, accept no responsibility f or variat ions which may be evident in the actual
specifications of its product s and t he statements and descriptions contained in this publication.

ii

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995
Program

If your Exmark dealer does not have the Exmark part in stock,
Exmark will get the parts to the dealer the next business day or the
part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

2. Distributor ships part(s) to dealer or customer, as

3. If distributor does not have the part(s) in stock to satisfy

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

5. The customer pays for the part

6. Who pays for the part
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

The following restrictions apply
Dealers and applies only to orders submitted on this program Monday through Thursday. Part Plus service is available only in
the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United
States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the
Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday
delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by 3:00 p.m., central time. Orders
must be six (6) line items or less. Exclusions from the Exmark Parts Plus
entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or
hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight
restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or
Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered
for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus

®

shipment of six (6) line items or less.

requested by dealer, same day, overnight UPS Distributor
bills dealer for part and freight charges where applicable.

Exmark Parts Plus
p.m., central time, with an Exmark Parts Plus

®

order, he contacts Exmark by 3:00

®

order of six (6) line items or less.

distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable.

and freight if it is shipped under the Exmark Parts Plus® and if it arrives in accordance

to the program.

and freight if it fails to arrive overnight in accordance to the program?

1. The dealer not submitting the Exmark Parts Plus
pays for the part and freight.

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

Exmark pays for the part and freight.

pays for the part.

-- The Exmark Parts Plus® Program is available only through participating Exmark

®

order to his Exmark distributor by 1:00 p.m., the dealer

®

order

®

Program are: Any wholegood or accessory in its

iii

CONGRATULATIONS on the purchase of your Exmark Mower. This product has been caref ully
designed and manufactured to give you a maximum amount of dependability and years of
trouble-free operation.

OPERATOR'S MANUAL

This manual contains operating, maintenance, adjustment, and safety instructions for
your Exmark mower.

BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.

By following the operating, m aintenance, and safety instructions, you will prolong the life
of your mower, maintain its maximum ef ficiency, and promote safe operation.

If additional information is needed, or should you require trained mechanic ser vice,
contact your authorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and distributors are kept infor med of the latest methods
of servicing and are equipped to provide prompt and efficient service in the f ield or at their
service stations. They carry ample stock of ser vice parts or can secur e t hem promptly for you
from the factor y.

All Exmark parts are thor oughly tested and inspected before leaving the factory,
however, attention is required on your part if you are t o obt ain the fullest measure of
satisfaction and performance.

iv

TABLE OF CONTENTS

DESCRIPTION PAGE

1. SAFETY

1.1 Safety Alert Symbol..................................................................................... 1

1.2 Training........................................................................................................ 1

1.3 Preparation...............................................................................................1-4

1.4 Operation.................................................................................................. 4-7

1.5 Maintenance & Storage................................................................................ 7

1.6 Riding Attachments...................................................................................... 8

1.7 Safety Signs........................................................................................ .....8-9

2. SPECIFICATIONS

2.1 Model Number............................................................................................ 10

2.2 Engine........................................................................................................ 10

2.3 Fuel System............................................................................................... 10

2.4 Safety Interlock System .............................................................................10

2.5 Steering/Brake Control............................................................................... 10

2.6 Transmission.............................................................................................. 10

2.7 Wheel Drive System................................................................................... 10

2.8 Tires........................................................................................................... 10

2.9 Deck........................................................................................................... 11

2.10 Dimensions .............................................................................................. 11

2.11 Torque Requirements .............................................................................. 11

3. OPERATION INSTRUCTIONS

3.1 Controls.................................................................................................11-13

3.2 Pre-Start..................................................................................................... 13

3.3 Operation Instructions...........................................................................13-16

3.4 Transporting............................................................................................... 16

4. MAINTENANCE & ADJUSTMENTS

4.1 Periodic Maintenance............................................................................ 17-23

4.2 Adjustments..........................................................................................24-31

5. WASTE DISPOSAL

5.1 Motor Oil Disposal....................................................................................... 31

6. TROUBLE SHOOTING

6.1 Mower Tracks Left or Right........................................................................31

6.2 Mower Cuts Unevenly...........................................................................31-32

6.3 Blades Do Not Stop When Disengaged ..................................................... 32

6.4 Engine Will Not Start.................................................................................. 32

7. BELT ROUTING (MOWER DECKS) .......................................................33

8. WIRING DIAGRAM

....................................................................................... 34

9. HYDRAULIC DIAGRAM............................................................................... 34

10. WARRANTY................................................................................................. 35

v

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL is used both in this manual and on the machine to

identify important safety messages which must be followed to avoid accidents. This
symbol means:

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The safety alert symbol appears above inform at ion which alerts you to unsafe actions or

situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: Whit e let tering/Red background. I ndicat es an imminently hazardous situation

which, if not avoided, WILL result in death or serious injur y.

WARNING: Black lettering/Orange background. Indicates a potentially hazardous

situation which, if not avoided, COULD result in deat h or serious injury.

CAUTION: Black lettering/Yellow background. Indicates a potentially hazardous situation

which, if not avoided, MAY result in minor or moderate injury.

1.2 TRAINING

1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard
to all who operate this unit.

1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the
proper use of the equipment. If the operator(s) or mechanic(s) can not read
English it is the owner’s responsibility to explain this material t o them.

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow
children, teenagers, or people unfamiliar with these instructions to use the
mower. Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in
mind that the operator or user is responsible for accidents or hazards occurring
to other people or their property.

1.3 PREPARATION

1.3.1 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.

1.3.2 The use of personal protective equipment, such as (but not limited to) protection
for the eyes, ears, feet and head is r ecom m ended.

CAUTION

POTENTIAL HAZARD
♦ This machine produces sound levels in

excess of 85 dBA at the operator’s ear

when in operation.
WHAT CAN HAPPEN
♦ Exposure to sound levels of 85 dBA or

above for extended periods of time can

cause hearing loss.
HOW TO AVOID THE HAZARD
♦ Wear hearing protection when operating

this machine.

1

1.3.3 While mowing, always wear substantial footwear and long trousers. Do not
operate equipment when barefoot or when wearing open sandals.

1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all
stones, sticks, wires, bones, and other foreign objects which may damage the
equipment or cause personal injury to the operat or or bystanders.

WARNING

POTENTIAL HAZARD
♦ Engine exhaust contains carbon

monoxide, which is an odorless deadly

poison.
WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.
HOW TO AVOID THE HAZARD
♦ Do not run engine indoors or in a small

confined area where dangerous carbon

monoxide fumes can collect.

DANGER

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely

flammable and highly explosive.
WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can burn

you, others, and cause property damage.
HOW TO AVOID THE HAZARD

♦ DO NOT smoke while refueling , and stay

away from an open flame or where
gasoline fumes may be ignited by spark .

♦ Refuel only outdoors.
♦ Store gasoline in an approved container

and keep it out of the reach of children.

♦ Add fuel before start ing the engine.

Never remove the cap of the fuel t ank or

add fuel when engine is running or when
the engine is hot.

♦ Never fill the fuel tank so that the gasoline

level rises above a level that is 1/2” below
the bottom of the filler neck to allow for
gasoline expansion and prevent fuel
spillage.

♦ 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.

♦ Do not operate without entire exhaust

system in place and in proper working

condition.

2

DANGER

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely

flammable and highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite g asoline

vapors. A fire or explosion from g asoline

can burn you, others, and cause property

damage.
HOW TO AVOID THE HAZARD

♦ Purchase and store gasoline only in an

approved container.

♦ Always place gasoline containers on the

ground away from your vehicle before
filling.

♦ 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.

♦ When practical, r em ove g as- powered

equipment from t he t r uck or trailer and
refuel the equipment with its wheels on
the ground.

♦ If this is not possible, then refuel such

equipment on a truck or t r ailer from a
portable container, rather than from a
gasoline dispenser nozzle.

♦ 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 com p let e.

3

1.4 OPERATION

Although hazard control and accident prevention are parti al l y dependent upon the
design and configuration of the equipment, these factors are also dependent upon
the awareness, concern, prudence, and proper training of t he personnel i nvolved in
the operation, transport, maintenance, and st orage of t he equipment. It is essential
that all Operator Safety Mechanisms be connect ed and i n operat i ng condition prior
to use for mowing.

WARNING

POTENTIAL HAZARD
♦ Gasoline vapor can collect inside

enclosed trailers and may be ignited by
electrical sparks or hot engine/ exhaust

components.
WHAT CAN HAPPEN
♦ Explosion and fire may occur, resulting in

property damage, personal injury, and/or

death.
HOW TO AVOID THE HAZARD

♦ Provide adequate ventilation of any

enclosed trailer to prevent build up of
gasoline vapors, especially at floor level.

♦ Refuel only outdoors, never inside an

enclosed trailer.

♦ Be sure all fuel tanks and gasoline

storage containers have proper caps
installed to prevent spillage and minimize
vapor escaping into the trailer.

♦ Do not place any equipment that is

leaking gasoline in an enclosed trailer.

WARNING

POTENTIAL HAZARD
♦ Operating engine parts, especially the

muffler, become extremely hot.
WHAT CAN HAPPEN

♦ Severe burns can occur on contact.
♦ Debris, such as leaves, grass, brush, etc.

can catch fire.
HOW TO AVOID THE HAZARD

♦ Allow engine parts, especially the muff ler ,

to cool before touching.

♦ 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 br ush-

covered unimproved land.

4

WARNING

POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories

can become entangled in rotating part s .
WHAT CAN HAPPEN
♦ Contact with rotating parts can cause

traumatic amputation or severe

lacerations.
HOW TO AVOID THE HAZARD

♦ Do not operate the machine without

guards, shields, and safety devices in
place and working properly.

♦ Keep hands, feet, hair, j ewelry, or clot hing

1.4.1 Give complete, undivided attention to the job at hand.

1.4.2 Mow only in daylight or good artificial light, keeping away from holes and hidden
hazards. Do Not operate the mower when children or others are in the area.

1.4.3 When feasible, avoid operating the equipment in wet grass.

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of
traction and/or control could occur.

away from rotating parts.

DANGER

POTENTIAL HAZARD
♦ Mowing on wet grass or steep slopes can

cause sliding and loss of control.
WHAT CAN HAPPEN
♦ Loss of control and/or loss of oper ator’s

footing could result in a fall with an arm or

leg getting under the m ower or engine

deck, which may result in serious injury or

death.
HOW TO AVOID THE HAZARD

♦ Mow across slopes, never up and down.
♦ Do not mow slopes when grass is wet.
♦ Do not mow near drop-offs or near water.
♦ Do not mow slopes greater than 20

degrees.

♦ Reduce speed and use extreme caution

on slopes.

♦ Avoid sudden turns or rapid speed

changes.

• See inside the back cover to determine the approximate slope angle of the
area to be mowed.

• Progressively greater care is needed as the slope increases.

5

• Always avoid sudden starting or stopping on a slope. If tires lose traction,
disengage the blades and proceed slowly off the slope.

• Be aware that loss of traction may occur going downhill. Weight transfer to the
front wheels may cause drive wheels to slip and cause loss of braking and
steering.

• Watch for ditches, holes, rocks, dips, and r ises t hat change the operating
angle, as rough terrain could overtur n the machine.

• Remove or mark obstacles such as rocks, t r ee lim bs, etc. from the mowing
area. Tall grass can hide obstacles.

• Use extreme care with grass catchers or attachments. These can change the
stability of the machine and cause loss of control.

1.4.5 Use EXTREME caution when backing up. LOOK BEHIND YO U!!

1.4.6 Stop the blades when crossing surfaces other than grass, if mower must be t ilt ed
for transportation, and when transpor t ing the mower to and from the area to be
mowed.

1.4.7 Never operate the mower with defective guards, shields, or covers. Always have
safety shields, guards, switches, and other devices in place and in proper
working condition.

1.4.8 Do Not change the engine governor sett ings or over speed the engine. Operating
an engine at excessive speed may increase the hazard of personal injury.

1.4.9 Place speed control lever in neutral, lock drive levers in neutral, disengage PTO,
and engage park brake before starting engine.

1.4.10 Start the engine caref ully with feet well away from the blades.

1.4.11 Keep hands, feet, and clothing away from rot at ing parts while the mower is being
operated.

1.4.12 St op t he engine and wait for all moving parts to stop. Engage parking brake.
Remove plug wire(s) or ignition ke y:

• Before checking, cleaning or working on the mower.

• After strik ing a foreign object (inspect t he m ower for damage and make

repairs before restart ing and operating the mower).

• Before clearing blockages.

• Whenever you leave the mower.

1.4.13 Stop the engine and wait for all moving part s t o stop:

• Before removing the gr ass cat c her .

• Before refueling.

• Before making height adjustments.

1.4.14 Before stopping the engine, place t he t hr ottle control midway between the “slow”
and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then stop
the engine.

1.4.15 The fuel system is provided with a shut-off valve. The fuel shut-off valve is used
to shut off the fuel when:

• The machine will not be used for a f ew days.

• During transport to and from the job.

• When par king inside a building.

1.4.16 This mower was designed for one operator only. Keep all others away from
mower during operation.

1.4.17 Do Not mow with the grass deflector raised, rem oved, or alt er ed unless there is
a grass collection system or mulch kit in place and working properly.

6

1.4.18 Be aware of the mower discharge and direct discharge away from others.

1.4.19 Do NOT operate the mower under the influence of alcohol or dr ugs.

1.4.20 Use care when approaching blind corners, shrubs, trees, or other objects that
may obscure vision.

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maintenance, follow the engine m anufacture’s recommendations
precisely as stated in the engine manual.

1.5.2 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 fir e.

1.5.3 Store fuel in a container specif ically desig ned for this purpose in a cool, dry place.

1.5.4 Keep the mower and fuel container in locked storage to prevent children from
playing or tampering with them.

1.5.5 Gasoline powered equipment or fuel containers should not be stored in a basement
or any enclosed area where open pilot lights or heat appliances are present.

1.5.6 Maximum mowing results and safety can only be achieved if the mower is
properly maintained and operated correctly.

1.5.7 Check all bolts frequent ly to maintain proper tightness.

1.5.8 Keep all guards, shields, and all safety devices in place and in safe work ing condition.

1.5.9 Frequently check for worn or deterior ating components that could create a hazard.

1.5.10 All replacement parts must be the same as or equivalent to the parts supplied as
original equipment.

WARNING

POTENTIAL HAZARD
♦ Hydraulic fluid escaping under pressure

can penetrate skin and cause injury.
WHAT CAN HAPPEN
♦ Fluid accidentally injected into the skin

must be surgically removed within a few

hours by a doctor familiar with this for m of

injury or gangrene may result.
HOW TO AVOID THE HAZARD

♦ 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 and not hands to

find hydraulic leaks.

♦ Safely relieve all pressure in the hydraulic

system by locking drive levers in neutral

and shutting off engine before performing

any work on the hydraulic system.

7

1.6 RIDING ATTACHMENTS

1.6.1 Use only Exmark riding attachments. The use of ot her than Exmark riding
attachments may create a hazardous condition resulting in injury.

1.7 SAFETY SIGNS

1.7.1 Keep all safety signs legible. Remove all grease, dirt and debris from safety
signs and instructional labels.

1.7.2 Safety signs must be replaced if they are missing or illegible.

1.7.3 When new components are installed, be sure that current saf et y sig ns ar e
affixed to the replaced components.

1.7.4 New safety signs may be obtained from your aut hor ized Exmark equipment
dealer or distributor or fr om Exmar k Mfg. Co. Inc.

1.7.5 Safety signs may be affixed by peeling off the backing t o expose the adhesive
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.

1.7.6 Familiarize yourself with the following safety signs and inst r uct ion labels. They
are critical to the safe operat ion of your Exmark commercial mower.

PART NO. 1-303508
LOCATION: On Top Rear Right Hand
Surface of Mower Deck

PART NO. 1-323427
LOCATION: 36” Deck

PART NO. 1-303517
LOCATION: Left Side of Rear
Surface on Engine Deck

PART NO. 1-403005
LOCATION: Front Corners of Mower Deck
36” – RH Front Corner
48” – RH & LH Front Corners

PART NO. 1-403143
LOCATION: Right Side of Rear
Surface on Engine Deck

PART NO. 1-413214
LOCATION: Right Side of Hydro
Control Crank Arm

8

PART NO. 1-513746
LOCATION: On Engine Blower

Housing Next to Muffler

PART NO. 103-2196
LOCATION: Console

PART NO. 98-5954
LOCATION: Under Mower

PART NO. 103-2243
LOCATION: RH Side of Console

PART NO. 1-523552
LOCATION: On Top of
Hydraulic Tank

PART NO. 103-1798
LOCATION: RH Side of

Console

PART NO. 103-2103
LOCATION: On Park

Brake Lever

Deck Belt Shield

PART NO. 103-2242
LOCATION: LH Side of Console

PART NO. 103-4935
LOCATION: Rear Center of

Top Surface of
Engine Deck

PART NO. 103-5626
LOCATION: 48” Deck

9

2. SPECIFICATIONS

2.1 MODEL NUMBER:

Serial Nos. 670,000 & Higher: VH15KA362; VH15KA483

2.2 ENGINE

2.2.1 Engine Specifications: See your Engine Owner's Manual.

2.2.2 3600 RPM (No Load).

2.3 FUEL SYSTEM

2.3.1 Capacity: 5.0 gal. (18.9 L.)

2.3.2 Type of Fuel: Regular unleaded g asoline, 87 oct ane or higher. In countries
using the research method, it should be a 90 oct ane minimum.

2.3.3 Fuel Filter: Replaceable in- line

2.3.4 Fuel Shut-Off Valve: 1/4 turn

2.4 SAFETY INTERLOCK SYSTEM

Operator must have speed control lever in neutral and PT O disengaged to start engine.

Release of OPC levers will cause the engine to stop if speed cont rol lever is not in
neutral and/or PTO is engaged.

2.5 STEERING/BRAKE 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.

2.6 TRANSMISSION

Twin Hydrostatic Drive

2.6.1 Two Hydro Gear variable displacement pum ps independently coupled to two
high efficiency Parker / Ross wheel drive motors .

2.6.2 Hydraulic Filter is replaceable cartridge type.

P/N 109-4180: 25 microns, 10 psi bypass (Summer use above 32°
P/N 1-523541: 40 microns, 18 psi bypass (Winter use below 32°

2.6.3 Speed Range: Forward 0 - 6.2 mph (10.0 km/h)

Reverse 0 - 2.2 mph (3.5 km/h)

F (0° C))

F (0° C))

2.7 WHEEL DRIVE SYSTEM

Drive wheels are direct coupled to Parker/Ross wheel drive motors with 1.0" (25. 4 m m )

tapered shaft.

2.8 TIRES

Drive Front Caster

36” Deck 48” Decks All decks

Size 16 x 6.50-8 16 x 7.50-8 9 x 3.50-4
Quantity 2 2 2
Tread Turf Master Turf Master Smooth
Ply Rating 4 4
Pressure 14 psi (97 kPa) 14 psi (97 kPa)

Pneumatic (Air-Filled) Pneumatic (Air-Filled)

Semi-Pneumatic

10

2.9 DECK

2.9.1 Cutting Width:

35.38 in. (89.9 cm) 47.24 in. (120.0 cm)

36” 48”

2.9.2 Discharge: Right Side

2.9.3 Blade Size:

Length
Qty

18.00 in. (45.7 cm) 16.25 in. (41.3 cm)

36” 48”

2 3

2.9.4 Type of Drive: Manual engagement of belt with over-center lock. Belt tension is

adjustable via turnbuckle.

2.9.5 Blade Brake: When the PTO engagement control is move to the disengaged

position a friction brake pad stops the rotation of the blades.

2.9.6 Deck Mounting: Bolted directly to the engine deck.

2.9.7 Cutting Height: Adjusts in 1/4” (.63 cm) increments f r om 1” (2.5 cm) to 4 1/4”

(10.8 cm).

2.10 DIMENSIONS

2.10.1 Overall Width:

Discharge chute down 47.0” (119.4 cm) 57.9” (147.1 cm)
Discharge chute up

(Transport only)

36” 48”

36.4” (92.5 cm) 48.1” (122.2 cm)

2.10.2 Overall Length:

36” 48”

77.3” (196.3 cm) 72.3” (183.6 cm)

2.10.3 Curb Weight:

2.10.4 Overall Height:

498 lbs. (226 kg) 551 lbs. (250 kg)

36” 48”

36” 48”

43.2” (109.7 cm) 43.2” (109.7 cm)

2.10.5 Tread Width:

(to outside of tires)

36” 48”

35.6” (90.4 cm) 40.4” (102.6 cm)

2.11 TORQUE REQUIREMENTS

BOLT LOCATION TORQUE

Blade/Cutter Housing Spindle Bolt................................ 75-85 ft -lbs. (102-115 N-m)

Caster Bracket Mounts.................................................. 30-35 ft-lbs. (41-47 N-m)

Cutter Deck/Engine Deck Mount................................... 30-35 ft-lbs. (41-47 N-m)

Engine Mounting Bolts.................................................. 15-20 ft-lbs. (20-27 N-m)

Wheel Lug Nuts ............................................................ 90-95 ft-lbs. (122-129 N-m)

Wheel Hub Slotted Nut.................................................. minimum 100 ft-lbs (136 N-m)

3. OPERATION INSTRUCTIONS

3.1 CONTROLS

3.1.1 Familiarize yourself with the controls and operation of the unit.

Carefully read the following information about the controls and t heir operation.

3.1.2 Operator Presence Control (OPC) Levers
assembly directly above the handle grips (See Figure 1). When these l evers 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 positi on and will kill
the engine if either the speed cont rol lever is not in the neutral position or the
PTO is engaged.

11

: Located on the upper handle

3.1.3 Speed Control Lever: Locat ed in middle of control console, it controls t he
maximum forward speed and is infinitely variable from neutral (0 mph) to 6.2
mph. Park brake must be disengaged before speed control lever is moved out
of neutral or engine will kill.

3.1.4 Drive Levers

: Located on each side of the upper handle assembly directly below
the handle grips (See Figure 1). These levers individually control the speed and
direction of each drive wheel. When the speed control lever is moved out of the
neutral position and the neutral lock lat ches are moved into the drive position, as
shown in Figure 2, and the drive levers are released, the drive wheels are
engaged in the forward direction.

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.

3.1.5 Neutral Lock Latch

: Located at the end of the handles. The purpose of these
latches is to allow the operator to lock the dr ive levers in a "neut ral" position where
neither of the drive wheels are engaged in either a forward or reverse direction.
(See Figure 1).

Apply parking brakes whenever leaving the operators position.

FIGURE 1

3.1.6 PTO Engagement

: The “push/pull” PTO knob is located on the left side of t he
control console. To engage the blades, the knob must be pulled toward the
operator until the turnbuckle ( at tached to the blade engagement idler) locks over­center. To disengage the blades, push the knob down until the assist arm
contacts the pin on the deck.

Park brake m ust be disengaged before PTO is engaged or engine will kill.

3.1.7 Throttle Control

: The throttle is located on the cont r ol console r ight side. The
throttle is used to control engine speed. Moving the thr o t t le cont rol forward will
increase engine speed and moving it to the rear will decrease engine speed.
Moving the throttle forward into the detent is full position.

3.1.8 Choke Control

: Choke aids in starting a cold engine.

The choke control is locat ed on t he front left corner of the fuel tank support and

is activated by pulling the control outward.

Once the engine has start ed, move the choke control to the off position and

move the throttle to the medium of full throttle posit ion.

3.1.9 “Off-Run” Switch

: Located on the console. Turn key to t he “ Run” position to

allow the engine to be started. Turn key to the “Off” posit ion to shut engine off.

3.1.10 Park Brake Lever

: Located on the right side of t he unit above the hydraulic tank.

The brake lever engages the par k brake on the drive wheels.

12

Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the brake.
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.

Park brake m ust be disengaged before the speed control lever is moved out of

neutral or PTO is engag ed or engine will kill.

3.1.11 Fuel Shut-Off Valve
engine. The fuel shut-off valve is used to shut off the flow of fuel when parking
inside a building, during transporta t ion t o and from the job sites, and when the
machine will not be used for a few days.

Rotate valve 1/4 turn clockwise to shut fuel off.
Rotate valve 1/4 turn counter-clockwise to turn fuel on.

3.1.12 Drive Wheel Release Valves
pumps. Drive wheel release valves are used to release the hydro-static drive system
to allow the machine to be moved by hand without the engine running. With a 5/8”
wrench, turn valves one turn counterclockwise to release the drive system.

Turn clockwise to reset the dr ive system. Do Not over-tighten.

3.1.13 Cold Start Kit
ahead of the hydro control shield. The cold star t kit is used to ease the starting
of the unit in cold weather or when the unit has not been operated for a period of
time. The cold start k it m oves the idler pulley away from t he pum p belt, releasing
the tension on the belt which allows the engine to turn over with less resistance.
See Section 3.3.2.

3.1.14 Tracking Adj ust m ent Knob
tank support. Can be adjusted so t hat m achine will “tr ack” straight ahead with
drive levers released.

: Located on the right hand side of engine deck, below and slightly

: Installed in the fuel line midway between the tank and

: Located on the top rear corner of the hydrostatic

: Located on the right-hand side of the rear of the fuel

3.2 PRE-START

3.2.1 Fill f uel t ank. For best results use only clean fresh re gular grade unleaded
gasoline with an octane rating of 87 or higher. Regular grade leaded g asoline
may also be used; however, combustion chamber and cylinder head will require
more frequent service. See Engine Owner's Manual.

Do not add oil to gasoline.
Do not overfill fuel tank. Never fill the fuel tank so that the fuel level rises above a

level that is 1/2” (1.3 cm) below the bottom of the filler neck t o allow f or fuel
expansion and prevent fuel spillage.

3.2.2 Refer to Maintenance and Adjustment Section 4.1 and perfor m all of the
necessary inspection and maintenance steps.

3.2.3 Make sure you understand the controls, their locations, their functions, and t heir
safety requirements.

3.3 OPERATING INSTRUCTIONS

3.3.1 Read the Engine Owner’s Manual carefully for detailed operating instruct ions
and maintenance regarding the engine.

Before attempting to oper at ed the unit, refer to Section 1 (Safety) and follow all

safety, operating, and prepar ation guidelines as stated in that section.

3.3.2 Starting Engine
in neutral.

Lock drive levers in neutral and engage park brake.
Open fuel shut-off valve.

: Operator must have PTO disengaged and speed control l ever

13

NOTE: A cold weather starting kit has been added for ease of st art i ng in

either cold weather or when the unit has not been run for a period of time.

To use cold start kit:
a) Pull split ring straight out the side of t he unit, and hook the ring over the

lower front hydro control shield bolt.
b) Start engine. Refer to the following guidelines for further starting suggestions.
To engage pump drive (disengage cold start k it ) :
a) Pull chain straig ht out from the side of t he unit until the split ring can be

removed from the bolt.
SLOWLY release tension on chain.
Pull out the choke control. Place the t hr ottle control midway between the “Slow”

and “Fast” positions. Turn the key switch to the “Run” position.

Pull recoil rope to start engine. After engine warms up, gradually push in the

choke control. DO NOT r un warm engine with the choke in the “ON” position.

NOTE: Kawasaki engines generally need to be “choked” even when warm.

3.3.3 Stopping Engine

: Lock the drive levers in neutral, diseng age PTO, position
speed control lever in neutral, and engage t he par k brake. Move throttle control
midway between the “slow” and “fast” positions. Allow the eng ine to run a
minimum of 15 seconds.

Turn the key to t he “Off” position.
Close the fuel shut off valve if machine will not be used for a few days; when

parking inside a building; or when transporting the unit.

3.3.4 Drive Lever/Neutral Lock Latch Operation

:

T o lock the drive levers in “neutral lock”, squeeze the drive levers to t he “ neutral”

position See Figure 2 (a). (Do Not squeeze at the drive levers all the way back as
this will cause the drive wheels to go into the full reverse direct ion) . Place thumbs
on the inner thumb lobe of the neutr al lock latches and rotate them to t he “ neut ral
lock” position. See Figure 2 (b). Release the drive levers.

CAUTION

POTENTIAL HAZARD
♦ If the neutral lock/ par k brake latches are

not completely engaged the drive levers
could unexpectedly slip into the forward

drive position.
WHAT CAN HAPPEN
♦ If the drive levers slip into the drive

position, the unit could lurch for ward and

cause injury or property damage.
HOW TO AVOID THE HAZARD
♦ Be sure the pins protruding through the

slots of each neutral lock latch ar e

completely engaged in the rear slot of

each latch.

To place the drive levers in the “forward” position, slightly squeeze the drive

levers while placing thumbs on the outer thumb lobe of t he neutral lock latches

14

(or the index finger on the front lobe) and rotate them from under the drive
levers. Slowly and carefully release the drive levers. See Figure 2 (d).

To place the drive levers in the “reverse” posit ion, squeeze the drive levers past

the neutral position. See Figure 2 ( c).

FIGURE 2

3.3.5 Drive Wheel Engagement and Turning
position, shift speed control lever into desir ed forward speed.

Note: The park brake must be disengaged befor e t he speed cont rol lever is

moved out of neutral or the engine will kill.

Slowly squeeze and hold both drive levers in the neutral position and move both

neutral lock latches fr om t he neutral lock position. Do Not squeeze both drive
levers all the way back, this will cause the drive wheels to be engaged in the
reverse direction.

For straight ahead motion: Smoothly release both dr ive levers to engage drive

wheels.

For turning: 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.

For reverse: Squeeze both drive levers into the reverse position. See Figure 2 (c).
For smooth operation of this machine, avoid quick, jerky movements of the drive

levers. Move the drive levers smoothly and deliberately.

3.3.6 To Stop
Move neutral lock latches into the “neutral lock ” posit ion. See Figure 2 (b) and
release drive levers. Move the speed control lever to the neutral position.

3.3.7 PTO Engagement

: Squeeze drive levers back to the “neutral” position. See Figure 2 (a)

:

: With dr ive levers lock ed in the “neutral”

DANGER

POTENTIAL HAZARD
♦ The rotating blades under the mower

deck are dangerous.
WHAT CAN HAPPEN
♦ Blade contact can cause serious injury or

kill you.
HOW TO AVOID THE HAZARD
♦ DO NOT put hands or feet under t he

mower or mower deck when the blades

are engaged.

15

DANGER

POTENTIAL HAZARD
♦ 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.
WHAT CAN HAPPEN
♦ Thrown objects or blade contact can

cause serious injury or death.
HOW TO AVOID THE HAZARD
♦ Never operate the mower with the

discharge deflector raised, r emoved, or

altered unless there is a grass collection

system or mulch kit in place and working

properly.

Be sure that all persons are clear of mo wer deck and dischar ge area before engaging

the PTO. Set throt tle to “midway” position. Pull the PTO engagement knob up
to engage blades. Accelerate to full throttle to begin mowing ( See Sect ion

3.1.6).

Park brake m ust be disengaged before PTO is engaged or engine will kill.

3.3.8 PTO Disengagement
the blades. (See Section 3.1.6)

: Push down on the PTO engagement k nob to disengage

3.4 TRANSPORTING

WARNING

POTENTIAL HAZARD
♦ Loading the mower onto a trailer without

strong enough or properly supported

ramps could be dangerous.
WHAT CAN HAPPEN
♦ The ramps could collapse causing the

unit to fall, which could cause injury.
HOW TO AVOID THE HAZARD

♦ Use proper ramps that are secured to the

truck or trailer.

♦ Keep feet and legs out f r om under the

unit when loading and unloading.

♦ If necessary, use assistance when

Be sure fuel shut-off valve is closed.
Use a heavy duty trailer to transport the m achine. Engage park brakes and block

wheels. Securely fasten the machine to the trailer with str aps, chains, cables, or
ropes. Be sure that the trailer has all necessary lighting and marking as
required by law and use a safety chain.

Do not rely solely on parking brake to hold machine on trail er.

loading.

16

4. MAINTENANCE & ADJUSTMENTS

WARNING

POTENTIAL HAZARD
♦ While maintenance or adjustments are

being made, someone could start the

engine.
WHAT CAN HAPPEN
♦ Accidental starting of the engine could

seriously injure you or other bystanders.
HOW TO AVOID THE HAZARD
♦ Remove the key from the ignition switch

and/or 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) .

WARNING

POTENTIAL HAZARD
♦ The engine can become very hot.
WHAT CAN HAPPEN
♦ Touching a hot engine can cause severe

burns.
HOW TO AVOID THE HAZARD
♦ Allow the engine to cool completely before

service or making repairs around the

engine area.

4.1 PERIODIC MAINTENANCE

4.1.1 Check engine oil level:
Service Interval: See Engine Owner's Manual
a) Make sure engine is on a level surface. Stop engine and wait for all

moving parts to stop.
b) Check with engine cool.
c) Clean area ar ound dipstick. Remove dipstick and wipe oil off. Reinser t the

dipstick (DO NOT screw into place). Remo ve dipstick and check oil level.
d) If the oil level is low, add oil as specified in the Engine Owner’s Manual to

bring the oil level up to the “Full” mark on the dipstick.
DO NOT OVERFILL.

IMPORTANT: DO NOT operate the engine with oil level below the “LOW”

(or “ADD”) mark or over the “FULL” mark.

4.1.2 Clean engine air cooling system:

Service Interval: See Engine Owner's Manual
a) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).

17

b) Clean all debris from engine air intake screen and from around engine

shrouding.

4.1.3 Clean grass build-up under deck and check mower blades:

Service Interval: Daily

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous.
WHAT CAN HAPPEN
♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

could cause injury.
HOW TO AVOID THE HAZARD
♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

jack stands or equivalent support.

a) Disengage PTO.
b) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).
c) Raise deck and block up using proper safety precautions.
d) Clean out any grass build-up from underside of deck and in deck discharge

chute.
e) Inspect blades and sharpen or replace as required.
f) If blade removal is necessary, be car eful for the sharp cutting edges of the

blades.

g) Re-install the blades (if they were removed) and torque blade bolts to 75-85

ft. lbs. (102-115 N-m ) . Be sure the spring disk washer cone is installed

toward the bolt head (See Figure 3).

h) Remove jack stands (or equivalent support) and lower deck to ground.

FIGURE 3

18

(102-115 N-m)

4.1.4 Check safety interlock system:
Service Interval: Daily
a) For your safety, your Exmark mower is equipped with Operator Pr esence

Controls (OPC). When either the PTO is engaged, or the speed control
lever is not in neutral and both hands are removed from t he handles, the
mower engine MUST stop.

b) Check OPC circuits. Clear the ar ea. Disengage the park brake. Run

engine at one-third throttle, then with drive levers and neutral lock latches
in neutral lock position, move the speed control lever out of neutr al and
release OPC levers - engine MUST stop.

Again, run engine at one-third th r ot tle, move the speed control lever to

neutral, engage PTO and r elease O PC levers - engine MUST stop.

Note: Park brake must be disengaged before the speed control lever is

moved out of neutral or PTO is engaged or engine will kill.

c) If machine does not pass any of these tests, DO NO T oper ate. Contact

your authorized EXMARK SERVICE DEALER.

IMPORTANT: It is essential that all Operator Safety Mechanisms be

connected and in proper operating condition prior to the use of the
mower.

4.1.5 Check for loose hardware:
Service Interval: Daily

a) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).

b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten hardware or correct the problem before operating .

4.1.6 Service pre-cleaner element and air cleaner

.

Service Interval: See Engine Owner's Manual
a) Stop engine and wait for all moving parts t o st op. Engage parking brake.

Remove key or spark plug wire(s).

b) See engine owners manual for cleaning instructions.

4.1.7 Change engine oil

:

Service Interval: See Engine Owner's Manual

NOTE: Change oil after first five (5) hours of operation. Follow engine

manufacturers recommendations for future oil changes.

a) Disengage PTO.
b) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).
c) Drain oil while engine is warm from operation.
d) The oil drain hose assembly is located on the left side of the engine.

Place pan under machine to catch oil. Remove oil drain plug. Allow oil to

drain and replace oil drain plug. Torque plug to 20-24 ft-lbs.
e) Replace the oil filter as per Engine O wner's Manual. Clean around oil filter

and unscrew filter to remove. Bef o r e r e inst alling new filter, apply a thin

coating of oil on the surface of the rubber seal. Tur n filter clockwise until

rubber seal contacts the filter adapter then tighten f ilt er an additional 2/3 to

3/4 turn.
f) Clean around oil fill cap and rem ove cap. Fill to the specified capacity and

replace cap. Use oil as specified in Engine Owners Manual. Do not overfill.
g) Start the engine and check for leaks. Stop engine and recheck oil levels.

19

4.1.8 Check hydraulic oil level:
Service Interval: 40 hr.
a) Stop engine and wait for all moving parts t o stop.
b) Clean area around hydraulic reservoir cap and remove cap. Oil level

should be to the top of the baf fle inside the tank. If not, add oil. Use only

Mobil 1 15W-50 synthetic motor oil. Replace hydraulic r eser voir cap and

tighten until snug. Do not overt i ghten.
NOTE: The baffle is labeled “HOT” and “ CO LD”. 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 t he oil when it is

a 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° ) , fill to

halfway between the “HOT” and “COLD” levels. If the oil is at room

temperature (about 75°F ( 24° C) ), fill only to the “COLD” level.

4.1.9 Change hydraulic system filter:
Service Interval: After First 250 hrs, then yearly thereafter.
Note: Use Exmark Part No. 109-4180 for Summer use above 32°

F (0° C)and

use Part No. 1-523541 for Winter use below 32° F (0° C). (Refer to 2.6.2 for Filter
Specifications.)

a) Place unit on a level surface. Stop engine and wait for all moving parts to

stop. Engage parking br ake. Remove key or spark plug wire(s).
b) Carefully clean area around filter. It is important that no dir t or

contamination enters the hydraulic system.
c) Unscrew f ilter to remove and allow oil to drain from reser voir.
IMPORTANT: Before re-installing new f ilter, fill it complete ly with Mobil 1 15W-

50 and apply a thin coat of oil on the surface of the rubber seal. Turn filter
clockwise until rubber seal contacts the filter adapter. Do not tighten yet.

d) Fill reservoir as stated in Section 4.1.8.
e) Loosen filter 1/2 turn and allow a small amount of oil to leak from t he oil

filter (this allows air to be purged from the oil filt er and supply hose from the

hydraulic reservoir). Turn filter clockwise until rubber seal contacts the filter

adapter. Then tighten t he filter an additional 2/3 to 3/4 turn.
f) Raise the rear of the machine up onto jack stands high enoug h t o r aise t he

drive wheels off of the gr ound. Run machine to allow any other air to be

purged from the hydraulic system and r echeck the oil level.
g) If either drive wheel does not rotate, one or bot h of the charge pumps

(located on the top of the main pump as shown in Figur e 4) m ay have lost

their “prime”. Ref er t o Sect ion 4. 1.10.
h) DO NOT change hydraulic system oil (except what can be dr ained when

changing filter) unless it is felt t hat oil has been contaminated. Changing

oil unnecessarily could damage the hydraulic system by introducing

contaminates into the system.

4.1.10 Hydraulic system air purge procedure:
Air m ust be purged from the hydraulic system when any hydraulic components,

including oil filter, are r em oved or any of the hydraulic lines are disconnected.
The critical area for purging air from the hydraulic system is bet ween the oil
reservoir and each charge pump located on the top of each variable
displacement pump. (See Figure 4).

Air in other parts of the hydraulic system will be purged thr ough normal operation

once the charge pump is “primed”.

20

a) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Raise the rear of the machine up onto j ack stands high enough to raise the

drive wheels off the ground.
b) Check oil level as stated in Section 4.1.8.
c) Start engine an move throttle cont r ol ahead to full throttle position. Move

the speed control lever to the middle speed position and place the drive

levers into the “drive” position.
I f either drive wheel does not rotate, it is possible to assist t he pur ging of

the charge pump by carefully rotating the tire in the forward direction.
NOTE: It is necessary to lightly touch the charge pump cap with your

hand to check the pump temperature. If the cap is too hot to touch, turn

off engine. The pumps may be damaged if the pump becomes too hot.
If either drive wheel still does not rotate cont inue with step ( d).

d) Thoroughly clean the area around each of the char ge pump housings.

FIGURE 4
e) To “prime” charge pump, loosen two hex socket head capscrews (shown in

Figure 4) 1-1/2 turns only. Make sure engine is not runni ng. Lift charge

pump housing upward and wait for a steady flow of oil to flow out from

under housing. Retighten capscrews. Do this for both pumps. Note:

Hydraulic reservoir can be pressurized to up to 5 psi (34 kPa) to speed this

process.
f) If either dr ive wheel still does not rot at e, stop and repeat steps (d) throug h

(e) above for the respective pump. If wheels rotate slowly, the system may

prime after additional running. Check oil level as stated in Section 4.1.8.
g) Allow unit to run several minutes after the charge pumps are “primed” with drive

system in the full speed position. Check oil level as stat ed in Sect ion 4.1.8.
h) Check hydro drive linkage adjustment as st at ed in Section 4.2.9.

4.1.11 Check tire pressures:

Service Interval: Pneumatic (air-filled) Drive Tires – 40 hrs.
Semi-pneumatic Caster Tires – No Maintenance

a) Stop engine and wait for all moving parts to stop. Engage parking brak e.

Remove key or spark plug wire(s). Check air pr essure in drive tires;

recommended tire pressure is: 12 to 14 psi (83- 97 kPa).
b) Inflate tires to pressures stated above. Measure circumference of each

drive tire. Adjust tire pressures within the above range to t ry to make tire

circumferences match as closely as possible.

21

4.1.12 Inspect Belt wear:
Service Interval: 40 hrs.

a) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).
b) Remove mower deck belt shield to check mower blade drive belt condition.
c) Look under engine deck to check the pump drive belt condit ion.
d) Check all idler arms to be sure they pivot f r eely. Disassem ble, clean and

grease pivot bushings if necessary.

4.1.13 Lubrication:
Service Interval: Refer to Chart.

a) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).
b) Lubricate fittings with one to two pumps of NG LI grade no.2 multi-purpose

gun grease.
Refer to the following chart for fitting locations and lubricat ion schedule.

GREASE LUBRICATION CHART

FITTING
LOCATIONS

1. Caster Wheel Bearings 12 2 Daily

2. Caster Pivots 2 2 Daily

3. PTO Engagement Bellcrank 1 1 Monthly

4. Pump Drive Idler Pivot 2 1 Weekly

5. Pump Control Bearings 2 2 Weekly

6. Mower Deck Idler Pivot 2 1 Weekly

No. 4 Idler Pivot (Pump Drive)

Located Under Engine Deck

No. 4 & 6 (Idler Pivots)
Disassemble and grease once a
month under a “No Load” condition.

INITIAL
PUMPS

NO. of

PLACES

SERVICE

INTERVAL

c) Lubricat e pivot point s with a spray penetrating lubricant as directed below.

SPRAY LUBRICANT CHART

PIVOT POINT

1. PTO Engagement Upper Bellcrank 1 Weekly

NO. OF

PLACES

4.1.14 Check spar k plugs:
Service Interval: See Engine Owners Manual
a) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).
b) Remove spark plugs, check condition and adjust plug gap or replace with

new plugs.

22

SERVICE

INTERVAL

4.1.15 Remove engine shr ouds and clean cooling fins:
Service Interval: See Engine Owner's Manual
a) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).
b) Remove cooling shrouds from engine and clean cooling fins. Also clean

dust, dirt and oil from external sur faces of engine which can cause

improper cooling.
c) Make sure cooling shrouds are properly reinstalled. Operating the engine

without cooling shrouds will cause engine damage due to overheating.

4.1.16 Chang e fuel filter

:
Service Interval: As Required
a) A fuel filter is installed in t he fuel line between the fuel tank and the engine.

Replace when necessary.

4.1.17 Refer to Eng ine Operators Manual for detailed maintenance regar ding the engine.

4.1.18 Wheel hub

- slotted nut torque specification.
When tightening the slotted nut on the wheel motor tapered shaf t :
a) Torque the slotted nut to 100 ft. lbs. (136 N-m).
b) Further tighten the nut until t he next set of slots line up with the cross hole

in the shaft.
c) Replace cott er pin.
Note: Do not use anti-seize compound on the wheel hub.

4.1.19 Thread locking adhesives such as “Loct it e 242” or “ Fel- Pr o, Pro-Lock Nut-Type”

are used on the following fasteners:
a) Pump sheave setscrews.
b) Square head setscrews on hydro pump control arms.
c) OPC lever setscrews.
d) Shoulder bolts in ends of speed control crank .
e) Sheave retaining bolt in end of eng ine crankshaft.
f) Fuel tank bulkhead fitting threads.
Adhesives such as “Loctite RC/609 or RC/680” or “ Fel-Pro Pro-Lock Retaining I

or Retaining II” are used on the following:
a) 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 coul d cause bi nding of the OPC levers and erratic
operation.

b) Fuel tank studs, where studs are inserted into tank.

4.1.20 An anti-seize compound

is used on the following locations:

a) Between the blade drive and pump drive sheaves and engine crankshaft.

4.1.21 Mobil HTS grease (or f ood- grade antisieze) is used in the following locations:
a) Between the cutter housing spindle and bearings.

b) Between the cutter housing spindle and sheave.
c) Under top cutter housing bearing guard.

4.1.22 Dielectric grease

is used on all blade type electrical connections to prevent

corrosion and loss of contact.

23

4.2 ADJUSTMENTS

4.2.1 Adjusting cutting height with blade spacers:
Blades may be adjusted for cutting height by using the four 1/ 4" ( . 64 cm) spacers

found on the blade spindle bolts (fact or y sett ing is two above and two below). This
allows a 1" (2.5 cm) range in 1/4" (.64 cm) increments of cutting height in any axle
position. The same number of blade spacer s must be used on all blades to
achieve a level cut (two above and two below, one above and three below, etc.).

For the best cut and discharg e a m inimum of two spacers should be placed

between the blade and spindle shaft. The highest quality cut can be achieved
with all four spacers between the blade and the spindle shaft.

If the mulching kit is installed, the highest quality cut can be obtained with 3

spacers between the blade and spindle (minimum is 1 for a g ood cut).

If you need to cut hig her or lower t han what the spacer s will allow, it will be necessary

to adjust the rear axle height and caster posit ion. See Section 4.2.2 below.

4.2.2 Axle height and caster spacer position

:

Desired cutting height range can be obtained by adjusting the rear axle and

placing caster spacers above or below the caster arm (See Figur e 5) .

To adjust rear axle:
a) Stop engine and wait f or all moving parts to stop. Engage parking brake.

Remove key or spark plug wire(s).

b) Raise the rear of the machine up onto jack stands and remove the dr ive

wheels.

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or

maintenance relying solely on mechanical

or hydraulic jacks could be dangerous.
WHAT CAN HAPPEN
♦ The mechanical or hydraulic jacks may

not be enough support or may

malfunction allowing the unit to fall, which

could cause injury.
HOW TO AVOID THE HAZARD
♦ DO NOT rely solely on mechanical or

hydraulic jacks for support. Use adequate

c) Loosen but do not r em ove the top two bolts on each hydraulic motor

mounting bracket, (See Figure 5).
d) Remove the bottom sets of hardware for each br acket.
e) Reposition the mounting bracket to the desired height and reinstall the

bottom hardware.
f) Tighten all hardware and rem ount drive wheels.

jack stands or equivalent support.

24

FIGURE 5

Refer to the following chart to properly adjust desired cutting height.

CUTTING HEIGHT ADJUSTMENT (1" (2.5 cm) to 4 1/4" (10.8 cm))

AXLE

POSITION

(FIG. 20)

A 0 0 1" (2.5 cm) 1 1/4" (3.2 cm) 1 1/2" (3.5 cm) 1 3/4" (4.4 cm) 2" (5.0 cm)
A 0 1 1 1/8" (2.9 cm) 1 3/8" (3.5 cm) 1 5/8" (4.1 cm) 1 7/8" (4.8 cm) 2 1/8" (5.4 cm)
A 1 0 1 3/8" (3.5 cm) 1 5/8" (4.1cm) 1 7/8" (4.8 cm) 2 1/8" (5.4 cm) 2 3/8" (6.0 cm)
B 0 1 1 3/8" (3.5 cm) 1 5/8" (4.1cm) 1 7/8" (4.8 cm) 2 1/8" (5.4 cm) 2 3/8" (6.0 cm)
B 1 0 1 5/8" (4.1 cm) 1 7/8" (4.8 cm) 2 1/8" (5.4 cm) 2 3/8" (6.0 cm) 2 5/8" (6.7 cm)
B 1 1 1 3/4" (4.4 cm) 2" (5.0 cm) 2 1/4" (5.7 cm) 2 1/2" (6.4 cm) 2 3/4" (7.0 cm)
B 2 0 2" (5.0 cm) 2 1/4" (5.7 cm) 2 1/2" (6.4 cm) 2 3/4" (7.0 cm) 3" (7.6 cm)
C 1 1 1 7/8" (4.8 cm) 2 1/8" (5.4 cm) 2 3/8" (6.0 cm) 2 5/8" (6.7 cm) 2 7/8" (7.3 cm)
C 2 0 2 1/8" (5.4 cm) 2 3/8" (6.0 cm) 2 5/8" (6.7 cm) 2 7/8" (7.3 cm) 3 1/8" (7.9 cm)
C 2 1 2 1/4" (5.7 cm) 2 1/2" (6.4 cm) 2 3/4" (7.0 cm) 3" (7.6 cm) 3 1/4" (8.3 cm)
C 3 0 2 1/2" (6.4 cm) 2 3/4" (7.0 cm) 3" (7.6 cm) 3 1/4" (8.3 cm) 3 1/2" (8.9 cm)
D 2 1 2 3/8" (6.0 cm) 2 5/8" (6.7 cm) 2 7/8" (7.3 cm) 3 1/8" (7.9 cm) 3 3/8" (8.6 cm)
D 3 0 2 1/2" (6.4 cm) 2 3/4" (7.0 cm) 3" (7.6 cm) 3 1/4" (8.3 cm) 3 1/2" (8.9 cm)
D 3 1 2 3/4" (7.0 cm) 3" (7.6 cm) 3 1/4" (8.3 cm) 3 1/2" (8.9 cm) 3 3/4" (9.5 cm)
D 4 0 3" (7.6 cm) 3 1/4" (8.3 cm) 3 1/2" (8.9 cm) 3 3/4" (9.5 cm) 4" (10.1 cm)
E 3 1 2 7/8" (7.3 cm) 3 1/8" (7.9 cm) 3 3/8" (8.6 cm) 3 5/8" (9.2 cm) 3 7/8" (9.8 cm)
E 4 0 3 1/8" (7.9 cm) 3 3/8" (8.6 cm) 3 5/8" (9.2 cm) 3 7/8" (9.8 cm) 4 1/8" (10.5cm)
E 4 1 3 1/4" (8.3 cm) 3 1/2" (8.9 cm) 3 3/4" (9.5 cm) 4" (10.1 cm) 4 1/4" (10.8cm)

# OF SPACERS

BELOW

CASTERS

1/2"

(1.2cm)

3/16"

(.48cm)

NUMBER OF 1/4" (.64 cm)BLADE SPACERS

BELOW SPINDLE

4 3 2 1 0

(1.3 cm)

(.47 cm)

IMPORTANT: To achieve the highest quality of cut, blades should be level w ith the

ground, or tipped slightly down at t he f r ont .

4.2.3 PTO Engagement Linkage Adjust ment

: Located between the PTO engagement
bellcrank and PTO engagem ent assist arm beneath the front , left hand corner of
the engine deck.

a) Stop engine and wait for all moving parts to stop. Engage parking brake.

Remove key or spark plug wire(s).

b) With PTO engaged (lever pulled up, adjust the linkage length to where the

lower end of the bellcrank just clears t he axle support gusset (See Figure 6).
Make sure the assist arm is against the rear assist ar m stop on the deck
(See Figure 7). Push the lever down to the disengag ed posit ion. The assist
arm should contact the front assist arm stop on the deck. If it does not
contact, readjust so that the bellcr ank is closer to the gusset.

25

PTO SAFETY SWITCH

THE BELLCRANK JUST CLEARS THE
GUSSET WITH THE PTO ENGAGED

FIGURE 6

4.2.4 PTO Safety Switch Adjustment

:

a) Stop engine and wait f or all moving parts to stop. Engage parking brake.

Remove key or spark plug wire(s).

b) With PTO disengaged and assist ar m against the front assist arm st op,

adjust the blade safety switch mounting bracket (if needed) until the
bellcrank depresses the plunger by 1/4” (. 64 cm ) .

c) Be sure t he bellcr ank DOES NOT touch the switch body or damage to the

switch could occur.

d) Retighten switch mounting bracket .

4.2.5 Engine to Mower Deck Belt Adjustment

:

a) Stop engine and wait f or all moving parts to stop. Engage parking brake.

Remove key or spark plug wire(s).
b) Engage PTO.
c) Check belt guides under rear engine and fr ont m ower deck to see that they

are properly set (See Section 4.2.7).
d) Belt must be tight enough so it does not slip during heavy loads while

cutting grass. Over-tensioning will reduce belt and spindle bearing life. T o

adjust belt tension, loosen the 5/16" whizlock nut on tur nbuckle and rotate

the turn buckle; rotate tur nbuckle toward rear of mower to tighten, and

toward front of mower to loosen belt t ension (See Figure 7).
For 48” Decks: If there is no adjust m ent left in the turnbuckle and the belt

is still loose, the rear idler pulley can be repositioned in the front hole (See

Figure 7). The belt guide located next to the pulley must also be

repositioned in the front hole when the pulley is moved. The t ur nbuckle will

need to be readjusted.
Check belt tension after the first hour of operation and at least t wice during

the first 24 hours of oper at ion. Adjust as necessary.
Not e: After readjusting t he belt tension check the belt guide adjustment

Section 4.2.7 and blade brake adjustm ent Section 4.2.6.

26

FIGURE 7

e) Proper belt tension will require about 10 lbs. (44.5 Nt.) side pull on the belt,

halfway between pulleys, to deflect belt 1/2” (1.3 cm ) . (See Figure 7, Point A).

4.2.6 Blade Brake Adjustment:
a) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).
b) Disengage PTO.
c) Make sure the blade brake pad rests against t he sheave. Adj ust the spring

mounting bolts to properly align t he pad on the sheave. See Figure 8.
d) Check the distance between the spacer and the nut at the end of the blade

brake rod. The distance should be between 1/8” (. 32 cm ) and

3/16” (.47 cm). See Figur e 8.
e) Engage the PTO and check to make sure the blade brake pad clears the

sheave.

(.32 - .47 cm)

FIGURE 8

4.2.7 Belt Guide Adjustment:
a) Stop engine and wait for all moving parts t o stop. Engage parking br ake.

Remove key or spark plug wire(s).
b) Engage the PTO.
c) Check belt guides under the engine deck f or pr oper adjustment (See

Figures 9 and 10). Adjust as necessary.

27

Note: T hese dr awings ar e viewed from under neath the engine deck
FIGURE 9 FIGURE 10

36" BELT GUIDE LOCATION 48" BELT GUIDE LOCATION

4.2.8 Pump Drive Belt Tension Adjustment

:

No adjustment necessary.

4.2.9 Hydro Drive Linkage Adjustment

:

a) Adjust Speed Control Linkage and neutr al safety switch

1. Stop engine and wait for all moving parts to stop.

2. Move the speed control lever (located on the console) to the full forward

position and check the orientation of t he tabs on the ends of the speed
control crank (Figure 11) . These tabs should be pointing straight down
at the 6 o’clock position or slightly forward. Adjust the threaded yoke at
the bottom of the speed control linkage (See Figure 11) until the tabs
are positioned correctly.

3. Pull the speed control lever back to neutral. Check that the neut r a l

safety switch actuating tab has depressed the plung er of the switch so
that there is about 5/16” (.79 cm ) between the tab and the switch. See
Figure 11. If necessary, move the switch f or e and aft.

(.79 cm)

FIGURE 11
b) Adjust Neutral Control Linkages

1. Raise the rear of the machine up onto jack stands high enough to raise

the drive wheels off of the g r ound.

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

2. Release the park brake and move the speed cont r ol lever t o the “mid­speed” position.

Note: The OPC levers must be held down and the park brake must be

disengaged whenever the speed control lever is moved out of neutral or
the engine will kill.

28

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 wheel stop then go to step 7.

FIGURE 12

4. Loosen the nut against the neutral control linkag e yok e as shown in

5. Adjust the neutral control linkage until t he respective drive wheel stops

6. Make this adjustment on both sides.

7. After adjustments are made and the wheels stop when the drive levers

c) Adju st Hydro Cont r ol Linkages:

1. Place the speed cont r ol lever in t he “neutral” position. This adjustment

Note: The neutr al lock latches should be “unlocked” and in the f orward

Figure 12.

when the lever is pulled against the neutral spring (neut r al position). Turn
the adjusting bolt approximately 1/4 tur n clockwise if the wheel is turning
in reverse or turn the bolt approximately 1/4 tur n counter-clockwise 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.

are in the neutral position, tight en t he nuts against the yokes.

is again made with rear of machine on jack st ands and engine running
at full throttle. O PC levers will have to be held down and the park brake
must be disengaged whenever speed control levers are moved out of
the neutral position.

position

2. Loosen the front nut on left hydro control linkage as shown in Figure

12. Turn the rear control linkage adjusting nut counter- c lockwise until
wheel rotates forward. Turn the r ear nut of left control linkage
clockwise 1/4 of a turn at a time, stopping to move the speed control
forward and back to neutral, unt il left wheel stops rotating for ward.

Turn the rear nut an addit ional 1/ 2 turn and tighten the front nut making

sure not to put a bind on the linkage. Make sure flat part of linkage is
perpendicular to pin part of swivel. See Figure 13.

29

FIGURE 13

After adjusting the left hydro control linkage, move the speed control

lever to the mid-speed position and then back to t he neutral position.
Recheck the left drive wheel rotation to see if further adjustm ent is
necessary - be sure the speed control lever is in the neutral position.

If inconsistent neut ral occurs, check to be sure both springs are

properly tightened on the speed control lever under the console -
especially the rear pivot spring.

Repeat above adjustments if necessary.

3. Place the speed cont rol lever in neutral. Adjust the right side linkage by

turning the quick t r ack knob counter-clockwise until the tire begins to
rotate forward. Begin to r et ighten 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 f urther adjustment is
necessary.

4. T he spr ing that keeps tension on the knob should norm ally not need

adjustment. However, if adjustm ent is needed, adjust to where length
of spring is about 1” (2.5 cm) bet ween the washers. Adjust spr ing
length by turning nut at f ront of spring.

d) Drive Lever Linkage Adjustment

1. With rear of m achine still on jack stands and engine running at full

throttle, disengage the par k brake and move the speed control lever to
the midway position. Move the respective drive lever upward until it
reaches the neutral position and engage neut r al lock latches. See
Figure 14. If the t ir e r otates in either direction, the length of the drive
lever link will need to be adjusted.

2. Adjust the linkage length by loosening the jam nuts at both ends of the

linkage and rotating the linkage in the ball joints. Lengthen the linkage
if the tire is turning in reverse and shorten the linkage if the tire is
creeping forward. Tight en the jam nuts at both ends. Release and re­engage the neutral lock lat ch checking that the tire stops. Cont inue t his
process until the tire is at a dead stop.

FIGURE 14

30

3. Make this adjust ment for both sides.
e) Tracking Adjustment

1. Stop engine and wait for all moving parts to stop. Engage parking

brake. Raise the rear of the machine, remove jack stands and
carefully lower the machine to the ground. ( Check the drive tire
pressure and tire circumference. See 4. 1.11.)

2. Run the unit and obser ve the t r acking on a level, smooth, hard surface

such as concrete or asphalt.

3. If the unit tracks to one side or the other, turn the quick t r ack knob.

Turn the knob right to “steer” right; t ur n the knob left to “steer ” left.

4.2.10 Hydro Pump Spr ing Tension Setting
a) For medium or heavy duty drive conditions such as operation with a sulky

on steep slopes, a higher spring f or ce may be required on the hydro pump

control arms to prevent the drive system f r om stalling.
b) For a heavier drive setting, relocate the spring anchor links to either the

“medium” or “heavy duty” positions as shown in Figure 15. The spring

anchor links are attached to the upper r ear corner of the hydro drive shields

on the left and right hand sides of the machine.

Note: In the “medium” or “heavy duty” positions, the drive lever forces at

the upper handle will also be increased.

:

FIGURE 15

4.2.11 Park Brake Adjustment

a) Shut off engine and wait for all moving parts to stop.
b) Disengage the park brake.
c) Remove the hairpin in the lower park brak e linkage. Turn the link age in the

yoke until there is 3/16” (.48 cm) to 1/4” (.64 cm) clearance between the

park brake tire bars and the t ir es with the park brake disengaged. Re-

install the hairpin.

:

5. WASTE DISPOSAL

5.1 MOTOR OIL DISPOSAL
Engine oil and hydraulic oil are both pollutants to the environment. Dispose of used oil

at a certified recycling center or accor d ing to your state and local regulations.

6. TROUBLE SHOOTING

6.1 MOWER TRACKS TO LEFT OR RIGHT

a) Check the drive tire pressures and circumferences. See 4.1.11.
b) Turn knob on the right hydro control linkage in the direction in which the mower

needs to be adjusted. Turn the k nob in 1/ 4 turn increments until the mower tracks
correctly.

6.2 MOWER CUTS UNEVENLY

a) Check the drive tire pressures and circumfer ences. See 4. 1.11. A more uniform

cutting height may be obtained with higher tir e pr essure on rough terrain. A lower tire
pressure provides more flotation.

31

b) Check blade spacers on each blade, the axle positions on each side of the unit, and

the spacers on each front caster wheel. They must be equal.
c) Check cast er m ount ing brackets to be sure all bolts are t ight.
d) Check blades tip to tip for straightness. (They should be within 3/16” (4.8 mm), or

one blade width from being in line.)

6.3 BLADES DO NOT STOP WHEN DISENGAGED

a) Check the blade brake adjustment. ( See Sect ion 4.2.6)
b) Check the belt guide under rear deck t o m ake sure they are properly set (See

Section 4.2.7) and check the PTO engagement adjustment (See Sect ion 4. 2. 3).

6.4 ENGINE WILL NOT START

a) Check that the key switch is in the “Run” position.
b) Check that the choke is in the “ON” position for a cold engine or in the “O FF”

position for a warm engine. See 3.3. 2.

NOTE: Kawasaki engines may need to be choked even when warm.

c) Make sure speed control lever is in t he “ true neutral” position. (See 4.2.9) .
d) Check that the PTO is disengaged and the PTO switch is depressed.
e) Check that there is fuel in the tank and that the fuel valve is open.
f) Check that the spark plug wire(s) are properly connected.
g) Check for loose or faulty wiring connections. If it is necessary to disconnect wire

connectors, Do Not pull on the wires while disconnecting.
h) Check for corrosion at all wiring connections. Even minor corr osion m ay cause a

faulty connection. Clean connector terminals t hor oughly with electrical contact

cleaner, apply dielectric grease and reconnect.

IM PO RTANT: It is essential that all operator safety mechanisms be connected

and in proper operating condition prior to mower use.
NOTE: After carefully checking the above steps, attempt to start the engine. If it

does not start, contact your authorized Exmark service dealer.

ENGINE TROUBLESHOOTING

When a problem occur s , do not overlook the simple causes. For example, starting pr oblem s
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 f or special timing or
adjustment procedures (such as valves, governor, etc.). Have this work done by your Engine

Service Dealer.

ENGINE TROUBLESHOOTING TABLE

PROBLEM

Will not start
Hard starting
Stops suddenly
Lacks power
Operates erratically
Knocks or pings
Skips or misfires
Backfires
Overheats
High fuel consumption

NO

FUEL

X

IMPROPER

FUEL

DIRT IN

FUEL LINE

DIRTY AIR

FILTER

X X X X X

FAULTY

SPARK

PLUG

ENGINE

OVERLOADED

X X X X X X X
X

X X X X X X
X X X X X X X X
X X X X X X X
X

X X

X X X X X

X X X X X

X X X X X

X X X X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

AIR

SCREEN

32

7. MOWER DECK BELT ROUTING

FIGURE 16 FIGURE 17
36" MOWER DECK 48" MOWER DECK

33

8. WIRING DIAGRAM

9. HYDRAULIC DIAGRAM

34

10. 2-Year Limited Warranty

Exmark Turf Equipment

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 manufactured by Exmark 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 turf equipment purchased on
or after October 1, 2004 sold in the US 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.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet. We are not authorized
to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

• Any damage or deterioration due to normal use, wear

• Cost of regular maintenance service or parts, such as

• Any product or part which has been altered or misused

• Any repairs necessary due to use of parts, accessories

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

1. 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. Customers
may also call 402-223-6375.

2. Bring the product and your proof of purchase (sales
receipt) to the Exmark Service Dealer.

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

Warranty Period

Items and Conditions Not Covered

Exmark Service Dealer.
and tear, or exposure.
filters, fuel, lubricants, tune-up parts, and adjustments.
or required replacement or repair due to normal wear,

accidents, or lack of proper maintenance.
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.

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

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
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.

As a condition to this warranty, customer shall have read the
operator's manual and shall have completed and submitted to
Exmark Warranty Company, within the prescribed time, the
Exmark warranty registration.

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement as
set forth herein. Neither Exmark nor Exmark Warranty

Company shall have any liability for any other cost, loss or
damage, including but not limited to, any incidental or
consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other

extraordinary repair charges or charge 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.

There are no understandings, agreements, representations, or
warranties, express or implied, including but not limited to any
regarding the merchantability (that product is fit for ordinary
use) or fitness for use (that product is fit for a particular
purpose), not specified herein, respecting the equipment which
is the subject of this 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.

35

NOTES

36

SERVICE RECORD

Date Description of Work Done Service Done By

37

ALIGN THIS EDGE WITH A VERTICAL SURFACE

(TREE, BUILDING, FENCE POST, POLE ETC.)

T
H

I

S

I

S

A

5

°

S
L
O

P
E

T

H

I

S

I

S

A

1
0

°

S

L

O

P

E

T

H

I

S

I

S

A

1

5

°

S

L

O

P

E

P

E

T

HI

S

I

S

A

2

0

°

S

L

O

FOLD ALONG APPROPRIATE LINE

EXAMPLE: COMPARE

SLOPE WITH FOLDED

EDGE.

38

M

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

Check us out on the Web:

www.exmark.com

WARNING

The engine exhaust from this product contains
chemicals known to the State of California to
cause cancer, birth defects, or other reproductive
harm.

©1997- 2007 PART NO. 109-6455 Rev. A
EXMARK MFG. CO. INC. [phone]
INDUSTRIAL PARK BOX 808 FAX [phone]
BEATRICE, NE 68310
ALL RIGHTS RESERVED PRINTED IN U.S.A.

®

FG. CO. INC.