Exmark Vikingtm Hydro Operator's Manual

VIKING™HYDRO

ForSerialNos.
790,000&Higher

PartNo.4500-355Rev.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

2

Contactusatwww.Exmark.com.

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.......................................................13

ModelNumbers............................................13

Systems.........................................................13

Dimensions...................................................14

TorqueRequirements....................................14

ProductOverview................................................15

Operation.............................................................15

Controls........................................................15

Pre-Start........................................................17

OperatingInstructions..................................17

Transporting.................................................19

Maintenance.........................................................20

RecommendedMaintenanceSchedule(s)...........20

PeriodicMaintenance.......................................21

CheckEngineOilLevel.................................21

CheckMowerBlades.....................................21

CheckSafetyInterlockSystem.......................22

CheckforLooseHardware............................22

ServicePre-CleanerElementandAir

Cleaner......................................................23

ChangeEngineOil........................................23

CheckHydraulicOilLevel.............................23

CheckTirePressures.....................................23

CheckConditionOfBelts..............................23

LubricateGreaseFittings...............................24

CheckSparkPlugs.........................................24

ChangeHydraulicSystemFilter.....................24

WheelHub-SlottedNutTorque

Specication..............................................26

ThreadLockingAdhesives.............................26

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................26

Copper-BasedAnti-seize..............................26

DielectricGrease...........................................26

Adjustments.....................................................27

AdjustingtheCuttingHeight.........................27

AdjustingtheAxlePosition............................28

AdjustingtheNumberofSpacersbelow

CasterSupportHub...................................29

AdjustingtheCuttingHeightwithBlade

Spacers......................................................29

PTOEngagementLinkage

Adjustment...............................................30

PTOSafetySwitchAdjustment......................30

EnginetoMowerDeckBelt

Adjustment...............................................31

BladeBrakeAdjustment................................32

BeltGuideAdjustment..................................32

PumpDriveBeltTensionAdjustment............32

HydroDriveLinkageAdjustment..................33

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

ParkBrakeAdjustment..................................35

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

CleanEngineAirCoolingSystem...................36

RemoveEngineShroudsandCleanCooling

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

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

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

Troubleshooting...................................................37

Schematics...........................................................39

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

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.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

•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

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

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

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.

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

•Keephandsandfeetawayfrommovingparts.
Ifpossible,donotmakeadjustmentswiththe
enginerunning.

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

8

Safety

WARNING

Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.

•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.

9

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.

•Replaceallworn,damaged,ormissingsafety
signs.

•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.

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

•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.

1-303508

1-303517

1-323427

36inchDeckUnitsOnly

1-403005

1-403143

1-413214

98-5954

10

Safety

103-1798

103-2076

103-2103

103-2196

103-2242

11

Safety

103-2243

103-4935

103-5626

48inchDeckUnitsOnly

116-0404

12

Specications

Specications

ModelNumbers

SerialNos:790,000andHigher

VH15KA362;VH15KA483;VH17KA362CA;VH17KA483CA

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s
Manual

•RPM:FullSpeed:3600RPM(NoLoad)

FuelSystem

•Capacity:5.0gal.(18.9L)

•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher.

•FuelFilter:ReplaceableIn-line

•FuelShut-OffValve:1/4turnincrements

SafetyInterlockSystem

Operatormusthavethespeedcontrolleverinneutral
andPTOdisengagedtostartengine.Releaseof
OperatorPresenceControl(OPC)leverswillcause
enginetostopifspeedcontrolleverisnotinneutral
and/orPTOisengaged.

Steering/BrakeControls

Fingertipdrivecontrolleversprovideindependent
speedcontrol,brakingandneutraltoeachdrive
wheelformovingforwardorreverse,stoppingand
powerturning.

Transmission

•TwoHydroGearvariabledisplacementpiston
pumpsindependentlycoupledtotwohigh
efciencyParkerwheeldrivemotors.

•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.

WheelDriveSystem

DrivewheelsaredirectcoupledtoParker/Rosswheel
drivemotorswith1.0inch(25.4mm)taperedshaft.

Tires&Wheels

DriveFrontCaster

Pneumatic

(Air-Filled)

Semi­Pneumatic

Quantity

22

Tread

TurfMasterSmooth

Size16x6.50–89x3.50-4

PlyRating

4

Pressure

14psi
(97kPa)

13

Specications

CuttingDeck

•CuttingWidth:

–36inchDeck:35.38inches(89.9cm)

–48inchDeck:47.25inches(120.0cm)

•Discharge:Side

•BladeSize:

–36inchDeck:18.00inches(45.7cm)—

Quantity:2

–48inchDeck:16.25inches(41.3cm)—

Quantity:3

•DeckDrive:Manualengagementofbeltwith
over-centerlock.Bladebelttensionisadjustable
viaturnbuckle.

•BladeBrake:WhenthePTOengagementcontrol
ismovedtothedisengagedpositionafriction
brakepadstopstherotationoftheblades.

•DeckMounting:Bolteddirectlytoenginedeck.

•DeckDepth:

–36inchDeck:5.0inches(12.7cm)

–48inchDeck:5.0inches(12.7cm)

•CuttingHeightAdjustment:

Adjustsfrom1inch(2.5cm)to41/4inches(10.8
cm)in1/4inch(6.4mm)incrementsbyvarious
adjustmentsofcasterspacers,bladespacers,and
axleheight.

Dimensions

OverallWidth:

36inchDeck48inchDeck

DeectorUp36.4inches

(92.5cm)

48.1inches
(122.2cm)

DeectorDown47.0inches

(119.4cm)

57.9inches
(147.1cm)

OverallLength:

36inchDeck48inchDeck

77.3inches(196.3cm)72.3inches(183.6cm)

OverallHeight:

36inchDeck48inchDeck

43.2inches(109.7cm)43.2inches(109.7cm)

TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)

36inchDeck48inchDeck

35.6inches
(90.4cm)

40.4inches
(102.6cm)

CurbWeight:

36inchDeck48inchDeck

498lb(226kg)551lb(250kg)

TorqueRequirements

BoltLocation

Torque

Blade/CutterHousing
SpindleBolt

75-80ft-lb(102-109N-m)

CasterBracketMounts

30-35ft-lb(41-48N-m)

MowerDeck/Engine
DeckMount

30-35ft-lb(41-48N-m)

EngineMountingBolts

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

WheelLugNuts

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

WheelHubSlottedNutminimum100ft-lbs

(136N-m)

WheelMotorMounting
Bolts

30-35ft-lb(41-48N-m)

14

Operation

ProductOverview

Figure3

1.ECSHandles3.FuelCap

2.Controls4.BladeSpacers

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

OperatorPresenceControl(OPC)
Levers

Locatedontheupperhandleassemblydirectlyabove
thehandlegrips.

Whentheseleversaredepressed,theOPCsystem
sensesthattheoperatorisinthenormaloperator’s
position.Whentheleversarereleased,theOPC
systemsensesthattheoperatorhasmovedfromthe
normaloperatingpositionandwillkilltheengineif
eitherthespeedcontrolleverisnotintheneutral
positionorthePTOisengaged(seeFigure4).

Figure4

1.OPCLever

3.NeutralLockLatch

2.Rotateneutrallocklatch
downwardforneutral
lockposition

4.DriveLeverinneutral
position

DriveLevers

Locatedoneachsideoftheupperhandleassembly
aheadofandbelowthehandlegrips.

Theseleversindividuallycontrolthespeedand
directionofeachdrivewheel.Whenthespeedcontrol
leverismovedoutoftheneutralpositionandthe
neutrallocklatchesaremovedintothedriveposition,

15

Operation

asshowninFigure4,andthedriveleversarereleased,
thedrivewheelsareengagedintheforwarddirection.

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

NeutralLockLatch

Locatedattheendofthehandles.

Thepurposeoftheselatchesistoallowtheoperator
tolockthedriveleversina"neutral"positionwhere
neitherofthedrivewheelsareengagedineithera
forwardorreversedirection(seeFigure4).

ParkBrakeLever

Locatedontherightsideoftheunitabovethe
hydraulictank.

Thebrakeleverengagestheparkbrakeonthedrive
wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe
brake.

Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
engaged.Theunitmustbetieddownandbrake
engagedwhentransporting.

Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.

ChokeControl

Locatedonthefrontleftcornerofthefueltank
support.

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

ThrottleControl

Locatedontheonthecontrolconsolerightside.

Thethrottleisusedtocontrolenginespeed.Moving
thethrottlecontrolforwardwillincreaseengine

speedandmovingittotherearwilldecreaseengine
speed.Movingthethrottleforwardintothedetent
isfullposition.

SpeedControlLever

Locatedinmiddleofcontrolconsole.

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

Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.

“Off-Run”Switch

Locatedonthecontrolconsole.

Turnthekeytothe“Run”positiontoallowthe
enginetobestarted.Turnthekeytothe“Off”
positiontoshutengineoff.

FuelShut-OffValve

Locatedinthefuellinemidwaybetweenthetank
andengine.

Thefuelshut-offvalveisusedtoshutoffthe
owoffuelwhenparkinginsideabuilding,during
transportationtoandfromthejobsites,andwhen
themachinewillnotbeusedforafewdays.

Rotatevalve1/4turnclockwisetoshutfueloff.
Rotatevalve1/4turncounterclockwisetoturnfuel
on.

DriveWheelReleaseValves

Locatedonthetoprearcornerofthehydrostatic
pumps.

Drivewheelreleasevalvesareusedtoreleasethe
hydro-staticdrivesystemtoallowthemachinetobe
movedbyhandwithouttheenginerunning.

Witha5/8wrench,turnbothvalvesoneturn
counterclockwisetoreleasethedrivesystem.

Turnclockwisetoresetthedrivesystem.DoNot

overtighten.

TrackingAdjustmentKnob

Locatedontheright-handsideoftherearofthefuel
tanksupport.

16

Operation

Theknobcanbeadjustedsothatmachinewill
“track”straightaheadwiththedriveleversreleased.

PTOEngagementControl

Locatedonleftsideofcontrolconsole.

Toengagetheblades,theknobmustbepulled
towardtheoperatoruntiltheturnbuckle(attached
tothebladeengagementidler)locksover-center.To
disengagetheblades,pushtheknobdownuntilthe
assistarmcontactsthepinonthedeck.

ParkbrakemustbedisengagedbeforePTOis
engagedorenginewillkill.

ColdStartKit

Locatedontherighthandsideofenginedeck,below
andslightlyaheadofthehydrocontrolshield.

Thecoldstartkitisusedtoeasethestartingofthe
unitincoldweatherorwhentheunithasnotbeen
operatedforaperiodoftime.Thecoldstartkit
movestheidlerpulleyawayfromthepumpbelt,
releasingthetensiononthebeltwhichallowsthe
enginetoturnoverwithlessresistance(seeStarting
theEnginesectioninOperation).

Pre-Start

Fillfueltank.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.

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethevalve1/4turncounterclockwisetoturn
fuelon.

StartingtheEngine

Note:OperatormusthavePTOdisengagedand

speedcontrolleverinneutralpositionwhenstarting
theengine.

Lockdriveleversinneutralandengageparkbrake

Note:Acoldweatherstartingkithasbeenaddedfor
easeofstartingineithercoldweatherorwhenthe
unithasnotbeenrunforaperiodoftime.

•Tousecoldstartkit:

1.Pullsplitringstraightoutthesideoftheunit,
andhooktheringoverthelowerfronthydro
controlshieldbolt.

2.Startengine.Refertothefollowingguidelines
forfurtherstartingsuggestions.

•Toengagepumpdrive(disengagecoldstartkit):

1.Pullchainstraightoutfromthesideofthe
unituntilthesplitringcanberemovedfrom
thebolt.

2.Slowlyreleasetensiononchain.

1.Pulloutthechokecontrol.Placethethrottle
controlmidwaybetweenthe“Slow”and“Fast”
positions.Turnthekeyswitchtothe“Run”
position.

2.Pullrecoilropetostartengine.Afterengine
warmsup,graduallypushinthechokecontrol.
DoNotrunwarmenginewiththechokeinthe
“ON”position.

Note:Kawasakienginesgenerallyneedtobe
“choked”evenwhenwarm.

PTOEngagement

DANGER

Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.

17

Operation

DANGER

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

Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunless
thereisagrasscollectionsystemormulch
kitinplaceandworkingproperly.

ThePTOswitchengagesthecuttingblades.Besure
thatallpersonsareclearofmowerdeckanddischarge
areabeforeengagingthePTO .

1.Setthrottleto“MIDW AY”position.

2.PullthePTOengagementknobuptoengage
blades.

3.Placethethrottleinthe“FAST”positiontobegin
mowing.

Note:ParkbrakemustbedisengagedbeforePTOis
engagedorenginewillkill.

DisengagingthePTO

1.Setthrottleto“MIDW AY”position.

2.PushdownonthePTOengagementknobto
disengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Lockdriveleversin“neutral”position.

3.Engagetheparkingbrake.

4.DisengagethePTO.

5.Movespeedcontrollevertoneutral.

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

7.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.

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.

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.

18

Operation

Figure5

1.DriveLeverinneutral
position

3.DriveLeverinforward
position

2.DriveLeverlockedin
neutralposition

4.DriveLeverinreverse
position

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.

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.

Transporting

TransportingaUnit

WARNING

Loadingthemowerontoatrailerwithout
strongenoughorproperlysupportedramps
couldbedangerous.Therampscould
collapsecausingtheunittofall,whichcould
causeinjury.

•Useproperrampsthataresecuredtothe
truckortrailer.

•Keepfeetandlegsoutfromunderthe
unitwhenloadingandunloading.

•Ifnecessary,useassistancewhenloading .

Besurethefuelshut-offvalveisclosed.

Useaheavydutytrailertotransportthemachine.
Engageneutrallocklatchesandparkbrake,then
blockwheels.

Securelyfastenthemachinetothetrailerwithstraps,
chains,cables,orropes.

DoNotrelysolelyontheparkingbraketoholdthe
machineonthetrailer.

Besurethatthetrailerhasallnecessarylightingand
markingasrequiredbylawanduseasafetychain.

19

Maintenance

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

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

WARNING

Theenginecanbecomeveryhot.Touching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst5hours

•Changetheengineoil.

Aftertherst100hours

•Checkwheelhub-slottedtorquespecication.

Aftertherst250hours

•Changethehydrauliclter.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Greasethecasterwheelbearings.

•Greasecasterpivots.

•Cleanengineaircoolingsystem(SeeEngineOwner’sManual)

•Cleanthegrassbuild-upfromunderthedeck.

Every25hours

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

Every40hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethepumpdriveidlerpivot.

•Greasethepumpcontrolbearings.

•Greasethemowerdeckidlerpivot

Every80hours

•Removeengineshroudsandcleancoolingns.

Every100hours

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

Every160hours

•Checkthesparkplugs.

Every500hours

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Checkwheelhub-slottedtorquespecication.

Monthly

•GreasethePTOengagementbellcrank.

20

Maintenance

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.

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstated
intheCleanGrassBuild-UpUnderDeck
procedure.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Re-installtheblades(iftheywereremoved)and
torquebladeboltsto75-80ft-lb(102-109N-m).
Besurethespringdiscwasherconeisinstalled
towardthebolthead(seeFigure6).

Figure6

1.Springdiscwasher(conetowardsbolthead)

2.Bladebolttorqueto75-80ft-lb(102-109N-m).

ReplacingtheDischarge
Deector

ServiceInterval:Asrequired

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
springontherodasshowninFigure7.Slidethe
rodthroughthefrontdischargedeectorbracket,
dischargedeector,andreardeectorbracket.

21

Maintenance

Figure7

1.Rod4.Mowerdeck

2.Spring5.Dischargedeector
bracket

3.Dischargedeector

6.Assembledview

3.Hookthebentendoftherodaroundthefront
dischargedeectorbrackettoretainitfrom
slidingout.Placethelegofthespringwiththe
loopinthenotchinthedischargedeectorto
holdthedischargedeectorinthedownposition
(seeFigure7).

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

CheckSafetyInterlock
System

ServiceInterval:Beforeeachuseordaily

1.Foryoursafety,yourExmarkmowerisequipped
withOperatorPresenceControls,referredtoas
(OPC).WheneitherthePTOisengaged,or
thespeedcontrolleverisnotinneutralandthe
operatorremovesbothhandsfromthehandles,
themowerenginemuststop.

2.TodetermineiftheOPCisinoperatingcondition,
clearareaofbystanders.Runtheengineat
one-thirdthrottle,thenwiththedriveleversand
neutrallocklatchesinthe“neutrallock”position,
movethespeedcontrolleveroutofneutraland
releasetheOPClevers–theenginemuststop.

3.Again,runtheengineatone-thirdthrottle,move
thespeedcontrollevertoneutral,engagethe
PTOandreleasetheOPClevers–theengine
muststop.

Note:Parkbrakemustbedisengagedbeforethe
speedcontrolleverismovedoutofneutralor
PTOisengagedorenginewillkill.

Note:Ifmachinedoesnotpassanyofthesetests,
donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety
mechanismsbeconnectedandinproper
operatingconditionpriortouseformowing.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware
oranyotherpossibleproblem.Tightenhardware
orcorrecttheproblembeforeoperating.

22

Maintenance

ServicePre-CleanerElement
andAirCleaner

ServiceInterval:Every25hours—Service

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

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.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

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

Note:Thebafeislabeled“HOT”and
“COLD”.Theoillevelvarieswiththe
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atedrivetiresto12–14psi(83–97kPa).

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.

23

Maintenance

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.LubricatettingswithNGLIgrade#2
multi-purposegungrease.

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.CasterWheel
Bearings

122

Daily

2.CasterPivots

22

Daily

3.PTO
Engagement
Bellcrank

11

Monthly

4.PumpDrive
IdlerPivot

21

40hours

5.Pump
Control
Bearings

22

40hours

6.MowerDeck
IdlerPivots

21

40hours

Number4IdlerPivot(PumpDrive)Located

underenginedeck

Number4and6(IdlerPivots)Disassembleandgrease

onceamonthundera“NoLoad”condition.

3.Lubricatepivotpointswithaspraypenetrating
lubricantasshownintheSprayLubricantChart.

SprayLubricantChart

SprayLubricantChart(cont'd.)

PivotPoint

NumberofPlaces

ServiceInterval

1.PTOEngagement
UpperBellcrank

1

40hours

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps,
orreplacewithnewplugs.SeeEngineOwner’s
Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledinthefuellinebetweenthe
fueltankandtheengine.Replacewhennecessary.

ChangeHydraulicSystem
Filter

ServiceInterval:Aftertherst250hours

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

Note:UseonlyExmarkPartNo.109–4180for

Summeruseabove32°F(0°C)orP/N1-523541for
Winterusebelow32°F(0°C)(RefertoTransmission
sectioninSpecicationsforlterspecications).

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Carefullycleanareaaroundlter.Itisimportant
thatnodirtorcontaminationenterhydraulic
system.

3.Unscrewltertoremoveandallowoiltodrain
fromreservoir.

Important:Beforereinstallingnewlter,ll
itwithExmarkPremiumHydrooilandapply
athincoatofoilonthesurfaceoftherubber
seal.

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

24

Maintenance

4.FillreservoirasstatedinCheckHydraulicOil
Level.

ExmarkPremiumHydroOilisrecommended.
Refertothechartforanacceptablealternative:

HydroOil

ChangeInterval

ExmarkPremiumHydro
Oil(Preferred)

500Hours

Mobil115W50

250Hours

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
mainpumpasshowninFigure8)mayhavelost
their“prime”.RefertoHydraulicSystemAir
Purgesection.

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

Changingoilunnecessarilycoulddamagehydraulic
systembyintroducingcontaminatesintothesystem.

HydraulicSystemAirPurge

ServiceInterval:Asrequired

Airmustbepurgedfromthehydraulicsystem
whenanyhydrauliccomponents,includingoil
lter,areremovedoranyofthehydrauliclinesare
disconnected.

Thecriticalareaforpurgingairfromthehydraulic
systemisbetweentheoilreservoirandeach
chargepumplocatedonthetopofeachvariable
displacementpump(Figure8).Airinotherpartsof
thehydraulicsystemwillbepurgedthroughnormal
operationoncethechargepumpis“primed”.

Figure8

1.Chargepumpcap2.Loosen11/2turnsonly

1.Stopengineandwaitforallmovingpartstostop.
Raisetherearofthemachineupontojackstands
highenoughtoraisethedrivewheelsoffthe
ground.

2.CheckoillevelasstatedinCheckEngineOil
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(showninFigure8)11/2turns
only.Makesureengineisnotrunning.Lift
thechargepumphousingupwardandwaitfor
asteadyowofoiltoowoutfromunderthe
housing.Retightenthecapscrews.Dothisfor
bothpumps.

25

Maintenance

Note:Hydraulicreservoircanbepressurizedup

to5psitospeedthisprocess.

6.Ifeitherdrivewheelstilldoesnotrotate,stop
andrepeatsteps4and5abovefortherespective
pump.Ifwheelsrotateslowly,thesystemmay
primeafteradditionalrunning.Checkoillevelas
statedinChecktheEngineOilLevelsection.

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

8.Checkhydrodrivelinkageadjustmentasstatedin
HydroDriveLinkageAdjustmentsectionin
Adjustments.

WheelHub-SlottedNut
TorqueSpecication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Whentighteningtheslottednutonthewheelmotor
taperedshaft:

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

2.Furthertightenthenutuntilthenextsetofslots
lineupwiththecrossholeintheshaft.

3.Replacecotterpin.

Note:Donotuseanti-seizecompoundonthewheel
hub.

ThreadLockingAdhesives

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

•Pumpsheavesetscrews.

•Squareheadsetscrewsonhydropumpcontrol
arms.

•OPCleversetscrews.

•Shoulderboltsinendsofspeedcontrolcrank.

•Sheaveretainingboltinendofenginecrankshaft.

•Fueltankbulkheadttingthreads

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

•OPCleverhubsandcross-shaft.

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

•Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or
Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused
inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

•Undertopcutterhousingbearingguard.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing
locations:

Betweenthebladedriveandpumpdrivesheavesand
enginecrankshaft.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical
connectionstopreventcorrosionandlossofcontact.

26

Maintenance

Adjustments

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

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted
from1inchto41/4inches(2.54cmto11.4cm)in
1/4inch(.64cm)incrementsbyadjustingtheaxle
position,numberofspacersbelowthecasterhub,
andnumberofspacersbetweenbladeandspindle.

RefertotheCuttingHeightAdjustmenttableand
selectacuttingheightrangeinthelefthandcolumn
whichcorrespondstotherangeofcuttingheights
youwillmostoftenbeusing.Adjustmentswithinthis
rangecanthenbemadebyadjustingthenumberof
bladespacersbetweenthebladeandthebottomof
thespindle(thisisamucheasieradjustmenttomake

thanadjustingaxlepositionandnumberofspacers
belowcastersupporthub).

Notethat:

•Forthebestcutanddischarge,placeaminimum
oftwospacersbetweenthebladeandthespindle.

•Forhighestqualitycut,placeallfourspacers
betweenthebladeandthespindle.

•Ifmulchingkitisinstalled,thehighestqualitycut
canbeobtainedwith3spacersbetweentheblade
andthespindle(minimumis1foragoodcut).

•Whenmulchingleavesitisbesttohavefewer
spacersbetweenbladeandspindle.

Refertothetableandselectdesiredcuttingheight
range.RefertoAdjustingtheAxlePosition,

AdjustingtheNumberofSpacersbelowCaster
SupportHub,andAdjustingtheCutting
HeightwithBladeSpacersandsectionstomake

adjustmentsmakeadjustmenttoobtainspecic
cuttingheight.

CuttingHeightAdjustmentT able(1inchto41/4inches(2.5cm-10.8cm))

NumberOfSpacers

BelowCaster

SupportHub

Numberof1/4inch(.64cm)BladeSpacersBelowSpindle

Cutting

Height

Range

Axle

Position

(Figure9)

1/2
inch

(1.2cm)

3/16

inch

(.48cm)

4

32

10

1–2inches

(2.5–5.0cm)A00

1inch

(2.5cm)

11/4inch

(3.2cm)

11/2inch

(3.5cm)

13/4inch

(4.4cm)

2inch

(5.0cm)

11/8–

21/8inches

(2.9–5.4cm)A01

11/8inch

(2.9cm)

13/8inch

(3.5cm)

15/8inch

(4.1cm)

17/8inch

(4.8cm)

21/8inch

(5.4cm)

13/8–

23/8inches

(3.5–6.0cm)A10

13/8inch

(3.5cm)

15/8inch

(4.1cm)

17/8inch

(4.8cm)

21/8inch

(5.4cm)

23/8inch

(6.0cm)

13/8–

23/8inches

(3.5–6.0cm)B01

13/8inch

(3.5cm)

15/8inch

(4.1cm)

17/8inch

(4.8cm)

21/8inch

(5.4cm)

23/8inch

(6.0cm)

15/8–

25/8inches

(4.1–6.7cm)B10

15/8inch

(4.1cm)

17/8inch

(4.8cm)

21/8inch

(5.4cm)

23/8inch

(6.0cm)

25/8inch

(6.7cm)

13/4–

23/4inches

(4.4–7.0cm)B11

13/4inch

(4.4cm)

2inch

(5.0cm)

21/4inch

(5.7cm)

21/2inch

(6.4cm)

23/4inch

(7.0cm)

2–3inches

(5.0–7.6cm)B20

2inch

(5.0cm)

21/4inch

(5.7cm)

21/2inch

(6.4cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

17/8–

27/8inches

(4.8–7.3cm)C11

17/8inch

(4.8cm)

21/8inch

(5.4cm)

23/8inch

(6.0cm)

25/8inch

(6.7cm)

27/8inch

(7.3cm)

27

Maintenance

CuttingHeightAdjustmentTable(1inchto41/4inches(2.5cm-10.8cm))(cont'd.)

NumberOfSpacers

BelowCaster

SupportHub

Numberof1/4inch(.64cm)BladeSpacersBelowSpindle

Cutting

Height

Range

Axle

Position

(Figure9)

1/2
inch

(1.2cm)

3/16

inch

(.48cm)

4

32

10

21/8–

31/8inches

(5.4–7.9cm)C20

21/8inch

(5.4cm)

23/8inch

(6.0cm)

25/8inch

(6.7cm)

27/8inch

(7.3cm)

31/8inch

(7.9cm)

21/4–

31/4inches

(5.7–8.3cm)C21

21/4inch

(5.7cm)

21/2inch

(6.4cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

31/4inch

(8.3cm)

21/2–

31/2inches

(6.4–8.9cm)C30

21/2inch

(6.4cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

23/8–

33/8inches

(6.0–8.6cm)D21

23/8inch

(6.0cm)

25/8inch

(6.7cm)

27/8inch

(7.3cm)

31/8inch

(7.9cm)

33/8inch

(8.6cm)

21/2–

31/2inches

(6.4–8.9cm)D30

21/2inch

(6.4cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

23/4–

33/4inches

(7.0–9.5cm)D31

23/4inch

(7.0cm)

3inch
(7.6cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

33/4inch

(9.5cm)

3–4inches

(7.6–10.1cm)D40

3inch

(7.6cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

33/4inch

(9.5cm)

4inch

(10.1cm)

27/8–

37/8inches

(7.3–9.8cm)E31

27/8inch

(7.3cm)

31/8inch

(7.9cm)

33/8inch

(8.6cm)

35/8inch

(9.2cm)

37/8inch

(9.8cm)

31/8–
41/8inches
(7.9–10.5cm)E40

31/8inch

(7.9cm)

33/8inch

(8.6cm)

35/8inch

(9.2cm)

37/8inch

(9.8cm)

41/8inch

(10.5cm)

31/4–
41/4inches
(8.3–10.8cm)E41

31/4inch

(8.3cm)

31/2inch

(8.9cm)

33/4inch

(9.5cm)

4inch

(10.1cm)

41/4inch

(10.8cm)

Important:AlwaysadjusttheNumberofSpacersbelowCasterHubtocorrespondtotheAxle
Positionasshownintabletoobtainproper“rake”(bladesshouldalwaysbeleveltotheground
ortippedslightlydownatthefront).

AdjustingtheAxlePosition

Desiredcuttingheightrangecanbeobtainedby
adjustingtherearaxleandplacingcasterspacers
aboveorbelowthecasterarm(seeFigure9and
Figure10alongwiththeCuttingHeightAdjustment
Chart).

Toadjustrearaxle:

1.Stopthemachineandmovethedriveleversto
theneutrallockposition.

2.DisengagethePTO.

3.Raisetherearofthemachineupontojackstands
andremovethedrivewheels.

28

Maintenance

CAUTION

Raisingthemowerforserviceormaintenance
relyingsolelyonmechanicalorhydraulic
jackscouldbedangerous.Themechanicalor
hydraulicjacksmaynotbeenoughsupport
ormaymalfunctionallowingtheunittofall,
whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic
jacksforsupport.Useadequatejackstands
orequivalentsupport.

4.Loosenbutdonotremovethetoptwobolts
oneachhydraulicmotormountingbracket(see
Figure9).

5.Removethebottomsetsofhardwareforeach
bracket.

6.Repositionthemountingbrackettothedesired
heightandreinstallthebottomhardware.

7.Tightenallhardwareandremountdrivewheels.

8.Removejack.

9.Adjustwheeldriveandbrakelinkagesas
required(seeBrakeandWheelDriveLinkage
Adjustmentsection).

Figure9

1.PositionA4.PositionD

2.PositionB5.PositionE

3.PositionC

6.AxlePivotBolt-loosen
butDoNotremove

Note:Theaxlepositionsarein1/2inch(1.3cm)
incrementsandthelargecasterspacersare1/2
inch(1.3cm)thick.Therefore,byadjustingthe
samenumberof1/2inch(1.3cm)casterspacersas

axleholepositionsthebladeswillretainthesame
front-to-backtip(rake).

AdjustingtheNumber
ofSpacersbelowCaster
SupportHub

1.Stopthemachineandmovethedriveleversto
theneutrallockposition.

2.DisengagethePTO.

3.Placethedriveleversinthe“parkbrake”position.

4.Pushdownonhandlestoliftfrontcastersoffthe
ground.

5.Supportwithjackstands.

6.Remove“quickpin”fromonecasterandremove
casterfromhub(seeFigure10).

Figure10

1.Four1/2inch(127mm)
spacers

3.3/16inch(4.8mm)
spacer

2.QuickPin4.Castersupport

7.Adjustthenumberof1/2inchspacersbetween
bottomofhubandcasteryoketoobtainthe
desiredcuttingheightfromtheCuttingHeight
AdjustmentTableintheAdjustingtheCutting
Heightsection.

8.Installremainingspacersontopofhub.

9.Install“quickpin”.

10.Repeatforothercaster.

AdjustingtheCuttingHeight
withBladeSpacers

1.Stopthemachineandmovethedriveleverstothe
neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

29

Maintenance

4.Stoptheengine,removethekeyandwaitforall
movingpartstostop.

5.Bladesmaybeadjustedforcuttingheightbyusing
thefour1/4inch(.64cm)spacersfoundonthe
bladespindlebolts(factorysettingistwoabove
andtwobelow).Thisallowsa1inch(2.5cm)
rangein1/4inch(.64cm)incrementsofcutting
heightinanyaxleposition.Thesamenumber
ofbladespacersmustbeusedonallbladesto
achievealevelcut(twoaboveandtwobelow ,one
aboveandthreebelow ,etc.).

6.Raisefrontofdeckandsupportwithjackstands.

7.Holdbladeboltonbottomandloosenspindle
nutontop.

8.Adjustnumberofspacersbetweenbottomof
spindleandbladeasindicatedintheCutting
HeightAdjustmentTableandnotesinthe
AdjustingtheCuttingHeightsection.

9.Installunusedspacersbetweentopofspindleand
spindlenut.

10.T orqueboltto75–80ft-lb(102–109N-m)(see
Figure11).

Figure11

1.Springdiscwasher
(conetowardsbolthead)

2.Bladebolttorqueto
75–80ft-lb(102–109
N-m)

PTOEngagementLinkage
Adjustment

LocatedbetweenthePTOengagementbellcrankand
PTOengagementassistarmbeneaththefront,left
handcorneroftheenginedeck.

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.Removekeyorsparkplug
wire(s).

2.WithPTOengaged(leverpulledup,adjustthe
linkagelengthtowherethelowerendofthe
bellcrankjustclearstheaxlesupportgusset(see
Figure12).Makesuretheassistarmisagainstthe
rearassistarmstoponthedeck(seeFigure13).
Pushtheleverdowntothedisengagedposition.
Theassistarmshouldcontactthefrontassistarm
stoponthedeck.Ifitdoesnotcontact,readjust
sothatthebellcrankisclosertothegusset.

Figure12

1.ThebellcrankjustclearsthegussetwiththePTO
engaged

2.PTOSafetySwitch(locatedbeneaththeenginedeck)

3.Bellcrank

PTOSafetySwitch
Adjustment

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.Removekeyorsparkplug
wire(s).

2.WithPTOdisengagedandassistarmagainstthe
frontassistarmstop,adjustthebladesafetyswitch
mountingbracket(ifneeded)untilthebellcrank
depressestheplungerby1/4inch(.64cm).

30

Maintenance

3.BesurethebellcrankDoesNottouchtheswitch
bodyordamagetotheswitchcouldoccur.

4.Retightenswitchmountingbracket.

EnginetoMowerDeckBelt
Adjustment

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.Removekeyorsparkplug
wire(s).

2.EngagePTO.

3.Checkbeltguidesunderrearengineandfront
mowerdecktoseethattheyareproperlyset(see
BeltGuideAdjustmentsectionforinstructions).

4.Beltmustbetightenoughsoitdoesnot
slipduringheavyloadswhilecuttinggrass.
Over-tensioningwillreducebeltandspindle
bearinglife.Toadjustbelttension,loosenthe
5/16inchwhizlocknutonturnbuckleandrotate
theturnbuckle;rotateturnbuckletowardrearof
mowertotighten,andtowardfrontofmowerto
loosenbelttension(seeFigure13).

For48inchDecks:Ifthereisnoadjustmentleft
intheturnbuckleandthebeltisstillloose,therear
idlerpulleycanberepositionedinthefronthole
(seeFigure13).Thebeltguidelocatednexttothe
pulleymustalsoberepositionedinthefronthole
whenthepulleyismoved.Theturnbucklewill
needtobereadjusted.

Checkbelttensionafterthersthourofoperation
andatleasttwiceduringtherst24hoursof
operation.Adjustasnecessary.

Note:Afterreadjustingthebelttensioncheck
thebeltguideadjustmentasstatedinthe

BeltGuideAdjustmentandBladeBrake
Adjustmentsections.

Figure13

48inchDeckShownforReferenceOnly

1.PulleylocationforVikingHydro

2.Beltguidemustbemovedtothefrontpositionifthe
pulleyismoved(48inchdeckonly)

3.Pulleycanbemovedtothefrontpositiontotightenthe
beltwhenthereisnoadjustmentleftintheturnbuckle
(48inchdeckonly)

4.Turnbuckle

5.5/16inch(.79cm)minimumengagement

6.5/16inchwhizlocknut

7.RearAssistArmStop

8.AssistArm

9.FrontAssistArmStop

10.Point“A”

5.Properbelttensionwillrequireabout10lb(4.5
kg)sidepullonbelt,halfwaybetweenpulleys(see
Figure13,item10–PointA)todeectbelt1/2
inch(1.3cm).

MowerDeckBeltRoutings:

Figure14

36inchMowerDeck

31

Maintenance

Figure15

48inchMowerDeck

BladeBrakeAdjustment

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.Removekeyorsparkplug
wire(s).

2.DisengagePTO.

3.Makesurethebladebrakepadrestsagainst
thesheave.Adjustthespringmountingbolts
toproperlyalignthepadonthesheave(see
Figure16).

Figure16

ShownwithBladesDisengaged

1.BladeBrakeRod

3.1/8inchto3/16inch
(.32–.47cm)

2.SpringMountingBolts

4.Checkthedistancebetweenthespacerandthe
nutattheendofthebladebrakerod.The
distanceshouldbebetween1/8inch(.32cm)and
3/16inch(.47cm)(seeFigure16).

5.EngagethePTOandchecktomakesurethe
bladebrakepadclearsthesheave.

BeltGuideAdjustment

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.Removekeyorsparkplug
wire(s).

2.EngagethePTO.

3.Checkbeltguideundertheenginedeckforproper
adjustment(seeFigure17andFigure18).Adjust
asnecessary.

Figure17

36inchBeltGuideLocation

(Viewedfromunderneaththeenginedeck)

1.11/4inch(3.1cm)3.Endofslot

2.1/4inch(.64cm)
clearance

Figure18

48inchBeltGuideLocation

(Viewedfromunderneaththeenginedeck)

1.13/8inch(3.5cm)3.Endofslot

2.1/4inch(.64cm)
clearance

PumpDriveBeltTension
Adjustment

Self-tensioning-Noadjustmentnecessary.

32

Maintenance

HydroDriveLinkage
Adjustment

•AdjustSpeedControlLinkageandNeutralSafety
Switch:

1.Stopengineandwaitforallmovingpartsto

stop.Engageparkingbrake.Removekeyor
sparkplugwire(s).

2.Movethespeedcontrollever(locatedon

theconsole)tothefullforwardpositionand
checktheorientationofthetabsontheends
ofthespeedcontrolcrank(seeFigure19).
Thesetabsshouldbepointingstraightdown
atthe6o’clockpositionorslightlyforward.
Adjustthethreadedyokeatthebottomofthe
speedcontrollinkage(seeFigure19)untilthe
tabsarepositionedcorrectly.

Figure19

ViewedfromLeftSideofUnit

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

2.ActuatingT ab

3.Pullthespeedcontrolleverbacktoneutral.

Checkthattheneutralsafetyswitchactuating
tabhasdepressedtheplungeroftheswitchso
thatthereisabout5/16inch(.79cm)between
thetabandtheswitch(seeFigure19).If
necessary,movetheswitchforeandaft.

•AdjustNeutralControlLinkages:

1.Raisetherearofthemachineupontojack

standshighenoughtoraisethedrivewheels
offoftheground.

2.Starttheengineandmovethethrottleahead

tothefullthrottleposition.Placetheneutral
locklatchesinthe“forward”positionas
showninFigure4.Releasetheparkbrake
andmovethespeedcontrollevertothe
“mid-speed”position.

Note:TheOPCleversmustbehelddown
andtheparkbrakemustbedisengaged
wheneverthespeedcontrolleverismoved
outofneutralortheenginewillkill.

3.Squeezetherespectivedriveleveruntilan
increasedresistanceisfelt,thisiswhere
neutralshouldbe.

Ifthewheelturnswhileholdingthedrive
leverinneutral,theneutralcontrollinkages
needtobeadjusted.Ifthewheelstopsthen
gotostep7.

Figure20

ViewedfromLeftSideofUnit

1.NeutralControlLinkage5.SpeedControlLinkage

2.HydroControlLinkage

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

3.DriveLeverLinkage7.Loosennut

4.SpeedControlCrank

8.Yoke

4.Loosenthenutagainsttheneutralcontrol
linkageyokeasshowninFigure20.

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

33

Maintenance

toseeifthewheelstops.Ifnot,repeatthe
aboveadjustmentprocedure.

6.Makethisadjustmentonbothsides.

7.Afteradjustmentsaremadeandthewheels
stopwhenthedriveleversareintheneutral
position,tightenthenutsagainsttheyokes.

•AdjustHydroControlLinkages:

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

Note:Theneutrallocklatchesshouldbe
“unlocked”andintheforwardposition.

2.Loosenthefrontnutonlefthydrocontrol
linkageasshowninFigure20.Turntherear
controllinkageadjustingnutcounterclockwise
untilwheelrotatesforward.Turntherearnut
ofleftcontrollinkageclockwise1/4ofaturn
atatime,stoppingtomovethespeedcontrol
forwardandbacktoneutral,untilleftwheel
stopsrotatingforward.

Turntherearnutanadditional1/2turnand
tightenthefrontnutmakingsurenottoput
abindonthelinkage.Makesureatpartof
linkageisperpendiculartopinpartofswivel
(seeFigure21).

Figure21

1.LeftHydroControlLink
(leftsideshown)

4.Linkageisperpendicular
topin(correctposition)

2.Frontnut5.Linkageinincorrect
position

3.Rearnut

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
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(Figure22).Ifthetirerotatesineither
direction,thelengthofthedriveleverlinkwill
needtobeadjusted.

Figure22

2.Adjustthelinkagelengthbylooseningthejam
nutsatbothendsofthelinkageandrotating
thelinkageintheballjoints.Lengthenthe
linkageifthetireisturninginreverseand

34

Maintenance

shortenthelinkageifthetireiscreeping
forward.Tightenthejamnutsatbothends.
Releaseandre-engagetheneutrallocklatch
checkingthatthetirestops.Continuethis
processuntilthetireisatadeadstop.

3.Makethisadjustmentforbothsides.

•TrackingAdjustment:

1.Stopengineandwaitforallmovingpartsto
stop.Engageparkingbrake.Raisetherearof
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
anchorlinkstoeitherthe“medium”or“heavy
duty”positionsasshowninFigure23.Thespring
anchorlinksareattachedtotheupperrearcorner
ofthehydrodriveshieldsontheleftandright
handsidesofthemachine.

Note:Inthe“medium”or“heavyduty”
positions,thedriveleverforcesattheupper
handlewillalsobeincreased.

Figure23

1.Heavyduty

3.Standard

2.Mediumduty4.Retainingbolt

ParkBrakeAdjustment

1.Stopengineandwaitforallmovingpartstostop.

2.Disengagetheparkbrake.

3.Removethehairpininthelowerparkbrake
linkage.Turnthelinkageintheyokeuntilthereis
3/16inch(.48cm)to1/4inch(.64cm)clearance
betweentheparkbraketirebarsandthetireswith
theparkbrakedisengaged.Re-installthehairpin.

35

Maintenance

Cleaning

CleanEngineAirCooling
System

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.Removekeyorsparkplug
wire(s).

2.Cleanalldebrisfromengineairintakescreenand
fromaroundengineshrouding.

RemoveEngineShroudsand
CleanCoolingFins

ServiceInterval:Every80hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.Removekey
orsparkplugwire(s).

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

3.Makesurecoolingshroudsareproperly
reinstalled.Operatingtheenginewithout
coolingshroudswillcauseenginedamagedueto
overheating.

CleanGrassBuild-UpUnder
Deck

ServiceInterval:Beforeeachuseordaily

1.DisengagePTO.

2.Stopengineandwaitforallmovingpartstostop.
Engageparkingbrake.Removekeyorsparkplug
wire(s).

3.Raisedeckandsupportunitusingjackstandsor
equivalentsupport.

4.Cleanoutanygrassbuild-upfromundersideof
deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilisapollutanttotheenvironment.Dispose
ofusedoilatacertiedrecyclingcenteroraccording
toyourstateandlocalregulations.

36

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused
byanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

2.Openthefuelshutoffvalve.

3.Thethrottleandchokearenotinthe
correctposition.

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

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

5.Dirt,water,orstalefuelisinthefuel
system.

5.ContactanAuthorizedServiceDealer.

6.Aircleanerisdirty.

6.Cleanorreplacetheaircleanerelement.

7.Electricalconnectionsarecorroded,loose
orfaulty.

7.Checktheelectricalconnectionsfor
goodcontact.Cleanconnectorterminals
thoroughlywithelectricalcontactcleaner,
applydielectricgreaseandreconnect.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Faultysparkplug.

9.Clean,adjustorreplacesparkplug.

10.Sparkplugwireisnotconnected.

10.Checkthesparkplugwireconnection.

11.PTOisengaged.

11.DisengagethePTO.

12.Speedcontrolleverisnotinneutral
position.

12.Ensuretheshifterleverisintheneutral
position.

Enginewillnotstart,startshard,orfailsto
keeprunning.

13.OPCleversarereleased.

13.DepressOPClevers.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow .

3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe
engineareplugged.

4.Removetheobstructionsfromthecooling
nsandairpassages.

5.Ventholeinthefuelcapisplugged.

5.Cleanorreplacethefuelcap.

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

Enginelosespower.

7.Dirt,water,orstalefuelisinthefuel
system.

7.ContactanAuthorizedServiceDealer.

1.Engineloadisexcessive.1.Reducethegroundspeed.

Engineoverheats.

2.Oillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

1.Trackingneedsadjustment.1.Adjustthetrackingbyturningknobonthe

righthydrocontrollinkageinthedirection
thatthemowerneedstobeadjustedto.
Turntheknobin1/4turnincrements
untilthemowertrackscorrectly.

Mowerpullsleftorright(withleversfully
forward).

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

37

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor
broken.

2.Changethebelt.

Machinedoesnotdrive.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

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

2.Cuttingblade(s)is/arebent.

2.Installnewcuttingblade(s).

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

front-to-rear.

4.Undersideofmowerisdirty .4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

Unevencuttingheight.

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

7.Replaceblades,spindlesand(or)check
fordamagetomowerdeck.

1.Cuttingblade(s)is/arebentorunbalanced.

1.Installnewcuttingblade(s).

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,orblade
pulley.

4.Tightentheappropriatepulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

Abnormalvibration.

7.Beltisdamaged.7.Installnewbelt.

1.Deckbeltisworn,looseorbroken.1.Installnewdeckbelt.

Bladesdonotrotate.

2.Deckbeltisoffpulley.2.Installdeckpulleyandchecktheidler

pulley,idlerarmandspringforcorrect
positionandfunction.

1.Bladebrakeisnotadjustedproperly.1.Adjustbladebrake.

2.Beltguideisnotproperlyset2.Adjustbeltguidetoproperposition.

Bladesdonotstopwhendisengaged.

3.PTOengagementisnotproperlyset.3.CheckthePTOengagementposition.

38

Schematics

Schematics

WiringDiagram

GREEN

BLACK

RED

RED

BLACK

GREEN

YELLOW

BLUE

ORANGE

BROWN

A

B

C

D

E

F

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

FROM SAFETY

INTERLOCK MODULE

TRANSMISSION

SWITCH

N.O.

PTO

SWITCH

N.O.

OPC

SWITCH

N.O.

KEY

SWITCH

ENGINE

PARK BRAKE

SWITCH

N.O.

G006968

39

Schematics

40

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

41

42

43

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

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

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

PartNo.4500-355Rev .A
[phone]
Fax[phone]
PrintedintheUSA

www.exmark.com