Exmark Lawn Mower PNS20KA443 User Guide

PIONEER S-SERIES  
For Serial Nos.  
920,000 & Higher  
Part No. 4500-898 Rev. A  
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Introduction  
CONGRATULATIONS on the purchase of your  
Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum  
amount of dependability and years of trouble-free  
operation.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
Figure 1  
1. Model and serial number location  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
Model No.  
Serial No.  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
Exmark parts manuals are available online at  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Contents  
Torque Requirements .................................... 17  
Periodic Maintenance ....................................... 28  
4
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Safety  
Safe Operating Practices  
Safety  
Safety Alert Symbol  
This lawn mower meets or exceeds the B71.4  
specifications of the American National Standards  
Institute in effect at the time of production.  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
Exmark designed and tested this lawn mower to offer  
reasonably safe service; however, failure to comply  
with the following instructions may result in personal  
injury.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents.  
• Never let children or untrained people operate  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• Only adults and mature teenagers should operate  
a mower, and even mature teenagers should have  
adult supervision. Be sure a teenager:  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
1. has read and understands the Operator’s  
Manual and recognizes the risks involved;  
2. is sufficiently mature to use caution; and  
Figure 2  
3. is of sufficient size and weight to operate  
the controls comfortably and to manage the  
mower without taking risks.  
Safety Alert Symbol  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
The safety alert symbol appears above information  
which alerts you to unsafe actions or situations  
and will be followed by the word DANGER,  
WARNING, or CAUTION.  
Preparation  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
• 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.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
CAUTION  
This machine produces sound levels in excess  
of 85 dBA at the operator’s ear and can cause  
hearing loss through extended periods of  
exposure.  
Wear hearing protection when operating this  
machine.  
5
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Safety  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
DANGER  
In certain conditions during fueling, static  
electricity can be released causing a spark  
which can ignite gasoline vapors. A fire or  
explosion from gasoline can burn you and  
others and cause property damage.  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
A fire or explosion from gasoline can burn  
you, others, and cause property damage.  
• 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.  
• Fill the fuel tank outdoors on level ground,  
in an open area, when the engine is cold.  
Wipe up any gasoline that spills.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Do Not fill the fuel tank completely full.  
Fill the fuel tank to the bottom of the filler  
neck. The empty space in the tank allows  
gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine  
or emission system.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Never smoke when handling gasoline, and  
stay away from an open flame or where  
gasoline fumes may be ignited by spark.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
WARNING  
• Add fuel before starting the engine. Never  
remove the cap of the fuel tank or add  
fuel when engine is running or when the  
engine is hot.  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• 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.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
6
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Safety  
damage and make repairs before restarting  
Operation  
WARNING  
Operating engine parts, especially the muffler,  
become extremely hot. Severe burns can occur  
on contact and debris, such as leaves, grass,  
brush, etc. can catch fire.  
and operating the mower).  
– Before clearing blockages.  
– Whenever you leave the mower.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
• Allow engine parts, especially the muffler, to  
cool before touching.  
– Before refueling.  
– Before dumping the grass catcher.  
• Remove accumulated debris from muffler  
and engine area.  
WARNING  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can kill  
you.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
Do Not run engine indoors or in a small confined  
area where dangerous carbon monoxide fumes  
can collect.  
NEVER carry passengers. DO NOT operate  
the mower when people, especially children, or  
pets are in the area.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine. Use seat belts  
with the roll bar in the raised and locked position.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
• Park machine on level ground. Stop engine, wait  
for all moving parts to stop, remove key and  
engage parking brake:  
Slope Operation  
– Before checking, cleaning or working on the  
mower.  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
occur. The operator is responsible for safe operation  
on slopes.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
7
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Safety  
• Be aware that operating on wet grass, across steep  
slopes or downhill may cause the mower to lose  
traction. Loss of traction to the drive wheels may  
result in sliding and a loss of braking and steering.  
DANGER  
Operating on wet grass or steep slopes can cause  
sliding and loss of control. Wheels dropping over  
edges, ditches, steep banks, or water can cause  
rollovers, which may result in serious injury,  
death or drowning.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Do Not mow slopes greater than 15 degrees.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Reduce speed and use extreme caution on  
slopes.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
• Avoid sudden turns or rapid speed changes.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
Using the Rollover Protection System  
(ROPS)  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
A Rollover Protection System (roll bar) is installed  
on the unit.  
• Use a walk behind mower and/or a hand trimmer  
near drop-offs, ditches, steep banks or water.  
(Figure 3).  
WARNING  
There is no rollover protection when the roll bar  
is down. Wheels dropping over edges, ditches,  
steep banks, or water can cause rollovers, which  
may result in serious injury, death or drowning.  
• Keep the roll bar in the raised and locked  
position and use seat belt.  
• Lower the roll bar only when absolutely  
necessary.  
• Do Not wear seat belt when the roll bar is  
down.  
• Drive slowly and carefully.  
Figure 3  
• Raise the roll bar as soon as clearance  
permits.  
1. Safe Zone-Use the mower here on slopes less than 15  
degrees  
2. Danger Zone-Use a walk behind mower and/or hand  
trimmer on slopes greater than 15 degrees, near  
drop-offs and water.  
• Check carefully for overhead clearances (i.e.  
branches, doorways, and electrical wires) before  
driving under any objects and Do Not contact  
them.  
3. Water  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• In the event of a rollover, take the unit to an  
Authorized Service Dealer to have the ROPS  
inspected.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
Maintenance and Storage  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
• Disengage drives, lower implement, set parking  
brake, stop engine and remove key or disconnect  
8
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Safety  
spark plug wire. Wait for all movement to stop  
before adjusting, cleaning or repairing.  
DANGER  
Battery electrolyte contains sulfuric acid,  
which is poisonous and can cause severe  
burns. Swallowing electrolyte can be fatal or  
if it touches skin can cause severe burns.  
• Keep engine and engine area free from  
accumulation of grass, leaves, excessive grease  
or oil, and other debris which can accumulate  
in these areas. These materials can become  
combustible and may result in a fire.  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
• Let engine cool before storing and Do Not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Do Not swallow electrolyte.  
• In the event of an accident, flush with  
water and call a doctor immediately.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
CAUTION  
• Use jack stands to support components when  
required.  
If the ignition is in the “ON” position there  
is potential for sparks and engagement  
of components. Sparks could cause an  
explosion or moving parts could accidentally  
engage causing personal injury.  
• Carefully release pressure from components with  
stored energy.  
• Disconnect battery or remove spark plug wire  
before making any repairs. Disconnect the  
negative terminal first and the positive last.  
Reconnect positive first and negative last.  
Be sure ignition switch is in the “OFF”  
position before charging the battery.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check all bolts frequently to maintain proper  
tightness.  
• Keep hands and feet away from moving parts.  
If possible, Do Not make adjustments with the  
engine running.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• Charge batteries in an open well ventilated area,  
away from spark and flames. Unplug charger  
before connecting or disconnecting from battery.  
Wear protective clothing and use insulated tools.  
WARNING  
Removing standard original equipment parts  
and accessories may alter the warranty, traction,  
and safety of the machine. Failure to use original  
Exmark parts could cause serious injury or  
death. Making unauthorized changes to the  
engine, fuel or venting system, may violate EPA  
and CARB regulations.  
DANGER  
Charging or jump starting the battery may  
produce explosive gases. Battery gases can  
explode causing serious injury.  
Replace all parts including, but not limited to,  
tires, belts, blades, and fuel system components  
with original Exmark parts.  
• Keep sparks, flames, or cigarettes away  
from battery.  
• Ventilate when charging or using battery  
in an enclosed space.  
• Make sure venting path of battery is  
always open once battery is filled with  
acid.  
• Always shield eyes and face from battery.  
9
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Safety  
WARNING  
Hydraulic fluid escaping under pressure  
can penetrate skin and cause injury. Fluid  
accidentally injected into the skin must be  
surgically removed within a few hours by a doctor  
familiar with this form of injury or gangrene may  
result.  
• If equipped, make sure all hydraulic fluid  
hoses and lines are in good condition and all  
hydraulic connections and fittings are tight  
before applying pressure to hydraulic system.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• Use cardboard or paper, not your hands, to  
find hydraulic leaks.  
• Safely relieve all pressure in the hydraulic  
system by placing the motion control levers  
in neutral and shutting off the engine before  
performing any work on the hydraulic system.  
10  
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
1-303508  
1-633922  
98-5954  
1-403005  
103-2076  
11  
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Safety  
109-6014  
116-1119  
107-2102  
116-1121  
1. Rotate the drive release 2. Push the machine.  
knob to loosen, slide the  
knob, and tighten.  
109-3148  
116-1496  
12  
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Safety  
116-3303  
116-4465  
3. Choke-on  
1. Fast  
2. Slow  
4. Choke-off  
PTO Switch Symbols  
1. PTO–disengage  
2. PTO–engage  
116-4308  
2. Unlatch  
1. Latch  
13  
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Safety  
109-6016  
4. Refer to the Operator’s manual for grease instructions  
1. Read the instructions before servicing or performing  
maintenance  
2. Time interval  
5. Check hydraulic oil level and refer to the Operator’s  
manual or further instructions  
3. Check oil level  
6. Check tire pressure  
116-4430  
1. Park brake — engage  
2. Fast  
3. Slow  
4. Neutral  
5. Reverse  
14  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 920,000 and Higher  
PNS20KA443; PNS22KA483; PNS24KA523  
Systems  
Safety Interlock System  
• PTO must be disengaged, brake engaged, and  
motion control levers out (neutral lock) to start  
engine. (It is not necessary for the operator to be  
in the seat to start the engine.)  
Engine  
• Engine Specifications: See your Engine Owner’s  
Manual  
• Operator must be in seat when PTO is engaged,  
brake is disengaged, or motion control levers are  
moved in or engine will stop.  
• Engine Oil Type: Exmark 4–Cycle Premium  
Engine Oil  
• RPM: Full Speed: 3750 ±50 RPM (PTO not  
engaged) Idle: 1500 ±100 RPM  
• Engine will stop if either the left, the right, or  
both levers are moved from neutral lock position  
while brake is engaged.  
Fuel System  
• Capacity: 7.0 gal. (26.5 L)  
Operator Controls  
• Steering and Motion Control:  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher; containing no more than 10%  
methanol or ethanol.  
Note: Motion control levers are adjustable to  
three heights.  
– Separate levers, on each side of the console,  
control speed and direction of travel of the  
respective drive wheels.  
• Fuel Filter:  
Kawasaki: Kawasaki P/N 49019-7005  
• Fuel Shut-Off Valve:  
– Steering is controlled by varying the position  
of the levers relative to each other.  
All Units: 1/4 turn increments (“ON”, “OFF”).  
– Moving motion control levers outward (in  
slots) locks the drive system in neutral.  
Electrical System  
• PTO Engagement Switch: Engages electric clutch  
(to drive belt) which engages mower blades.  
• Charging System: Flywheel Alternator  
• Charging Capacity: 15 amps  
• Battery Type: BCI Group U1  
• Recommended Minimum Battery CCA: 260 CCA  
• Battery Voltage: 12 Volt  
• Polarity: Negative Ground  
• Fuses:  
• Parking Brake Lever: Engages parking brake.  
• Deck Height Adjustment Lever: Sets cutting  
height to desired position.  
• Deck Lift Pedal: Foot pedal that lifts deck.  
• Transport Lock: Latching position: Automatically  
latches at the transport position.  
Seat  
All units:  
• Type: Standard seat with foam padded seat  
cushion with armrests and integral safety switch.  
– 25 amp main fuse  
– 25 amp charging system fuse  
– 10 amp PTO fuse  
Optional seat: Seat with high back, extra  
wide foam padded seat cushion with internal  
suspension, thick bolstering, two-tone cover,  
– 15 amp accessory fuse  
15  
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Specifications  
armrests, integral safety switch, and seat vibration  
isolation system.  
– 48 inch Deck: (121.9 cm)  
– 52 inch Deck: (132.1 cm)  
Optional seat accessories for units with standard  
seats:  
• Discharge: Side  
• Blade Size:  
– Custom ride suspension system to enhance  
Standard Seat. Adds approximately 3 inches  
(7.6 cm) to seat height.  
– 44 inch Deck: 22.25 inches (56.5 cm) – (2 ea.)  
– 48 inch Deck: 16.25 inches (41.3 cm) – (3 ea.)  
– 52 inch Deck: 18.00 inches (45.7 cm) – (3 ea.)  
– Deluxe suspension seat with high back,  
(dampened, adjustable spring suspension),  
armrests, and integral safety switch. Adds  
approximately 1/2 inch (1.3 cm) to seat height.  
• Blade Spindles: Solid steel spindles with .98 inch  
(25 mm) I.D. bearings.  
• Mounting: Adjustable fore and aft on seat tracks.  
• Armrests: Molded flip-up armrests.  
• Seat Safety Switch:  
• Deck Drive: “B” Section belt with self-tensioning  
idler.  
• Electric clutch: 175 ft-lb Mag Stop  
• Deck: Full floating deck is attached to out-front  
support frame. Anti-scalp rollers provide  
maximum turf protection. Deck design allows for  
bagging, mulching or side discharge.  
Integrated seat switch. Time delay seat switch  
eliminates rough ground cut-outs.  
Hydrostatic Ground Drive System  
• Two unitized hydrostatic transmissions:  
Hydro Gear ZT3100  
– 44 inch Deck: 2 anti-scalp rollers  
– 48 inch Deck: 3 anti-scalp rollers  
– 52 inch Deck: 3 anti-scalp rollers  
• Deck Depth:  
• Hydraulic Oil Type: Exmark Premium Hydro Oil.  
• Hydraulic Oil Capacity: 7.7 oz (2.3 L) per side  
• Hydraulic Filter: P/N 109-3321  
• Speeds:  
– 44 inch Deck: 5.0 inches (12.7 cm)  
– 48 inch Deck: 5.0 inches (12.7 cm)  
– 52 inch Deck: 5.0 inches (12.7 cm)  
• Cutting Height Adjustment:  
– 0-8 mph (12.9 km/hr) forward.  
– 0-5 mph (8.0 km/hr) reverse.  
• Drive wheel release valves allow machine to be  
moved when engine is not running.  
Foot activated lever is used to adjust the cutting  
height from 1 1/2 inch (3.8 cm) to 5 inches (12.7  
cm) in 1/4 inch (6.4 mm) increments.  
Tires & Wheels  
• Mulching Kit: Optional.  
Drive  
Front Caster  
Pneumatic (Air Pneumatic (Air  
Dimensions  
filled)  
filled)  
Quantity  
Tread  
2
2
Overall Width:  
Turf Master  
22 x 9.50-12  
4
Smooth  
44 inch  
Deck  
48 inch  
Deck  
52 inch  
Deck  
Size  
13 x 5.00-6  
4
Ply Rating  
Pressure  
Without  
Deck  
45.8 inches 45.8 inches 45.8 inches  
(116.3 cm) (116.3 cm) (116.3 cm)  
13 psi (90 kPa)  
13 psi (90 kPa)  
Deflector  
Up  
48.2 inches 50.7 inches 54.2 inches  
(122.4 cm) (128.8 cm) (137.7 cm)  
Cutting Deck  
• Cutting Width:  
Deflector  
Down  
56.4 inches 59.5 inches 64.3 inches  
(143.3 cm) (151.1 cm) (163.3 cm)  
– 44 inch Deck: (111.8 cm)  
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Specifications  
Overall Length:  
Bolt Location  
Torque  
Engine Mounting Bolts  
(Kawasaki)  
44 inch  
Deck  
48 inch  
Deck  
52 inch  
Deck  
27-33 ft-lb (37-45 N-m)  
Roll Bar -  
Up  
78.8 inches 77.8 inches 77.8 inches  
(200.2 cm) (197.6 cm) (197.6 cm)  
Wheel Lug Nuts  
70-90 ft-lb (95-122 N-m)  
77-95 ft-lb (104-129 N-m)  
Rollover Protection  
System (Roll Bar) 1/2  
inch Mounting Bolts  
Roll Bar -  
Down  
79.6 inches 78.6 inches 78.6 inches  
(202.2 cm) (199.6 cm) (199.6 cm)  
Clutch Retaining Bolt  
(secured with threadlocker)  
49-61 ft-lb (66-83 N-m)  
Overall Height:  
Roll Bar - Up  
Roll Bar - Down  
71.3 inches (181.1 cm)  
48 inches (121.9 cm)  
Tread Width: (Center to Center of  
Tires, Widthwise)  
44 inch  
Deck  
48 inch  
Deck  
52 inch  
Deck  
Drive  
Wheels  
36.8 inches 36.8 inches 36.8 inches  
(93.5 cm) (93.5 cm) (93.5 cm)  
Caster  
Wheels  
26.8 inches 33.5 inches 33.5 inches  
(68.1 cm) (85.1 cm) (85.1 cm)  
Wheel Base: (Center of Caster Tire to  
Center of Drive Tire)  
44 inch Deck  
48 inch Deck  
52 inch Deck  
49.7 inches  
(126.2 cm)  
48.7 inches  
(123.7 cm)  
48.7 inches  
(123.7 cm)  
Curb Weight:  
44 inch  
Deck  
48 inch  
Deck  
52 inch  
Deck  
Kawasaki  
Units  
822 lb  
(373 kg)  
862 lb  
(391 kg)  
873 lb  
(396 kg)  
Torque Requirements  
Bolt Location  
Torque  
Blade Drive Sheave  
Mounting Nut  
130-160 ft-lb (176-217  
N-m)  
Blade Mounting Bolt  
50-60 ft-lb (68-81 N-m)  
(lubricate with anti-seize)  
Anti-Scalp Roller Nyloc  
Nut See Figure 17  
27-33 ft-lb (41-47 N-m)  
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Operation  
Product Overview  
Operation  
Note: Determine the left and right sides of the  
machine from the normal operating position.  
Controls  
Motion Control Levers  
The motion control levers located on each side of  
the console control the forward and reverse motion  
of the machine.  
Moving the levers forward or backward turns  
the wheel on the same side forward or reverse  
respectively. Wheel speed is proportional to the  
amount the lever is moved.  
Moving the levers outward from the center position  
into the T-slot locks them in the neutral position  
(Figure 5).  
Figure 4  
1. Rollover Protection  
System (ROPS)  
5. Motion control levers  
2. Engine controls (right  
console)  
6. Parking brake  
3. Seat belt  
4. Fuel cap  
7. Height of cut adjustment  
Figure 5  
1. Neutral lock position  
(handles out)  
4. Forward  
2. Neutral operate position 5. Neutral (operate)  
(handles in)  
3. Front of unit  
6. Reverse  
Choke Control  
Located on right console (black lever) (see Figure 6).  
The choke is used to aid in starting a cold engine.  
Moving the choke lever forward will put the choke in  
the “ON” position and moving the choke lever to the  
rear, to the detent, will put the choke in the “OFF”  
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Operation  
position. Do Not run a warm engine with choke in  
the “ON” position.  
The ignition switch is used to start and stop the  
engine. The switch has three positions “OFF”, “ON”  
and “START”. Insert key into switch and rotate  
clockwise to the “ON” position. Rotate clockwise to  
the next position to engage the starter (key must be  
held against spring pressure in this position). Allow  
the key to return to the “on” position immediately  
after the engine starts.  
Figure 7  
1. Off  
2. On  
3. Start  
Figure 6  
1. Throttle lever  
4. Blade control switch  
(power take-off)  
2. Choke lever  
3. Hour meter  
5. Ignition switch  
Note: Brake must be engaged, motion control  
levers out (neutral lock position) and PTO switch  
disengaged to start engine. (It is not necessary for the  
operator to be in the seat to start the engine.)  
Throttle Control  
Hour Meter  
Located on right console (red lever) (see Figure 6).  
Located on the control panel (see Figure 6 and  
Figure 8).  
The throttle is used to control engine speed. Moving  
the throttle lever forward will increase engine speed  
and moving the throttle lever to the rear will decrease  
engine speed. Moving the throttle forward into the  
detent is full throttle.  
The hour meter records the number of hours that  
the engine has run.  
Brake Lever  
Located on left side of unit, just to the front of the  
LH motion control lever.  
The brake lever engages a parking brake on the drive  
wheels.  
Pull the lever up and rearward to engage the brake.  
Figure 8  
Push the lever forward and down to disengage the  
brake.  
1. LCD indicators  
3. Hour/Voltage display  
2. Low voltage indicator  
light  
The unit must be tied down and brake engaged when  
transporting.  
Ignition Switch  
Fuel Shut-Off Valve  
Located on right console (see Figure 6).  
Located by the lower LH ROPS tube mounting.  
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Operation  
The fuel shut-off valve is used to shut off the fuel  
when the machine will not be used for a few days,  
during transport to and from the jobsite, and when  
parked inside a building.  
Align valve handle with the fuel line to open. Rotate  
90° to close.  
Drive Wheel Release Valves  
WARNING  
Hands may become entangled in the rotating  
drive components below the engine deck, which  
could result in serious injury or death.  
Stop engine, remove key, allow all the moving  
parts to stop before accessing the drive wheel  
release valves.  
Figure 9  
1. Front of the machine  
WARNING  
2. Rotate bypass release knob counterclockwise to loosen  
3. Lever position for operating the machine  
4. Pull lever in this direction to push the machine  
5. Lever position for pushing the machine  
6. Rotate bypass release knob clockwise to tighten  
7. Release lever  
The engine and hydraulic drive units can become  
very hot. Touching a hot engine or hydraulic  
drive units can cause severe burns.  
Allow the engine and hydraulic drive units to  
cool completely before accessing the drive wheel  
release valves.  
To release the drive system (see item 1 in Figure 9),  
loosen the knob by turning counterclockwise. Then  
pull the release lever on the underside of machine  
towards the back of the machine and retighten the  
knob to hold the release lever back in the released  
state. Repeat this on each side of the machine.  
Located on the back of the unitized hydraulic drive  
units, below the engine deck.  
During normal operating conditions, the drive wheel  
release valves are positioned horizontally. If the  
machine has to be pushed by hand, the valves must  
be in the “released” position (see Figure 9).  
Release the parking brake. The machine is now able  
to be pushed by hand.  
During normal operating conditions, the drive wheel  
release valves are positioned horizontally. If the  
machine has to be pushed by hand, the valves must  
be in the “released” position (see Figure 9).  
To reset the drive system (see item 2 in Figure 9),  
loosen the knob by turning counterclockwise. Then  
push the release lever on the underside of machine  
towards the front of the machine and retighten the  
knob to hold the release lever in the operating state.  
Repeat this on each side of the machine.  
Do Not tow machine.  
PTO Engagement Switch  
Located on right console (see Figure 6).  
Switch must be pulled out (up) to engage the blades.  
Switch is pushed in to disengage the blades.  
20  
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Operation  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Deck Lift Pedal  
Located at the right front corner of the floor pan.  
Push the pedal forward with your foot to raise the  
cutting deck. Allow the pedal to move rearward to  
lower the cutting deck to the cut height that has been  
set.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Operating Instructions  
Raise the Rollover Protection System  
(ROPS)  
Important: The roll bar is an integral and  
effective safety device. Keep the roll bar in the  
raised and locked position when operating the  
mower. Lower the roll bar temporarily only when  
absolutely necessary.  
Figure 10  
1. Transport lock handle  
2. Height adjustment pin  
3. Height of cut decal  
4. Deck foot pedal  
1. The knob must be completely latched with the  
tabs interlocking as shown in Figure 11 to lock  
the roll bar in the raised, operate position.  
2. Apply forward pressure to the upper hoop of the  
roll bar.  
Transport Lock  
Located on the height of cut adjustment plate (see  
Figure 10).  
3. Pull the knob and rotate 90° to hold in the  
unlatched position to lower the roll bar.  
The transport latching mechanism will automatically  
engage when the deck is raised to the transport  
position. To release the deck from the transport  
position: push the foot pedal to remove the load from  
the transport latching mechanism, pull the transport  
lock handle rearward, and let the pedal come back to  
lower the deck down to the desired cut height.  
4. To return to the operate position, raise the roll  
bar, and then rotate knobs 90° so that the tabs  
interlock partially. Apply forward pressure to the  
roll bar upper hoop and observe that the knobs  
return to the completely latched position.  
Pre-Start  
Fill fuel tank on level ground. For best results use  
only clean, fresh regular grade unleaded gasoline with  
an octane rating of 87 or higher.  
Important: Never use methanol, gasoline  
containing methanol, gasohol containing more  
than 10% ethanol, premium gasoline, or white  
gas because the fuel system could be damaged.  
Do Not add oil to gasoline.  
Do Not overfill fuel tank. Fill the fuel tank to the  
bottom of the filler neck. The empty space in the  
tank allows gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine or emission  
system.  
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Operation  
Starting the Engine  
1
1. Move the motion control levers out to the neutral  
lock position.  
2. Pull up and back on the parking brake lever to  
engage the parking brake.  
3. Push down on the PTO switch to the “disengage”  
position.  
3
4
2
Note: It is not necessary for the operator to be  
in the seat to start the engine.  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
5
5. On a cold engine, push the choke lever forward  
into the “ON” position.  
G014402  
Figure 11  
1. Roll bar upper hoop  
2. Knob in “latched” position  
3. Pull knob to unlatch  
4. Rotate 90° to hold unlatched  
5. Knob in “unlatched” position  
On a warm engine, leave the choke in the “OFF”  
position.  
6. Turn ignition switch to the “START” position.  
Release the switch as soon as the engine starts.  
Important: Do Not crank the engine  
continuously for more than ten seconds at a  
time. If the engine does not start, allow a 60  
second cool-down period between starting  
attempts. Failure to follow these guidelines  
can burn out the starter motor.  
5. Make sure the knobs are fully engaged with the  
roll bar in the raised position. The upper hoop of  
the roll bar may need to be pushed forward or  
pulled rearward to get both knobs fully engaged  
(see Figure 12).  
7. If the choke is in the “ON” position, gradually  
return choke to the “OFF” position as the engine  
warms up.  
Engaging the PTO  
DANGER  
The rotating blades under the mower deck are  
dangerous. Blade contact can cause serious  
injury or kill you.  
Figure 12  
1. Engaged  
2. Partially engaged — Do  
Not operate with ROPS  
in this condition.  
Do Not put hands or feet under the mower or  
mower deck when the blades are engaged.  
DANGER  
Important: Always use the seat belt with the  
roll bar in the operate (raised) position. Ensure  
that the rear part of the seat is secured with the  
seat latch.  
An uncovered discharge opening will allow  
objects to be thrown in an operator’s or  
bystander’s direction. Also, contact with the  
blade could occur. Thrown objects or blade  
contact can cause serious injury or death.  
Open the Fuel Shut-Off Valve  
Never operate the mower with the discharge  
deflector raised, removed, or altered unless there  
is a grass collection system or mulch kit in place  
and working properly.  
Rotate the valve and align with the fuel line to open.  
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Operation  
The PTO push-pull switch engages the cutting blades.  
Be sure that all persons are clear of the mower deck  
and discharge area before engaging PTO.  
Important: To begin movement (forward or  
backward) the operator must be in the seat, the  
brake lever must be disengaged (pushed down)  
before the motion control levers can be moved in  
or the engine will stop.  
Important: Operator must be in seat before the  
PTO can be engaged.  
When the motion control levers are positioned fully  
outward (apart) in the T-slot, the drive system is in  
the neutral lock position (Figure 13).  
1. Set the throttle midway between the “SLOW”  
and “FAST” positions.  
2. Pull the PTO switch outward to engage the  
blades.  
When the motion control levers are moved directly  
inward (together) the drive system is in the neutral  
operate position.  
3. Place the throttle in the “FAST” position to begin  
mowing.  
Disengaging the PTO  
1. Set the throttle midway between the “SLOW”  
and “FAST” positions.  
2. Push the PTO switch in to disengage the blades.  
Stopping the Engine  
1. Bring the unit to a full stop.  
2. Move the motion control levers out to the neutral  
lock position.  
3. Engage the parking brake.  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
5. Disengage the PTO.  
Figure 13  
6. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
1. Neutral lock position  
(handles out)  
2. Neutral operate position 5. Neutral (operate)  
(handles in)  
4. Forward  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
3. Front of Unit  
6. Reverse  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
Driving Forward  
1. Release the parking brake.  
2. Move the motion control levers inward to the  
center to the neutral position.  
Driving the Machine  
CAUTION  
Machine can spin very rapidly by positioning one  
lever too much ahead of the other. Operator may  
lose control of the machine, which may cause  
damage to the machine or injury.  
3. To move forward in a straight line, move both  
levers forward with equal pressure.  
To turn left or right, pull the motion control lever  
back toward neutral in the desired turn direction.  
The machine will move faster the farther the  
motion control levers are moved from the neutral  
position.  
• Use caution when making turns.  
4. To stop, position both motion control levers in  
the neutral operate position.  
• Slow the machine down before making sharp  
turns.  
23  
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Operation  
Figure 15  
1. Transport lock handle  
2. Height adjustment pin  
3. Height of cut decal  
4. Deck foot pedal  
Figure 14  
3. Neutral  
1. Front of Unit  
2. Forward  
4. Reverse  
5. Insert the height adjustment pin into the hole  
corresponding to the desired cutting height.  
Driving in Reverse  
See the decal on the side of the deck lift plate for  
cut heights.  
1. Move the motion control levers inward to the  
neutral operate position.  
6. Push the foot lever forward, pull the transport  
lock handle rearward and let the deck lower  
down to the predetermined cut height by slowly  
decreasing foot pressure allowing the foot lever  
to travel rearward.  
2. To move rearward in a straight line, move both  
levers rearward with equal pressure.  
To turn right, release pressure on the RH motion  
control lever and the rear of the machine will  
move towards the rear and to the right.  
Adjusting the Anti-Scalp Rollers  
To turn left, release pressure on the LH motion  
control lever and the rear of the machine will  
move towards the rear and to the left.  
It is recommended to change the anti-scalp roller  
position, when the height of cut has changed.  
3. To stop, position both motion control levers in  
the neutral operate position.  
1. Stop the machine and move the motion control  
levers outward to the neutral locked position.  
2. Disengage the PTO.  
Adjusting the Cutting Height  
3. Engage the park brake.  
The cutting height of the mower deck is adjusted  
from 1 1/2 to 5 inches (3.8 cm to 12.7 cm) in 1/4  
inch (6.4 mm) increments.  
4. Stop the engine, remove the key and wait for all  
moving parts to stop.  
1. Stop the machine and move the motion control  
levers outward to the neutral locked position.  
5. After adjusting the height of cut, adjust the  
anti-scalp rollers by removing the nyloc nut,  
bushing, spring disc washer and whizlock nut.  
2. Disengage the PTO.  
6. Place the rollers in one of the positions shown  
(Figure 16). Rollers will maintain 3/4 inch (19  
mm) clearance to the ground to minimize gouging  
and roller wear or damage.  
3. Position the transport lock in the latching  
position.  
4. Raise and lock the deck to the 5 inch (12.7 cm)  
transport position (Figure 15).  
The deck is raised by pushing the foot operated  
deck lift pedal forward. The pedal is located at the  
front right corner of the floor pan.  
Note: When changing the cutting height  
positions, always come to a complete stop  
and disengage the PTO.  
24  
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Operation  
Transporting  
Transporting a Unit  
Use a heavy-duty trailer or truck to transport the  
machine. Lock brake and block wheels. Securely  
fasten the machine to the trailer or truck with straps,  
chains, cable, or ropes. Be sure that the trailer or truck  
has all necessary lighting and marking as required by  
law. Secure a trailer with a safety chain.  
CAUTION  
Figure 16  
For cutting heights above 3.5 inches (90 mm) use the  
bottom hole. The rollers will still be effective against  
scalping.  
This unit does not have proper turn signals,  
lights, reflective markings, or a slow moving  
vehicle emblem. Driving on a street or roadway  
without such equipment is dangerous and  
can lead to accidents causing personal injury.  
Driving on a street or roadway without such  
equipment may also be a violation of State laws  
and the operator may be subject to traffic tickets  
and/or fines.  
1. Anti-scalp roller  
mounting bracket  
2. Cutting height  
For Maximum Deck Flotation, place the rollers  
one hole position lower. Rollers should maintain  
1/4 inch (6.4 mm) clearance to the ground. Do  
Not adjust the rollers to support the deck.  
Do Not drive a unit on a public street or roadway.  
Note: The foot operated deck lift lever can be  
used to momentarily lift the deck to clear objects.  
Be sure that PTO is disengaged.  
WARNING  
Loading a unit on a trailer or truck increases  
the possibility of backward tip-over. Backward  
tip-over could cause serious injury or death.  
7. Torque the 3/8 nyloc nut to 27-33 ft-lb (37-45  
N-m).  
• Use extreme caution when operating a unit  
on a ramp.  
• Use only a single, full width ramp; Do Not  
use individual ramps for each side of the unit.  
• If individual ramps must be used, use enough  
ramps to create an unbroken ramp surface  
wider than the unit.  
• Do Not exceed a 15° angle between ramp and  
ground or between ramp and trailer or truck.  
• Avoid sudden acceleration while driving unit  
up a ramp to avoid tipping backward.  
Figure 17  
• Avoid sudden deceleration while backing unit  
down a ramp to avoid tipping backward.  
1. Wheel bolt  
3. 3/8 nyloc-torque to 27-33  
ft-lb (37-45 N-m)  
4. Front right anti-scalp  
bracket shown  
2. Anti-scalp roller  
Loading a Unit  
Use extreme caution when loading units on trailers or  
trucks. One full width ramp that is wide enough to  
extend beyond the rear tires is recommended instead  
of individual ramps for each side of the unit. The  
lower rear section of the tractor frame extends back  
between the rear wheels and serves as a stop for  
25  
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Operation  
tipping backward. Having a full width ramp provides  
a surface for the frame members to contact if the  
unit starts to tip backward. If it is not possible to use  
one full width ramp, use enough individual ramps to  
simulate a full width continuous ramp.  
Ramp should be long enough so that the angles  
between the ramp and the ground and the ramp and  
the trailer or truck Do Not exceed 15°. A steeper  
angle may cause mower deck components to get  
caught as the unit moves from ramp to trailer or  
truck. Steeper angles may also cause the unit to tip  
backward. If loading on or near a slope, position  
the trailer or truck so it is on the down side of the  
slope and the ramp extends up the slope. This will  
minimize the ramp angle. The trailer or truck should  
be as level as possible.  
Important: Do Not attempt to turn the unit  
while on the ramp, you may lose control and  
drive off the side.  
Avoid sudden acceleration when driving up a ramp  
and sudden deceleration when backing down a ramp.  
Both maneuvers can cause the unit to tip backward.  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could seriously  
injure you or other bystanders.  
The engine can become very hot. Touching a hot  
engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine area.  
Remove the key from the ignition switch, engage  
parking brake, and pull the wire(s) off the spark  
plug(s) before you do any maintenance. Also  
push the wire(s) aside so it does not accidentally  
contact the spark plug(s).  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
• Change the hydraulic filter and fluid.  
After the first 100 hours  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check the rollover protections systems (roll bar) knobs.  
• Check the seat belt.  
• Check for loose hardware.  
Before each use or daily  
• Check the hydraulic oil level in the expansion tank.  
• Clean the engine and exhaust system area.  
• Clean the hydro fan cooling guards.  
• Clean the grass and debris build-up from the machine and cutting deck.  
• Clean the grass build-up from under the cutting deck.  
• Check the tire pressures.  
• Check the condition of the belts.  
• Grease the deck and pump idler pivots.  
• Check spark arrester (if equipped).  
Every 50 hours  
• Change the engine oil. (May need more often under severe conditions.)  
• Remove the engine shrouds and clean the cooling fins.  
Every 100 hours  
Every 200 hours  
• Check the spark plugs.  
• Replace the primary air cleaner element — check secondary air cleaner element; replace if  
dirty. (May need more often under severe conditions. See the Engine Owner’s Manual for  
additional information.)  
Every 250 hours  
• Replace the secondary air cleaner element (May need more often under severe conditions.  
See the Engine Owner’s Manual for additional information.)  
• Change the hydraulic filter and fluid (Every 250 hours if using Mobil 1 15W50)  
• Check the park brake adjustment.  
Every 500 hours  
Monthly  
• Check the battery charge.  
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Maintenance  
the table and charge the battery for the recommended  
time interval to bring the charge up to a full charge  
of 12.6 volts or greater.  
Periodic Maintenance  
Check Engine Oil Level  
Service Interval: Before each use or daily  
Important: Make sure the negative battery cable  
is disconnected and the battery charger used for  
charging the battery has an output of 16 volts and  
7 amps or less to avoid damaging the battery (see  
chart for recommended charger settings).  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
2. Check with engine cold.  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
3. Clean area around dipstick. Remove dipstick  
and wipe oil off. Reinsert the dipstick according  
to the engine manufacturer’s recommendations.  
Remove the dipstick and read the oil level.  
Charger  
Settings  
Interval  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
4. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Exmark 4-Cycle Premium  
Engine Oil is recommended; refer to the Engine  
Owner’s manual for an acceptable alternative. Do  
Not overfill.  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
1 Hour  
16 volts/7  
amps  
12.0–12.2  
11.7–12.0  
25–50%  
0–25%  
2 Hours  
3 Hours  
14.4 volts/4  
amps  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
14.4 volts/4  
amps  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
Check Battery Charge  
Service Interval: Monthly  
Recommended Jump  
Starting Procedure  
Service Interval: As required  
WARNING  
CALIFORNIA  
Proposition 65 Warning  
Battery posts, terminals, and related  
accessories contain lead and lead  
compounds, chemicals known to the State of  
California to cause cancer and reproductive  
harm. Wash hands after handling.  
1. Check the weak battery for terminal corrosion  
(white, green, or blue “snow”), it must be cleaned  
off prior to jump starting. Clean and tighten  
connections as necessary.  
CAUTION  
Allowing batteries to stand for an extended period of  
time without recharging them will result in reduced  
performance and service life. To preserve optimum  
battery performance and life, recharge batteries in  
storage when the open circuit voltage drops to 12.4  
volts.  
Corrosion or loose connections can cause  
unwanted electrical voltage spikes at anytime  
during the jump starting procedure.  
Do Not attempt to jump start with loose or  
corroded battery terminals or damage to the  
engine may occur.  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
Check the voltage of the battery with a digital  
voltmeter. Locate the voltage reading of the battery in  
28  
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Maintenance  
DANGER  
Jump starting a weak battery that is cracked,  
frozen, has low electrolyte level, or an  
open/shorted battery cell, can cause an  
explosion resulting in serious personal injury.  
Do Not jump start a weak battery if these  
conditions exist.  
2. Make sure the booster is a good and fully charged  
lead acid battery at 12.6 volts or greater. Use  
properly sized jumper cables (4 to 6 AWG) with  
short lengths to reduce voltage drop between  
systems. Make sure the cables are color coded or  
labeled for the correct polarity.  
Figure 18  
1. Positive (+) cable on discharged battery  
2. Positive (+) cable on booster battery  
3. Negative (–) cable on the booster battery  
4. Negative (–) cable on the engine block  
5. Booster battery  
6. Discharged battery  
7. Engine block  
CAUTION  
Connecting the jumper cables incorrectly  
(wrong polarity) can immediately damage the  
electrical system.  
4. Connect the other end of the positive cable to the  
positive terminal of the booster battery.  
Be certain of battery terminal polarity and  
jumper cable polarity when hooking up  
batteries.  
5. Connect the black negative (–) cable to the other  
terminal (negative) of the booster battery.  
6. MAKE THE FINAL CONNECTION ON  
THE ENGINE BLOCK OF THE STALLED  
VEHICLE (NOT TO THE NEGATIVE POST)  
AWAY FROM THE BATTERY. STAND BACK.  
Note: The following instructions are adapted  
from the SAE J1494 Rev. Dec. 2001 – Battery  
Booster Cables – Surface Vehicle Recommended  
Practice (SAE – Society of Automotive  
Engineers).  
7. Start the vehicle and remove the cables in the  
reverse order of connection (the engine block  
(black) connection is the first to disconnect).  
WARNING  
Batteries contain acid and produce explosive  
gases.  
Check Mower Blades  
Service Interval: Before each use or daily  
• Shield the eyes and face from the batteries  
at all times.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
• Do Not lean over the batteries.  
2. Lift deck and secure in raised position as stated in  
Note: Be sure the vent caps are tight and level.  
Place a damp cloth, if available, over any vent  
caps on both batteries. Be sure the vehicles do  
not touch and that both electrical systems are  
off and at the same rated system voltage. These  
instructions are for negative ground systems only.  
the Clean Grass Build-Up Under Deck section.  
3. Inspect blades and sharpen or replace as required.  
4. Reinstall the blades (if they were removed) in the  
following order:  
A. Install the splined bushing through the blade  
with the bushing flange on bottom (grass)  
side of blade.  
3. Connect the positive (+) cable to the positive (+)  
terminal of the discharged battery that is wired to  
the starter or solenoid as shown in Figure 18.  
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Maintenance  
Try to start with operator in seat, parking brake  
disengaged, PTO disengaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Try to start with operator in seat, parking brake  
engaged, PTO engaged and motion control  
levers in the neutral lock position - starter must  
not crank.  
Figure 19  
1. Spindle  
2. Blade  
3. Splined bushing  
4. Blade bolt washer assembly — Torque to 50-60 ft-lb  
(68-81 N-m) Apply lubricant to threads as needed to  
prevent seizing. Copper-based anti-seize preferable.  
Grease acceptable substitute.  
Try to start with operator in seat, parking  
brake engaged, PTO disengaged, and the left  
motion control lever in, starter must not crank,  
repeat again with the right lever in, then with  
both levers in - starter must not crank.  
2. Check the kill circuits. Run engine at one-third  
throttle, disengage parking brake and raise off  
of seat (but do not get off of machine) engine  
must initiate shutdown after approximately 1/2  
second has elapsed (seat has time delay kill switch  
to prevent cut-outs on rough terrain).  
B. Apply lubricant to the threads of the blade  
bolt as needed to prevent seizing. Copper  
based anti-seize is preferable. Grease is an  
acceptable substitute.  
C. Install the splined bushing/blade assembly  
and blade bolt washer assembly into the  
spindle. Install blade bolt finger tight.  
Run engine at one-third throttle, engage PTO  
and raise off of seat (but do not get off of  
machine) engine must initiate shutdown after  
one second has elapsed if the handles are in. The  
delay will be 1/2 second if the handles are out.  
D. Place wrench on the top spindle nut then  
torque the blade bolts to 50-60 ft-lb (68-81  
N-m).  
Run engine at one-third throttle, with brake  
disengaged, move levers in and raise off seat (but  
do not get off of machine) engine must initiate  
shutdown after 1/2 second has elapsed.  
WARNING  
Incorrect installation of the blade or  
components used to retain the blade can  
be dangerous. Failure to use all original  
components and assembled as shown could  
allow a blade or blade component to be  
thrown out from under the deck resulting in  
serious personal injury or death.  
Again, run engine at one-third throttle, brake  
engaged, and move left motion control lever  
in - engine must initiate shutdown after 1/2  
second has elapsed.  
Repeat again moving the right lever in, then  
moving both levers in - engine must initiate  
shutdown after 1/2 second has elapsed whether  
operator is on seat or not.  
Always install the original Exmark blades,  
blade bushings, and blade bolts as shown.  
Note: If machine does not pass any of these tests,  
do not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
Check Safety Interlock  
System  
Service Interval: Before each use or daily  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
Note: To prevent engine cut-outs on rough terrain  
the seat kill switch has a 1/2 second delay.  
1. Check starting circuit. Starter should crank with,  
parking brake engaged, PTO disengaged and  
motion control levers moved out in the neutral  
lock position. The operator does not need to be  
in the seat to start the engine.  
Check Rollover Protections  
Systems (Roll Bar) Knobs  
Service Interval: Before each use or daily  
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Maintenance  
Check that both the mounting hardware and the  
knobs are in good working condition. Make sure the  
knobs are fully engaged with the ROPS in the raised  
position. The upper hoop of the roll bar may need  
to be pushed forward or pulled rearward to get both  
knobs fully engaged.  
Every 500 hours—Replace  
the secondary air cleaner  
element (May need more  
often under severe  
conditions. See the  
Engine Owner’s Manual  
for additional information.)  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. See the Engine Owner’s Manual for maintenance  
instructions.  
Change Engine Oil  
Service Interval: After the first 5 hours  
Every 100 hours/Yearly  
(whichever comes first)  
(May need more often  
under severe conditions.)  
Figure 20  
1. Engaged  
2. Partially engaged — Do  
Not operate with ROPS  
in this condition.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Check Seat Belt  
Service Interval: Before each use or daily  
2. Drain oil while engine is warm from operation.  
3. The oil drain hose is located on right hand side  
of engine at the rear. Place pan under machine  
to catch oil. Remove plug from end of drain  
hose. Allow oil to drain and replace oil drain plug.  
Torque plug to 20-24 ft-lb.  
Visually inspect seat belt for wear, cuts, and proper  
operation of retractor and buckle. Replace before  
operating if damaged.  
4. Replace the oil filter every other oil change. Clean  
around oil filter and unscrew filter to remove.  
Before reinstalling new filter, apply a thin coating  
of Exmark 4–Cycle Premium Engine Oil on the  
surface of the rubber seal. Turn filter clockwise  
until rubber seal contacts the filter adapter then  
tighten filter an additional 1/2 to 3/4 turn.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
5. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
6. Use oil recommended in the Check Engine Oil  
Level section. Do Not overfill. Start the engine  
and check for leaks.  
Service Air Cleaner  
Service Interval: Every 250 hours—Replace  
the primary air cleaner  
element — check  
7. Wipe up any spilled oil from engine deck  
mounting surfaces.  
secondary air cleaner  
element; replace if dirty.  
(May need more often  
under severe conditions.  
See the Engine Owner’s  
Manual for additional  
information.)  
Check Hydraulic Oil Level  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
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Maintenance  
2. Wait until the unit cools before checking the  
hydraulic oil.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
3. Check expansion tank and if necessary add  
Exmark Premium Hydro Oil to the FULL COLD  
line (see Figure 21).  
Lubrication Chart  
Fitting  
Locations  
Initial  
Number of  
Places  
Service  
Interval  
Pumps  
1
2
1. Deck and  
Pump Idler  
Pivots  
50 hours  
Figure 21  
1. Engine  
2. Expansion tank  
Check Tire Pressures  
Service Interval: Every 50 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Lubricate Caster Wheel Hubs  
Service Interval: As required  
2. Check tire pressure in drive tires.  
3. Inflate drive tires to 13 psi (90 kPa).  
4. Check tire pressure in caster tires.  
5. Inflate caster tires to 13 psi (90 kPa).  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Check Condition Of Belts  
Service Interval: Every 50 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove left and right belt shields on deck and  
lower the deck to inspect deck drive belt.  
3. Check under machine to inspect the pump drive  
belt.  
Figure 22  
1. Seal guard  
2. Spacer nut with wrench  
flats  
Note: No adjustments are required for belt  
tension.  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate fittings with one to two pumps of  
NGLI grade #2 multi-purpose gun grease.  
4. Remove one of the spacer nuts from the axle  
assembly in the caster wheel. Note that thread  
locking adhesive has been applied to lock the  
spacer nuts to the axle. Remove the axle (with  
the other spacer nut still assembled to it) from  
the wheel assembly.  
32  
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Maintenance  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
Change Fuel Filter  
Service Interval: As required  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
A fuel filter is installed between the fuel tank and the  
engine. Replace when necessary.  
7. Insert one bearing, one new seal into the wheel.  
Replacement Filters  
Note: Seals (Exmark P/N 103-0063) must be  
replaced.  
Kawasaki  
Kawasaki  
P/N 49019-7005  
8. If the axle assembly has had both spacer nuts  
removed (or broken loose), apply a thread locking  
adhesive to one spacer nut and thread onto the  
axle with the wrench flats facing outward. Do  
Not thread spacer nut all of the way onto the end  
of the axle. Leave approximately 1/8 inch (3 mm)  
from the outer surface of the spacer nut to the  
end of the axle inside the nut.  
Note: It is important to reinstall the fuel line hoses  
and secure with plastic ties the same as they were  
originally installed at the factory to keep the fuel line  
away from components that could cause fuel line  
damage.  
Change Hydraulic System  
Filter and Fluid  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
Service Interval: After the first 100 hours  
10. With the open end of the wheel facing up, fill  
the area inside the wheel around the axle full of  
NGLI grade #1 multi-purpose grease.  
Every 500 hours thereafter  
(Every 250 hours if using  
Mobil 1 15W50)  
11. Insert the second bearing and new seal into the  
wheel.  
1. Stop engine, wait for all moving parts to stop, and  
allow engine to cool. Remove key and engage  
parking brake.  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
2. Locate the two filters under the transmissions.  
Remove filter guards.  
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,  
then re-torque to 20-25 in-lb (2-3 N-m). Make  
sure axle does not extend beyond either nut.  
3. Carefully clean area around filters. It is important  
that no dirt or contamination enter hydraulic  
system.  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall caster bolt  
and tighten nut fully.  
4. Unscrew filters to remove and allow oil to drain  
from drive system.  
Important: To prevent seal and bearing damage,  
check the bearing adjustment often. Spin the  
caster tire. The tire should not spin freely  
(more than 1 or 2 revolutions) or have any side  
play. If the wheel spins freely, adjust torque on  
spacer nut until there is a slight amount of drag.  
Reapply thread locking adhesive.  
Important: Before reinstalling new filters,  
apply a thin coat of Exmark Premium Hydro  
Oil on the surface of the filters rubber seal.  
Turn the filters clockwise until rubber seal  
contacts the filter adapter then tighten the filter  
an additional 3/4 to 1 full turn.  
5. Remove the vent plug on each transmission and  
fill through expansion reservoir, when oil comes  
out of vent reinstall plug.  
Check Spark Plugs  
Service Interval: Every 200 hours  
Exmark Premium Hydro Oil is recommended.  
Refer to the chart for an acceptable alternative:  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner’s  
Manual.  
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Maintenance  
A. With the bypass valve open and the engine  
running, slowly move the directional control  
in both forward and reverse (5 or 6 times).  
Hydro Oil  
Change Interval  
500 Hours  
Exmark Premium Hydro  
Oil (Preferred)  
B. With the bypass valve closed and the engine  
running, slowly move the directional control  
in both forward and reverse directions (5 to  
6 times). Check the oil level, and add oil as  
required after stopping the engine.  
250 Hours  
Mobil 1 15W50  
Torque plugs to 180 in-lb (244 N-m). Continue to  
add oil until it reaches the FULL COLD line on  
the expansion reservoir.  
C. It may be necessary to repeat steps A and  
B until all the air is completely purged from  
the system. When the transaxle operates at  
normal noise levels and moves smoothly  
forward and reverse at normal speeds, then  
the transaxle is considered purged.  
Note: Do Not change the hydraulic system oil  
(except for what can be drained when changing filter),  
unless it is felt the oil has been contaminated or been  
extremely hot.  
Figure 23  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminants into the system.  
1. Oil filter  
2. Vent plug  
3. Left rear tire  
6. Raise the rear of machine up and support with  
jack stands (or equivalent support) just high  
enough to allow drive wheels to turn freely.  
Check Spark Arrester  
(if equipped)  
Service Interval: Every 50 hours  
CAUTION  
WARNING  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
Hot exhaust system components may ignite  
gasoline vapors even after the engine is stopped.  
Hot particles exhausted during engine operation  
may ignite flammable materials. Fire may result  
in personal injury or property damage.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
Do Not refuel or run engine unless spark arrester  
is installed.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
7. Start engine and move throttle control ahead to  
1/2 throttle position. Disengage parking brake.  
2. Wait for muffler to cool.  
3. If any breaks in the screen or welds are observed,  
replace arrester.  
WARNING  
Engine must be running and drive wheels  
must be turning so adjustments can be  
performed. Contact with moving parts or hot  
surfaces may cause personal injury.  
4. If plugging of the screen is observed, remove  
arrester and shake loose particles out of the  
arrester and clean screen with a wire brush (soak  
in solvent if necessary). Reinstall arrester on  
exhaust outlet.  
Keep fingers, hands, and clothing clear of  
rotating components and hot surfaces.  
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Maintenance  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
Adjustments  
Note: Disengage PTO, shut off engine, wait for  
all moving parts to stop, engage parking brake, and  
remove key before servicing, cleaning, or making any  
adjustments to the unit.  
• ROPS spring pin housing.  
• Sheave and clutch retaining bolt in the end of  
engine crankshaft.  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be enough  
support or may malfunction allowing the unit to  
fall, which could cause injury.  
• Hydro cross member mounting bolts  
Thread locking adhesives are required for some  
hardware on engines — see the Engine manual.  
Copper-Based Anti-seize  
Copper-based anti-seize is used in the following  
location:  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands or  
equivalent support.  
On threads of Blade Bolts. See Check Mower  
Blades section.  
Deck Leveling  
1. Position the mower on a flat surface.  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Check the tire pressure in the drive tires. Proper  
inflation pressure for tires is 13 psi (90 kPa).  
Adjust if necessary.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
4. Position the transport lock in the latching  
position.  
5. Carefully rotate the blades from side to side.  
6. Measure between the outside cutting edges and  
the flat surface (Figure 24 and Figure 25). If both  
measurements are not within 3/16 inch (5 mm),  
an adjustment is required; continue with this  
procedure.  
Figure 24  
48 and 52 Inch Decks  
1. Blades side to side  
2. Measure here  
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Maintenance  
Figure 26  
Figure 25  
1. Leveling adjust locking  
nuts  
2. Deck lift arm  
3. Deck hanger  
4. Chain  
44 Inch Deck  
1. Blades side to side  
2. Measure here  
11. Recheck that blocks fit just snugly under the deck  
skirt. Make sure all attachment bolts are tight  
7. Set anti-scalp rollers to top holes or remove  
completely for this adjustment.  
12. Continue leveling the deck by checking the  
front-to-rear blade slope; refer to Adjusting the  
Blade Slope.  
8. Set the height-of-cut lever to the 3 inch (76 mm)  
position. Place two “B” thick blocks (see Block  
Height and Rake Table) under the rear edge of the  
cutting deck skirt; one on each side of the cutting  
deck. Place two A” thick blocks under each side  
of the front edge of the deck, but not under the  
anti-scalp roller brackets.  
13. Recheck blades for levelness and repeat deck  
leveling procedure if necessary.  
Adjusting the Blade Slope  
Block Height and Rake Table  
1. Check the front-to-rear blade level any time you  
install the mower. If the front blade tip is not  
“R” (see Block Height and Rake Table in Deck  
Leveling) lower than the rear blade tip, adjust the  
blade level using the following instructions:  
Deck Front Block Rear Block  
Rake “R”  
Size  
Height A”  
Height “B”  
44  
2.69 inches  
(6.8 cm)  
2.99 inches  
(7.6 cm)  
1/8–3/8 inch  
(3.2–9.5 mm)  
2. Park the machine on a level surface and disengage  
the blade control switch.  
48 & 2.77 inches  
52  
(7.0 cm)  
2.81 inches  
(7.1 cm)  
1/16–5/16 inch  
(1.6–7.9 mm)  
3. Move the motion control levers outward to  
the neutral position, engage the parking brake,  
stop the engine, remove the key, and wait for all  
moving parts to stop before leaving the operating  
position.  
9. Carefully rotate the blades side to side (Figure 24  
and Figure 25).  
10. Loosen the leveling adjust locking nuts (item 1  
Figure 26) on all four corners so that the deck is  
sitting securely on all four blocks. Make sure that  
the slack is removed from the deck hangers and  
the deck lift foot lever is pushed back against the  
stop, then tighten the four leveling adjust locking  
nuts.  
4. Check the air pressure of all four tires. If needed,  
adjust to the recommended inflation; refer to  
Checking the Tire Pressure in Drive System  
Maintenance section.  
5. Check and adjust the side-to-side blade level if  
you have not checked the setting; refer to Deck  
Leveling.  
6. Set the height-of-cut lever to the 3 inch (76 mm)  
position. Place two “B” thick blocks (see Block  
Height and Rake Table in Deck Leveling) under  
the rear edge of the cutting deck skirt; one on  
each side of the cutting deck. Place two A” thick  
36  
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Maintenance  
blocks (see Block Height and Rake Table in Deck  
Leveling) under each side of the front edge of the  
deck, but not under the anti-scalp roller brackets.  
or when a brake component has been removed or  
replaced.  
1. Drive the machine onto a level surface.  
7. Loosen the leveling adjust locking nuts (item 1  
Figure 26) on all four corners so that the deck is  
sitting securely on all four blocks. Make sure that  
the slack is removed from the deck hangers and  
the deck lift foot lever is pushed back against the  
stop, then tighten the four leveling adjust locking  
nuts.  
2. Disengage the blade control switch (PTO), move  
the motion control levers to the neutral locked  
position and set the parking brake.  
3. Stop the engine, wait for all moving parts to stop,  
and remove the key.  
4. Setup the machine to be pushed by hand (see  
Drive Wheel Release Valves in the Operation  
section).  
8. Carefully rotate the blades so they are facing front  
to rear (Figure 27).  
9. Measure from the tip of the front blade to the flat  
surface and the tip of the rear blade to the flat  
surface (Figure 27). If the front blade tip is not  
“R” (see Block Height and Rake Table in Deck  
Leveling) lower than the rear blade tip, adjust the  
front deck hanger.  
5. Raise the back of the machine up and support the  
machine with jack stands.  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
6. Engage/disengage the brake and check each drive  
tire to make sure each brake engages/disengages.  
Figure 27  
7. If adjustment is necessary, loosen the jam nut  
from the yoke on the side that needs adjustment.  
Remove the hairpin and clevis pin (see Figure 28).  
1. Blades front to rear  
2. Measure here  
10. When the front-to-rear blade slope is correct  
check the side-to-side level of the mower again;  
refer to Deck Leveling.  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
Deck Belt Tension  
Self-tensioning - No adjustment necessary.  
Figure 28  
Adjusting the Parking Brake  
Service Interval: Every 500 hours  
1. Hairpin  
2. Clevis pin  
3. Yoke  
4. Jam nut  
Check to make sure brake is adjusted properly. This  
procedure must be followed after the first 100 hours  
37  
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Maintenance  
• Adjusting the Brake to Engage: Shorten the  
linkage by turning the yoke clockwise.  
1. Loosen the upper bolt holding the control lever  
to the control arm shaft.  
2. Loosen the lower bolt just enough to pivot the  
control lever fore or aft Figure 29. Tighten both  
bolts to secure the control in the new position.  
• Adjusting the Brake to Disengage:  
Lengthen the linkage by turning the yoke  
counterclockwise.  
3. Repeat the adjustment for the opposite control  
lever.  
8. Reinstall the clevis pin and hair pin and tighten  
down the jam nut. Repeat step 6 and readjust if  
necessary.  
Full Forward Tracking  
Adjustment  
9. When adjustment is complete, remove the jack  
stands or equivalent support and lower the  
machine.  
If the machine travels or pulls to one side when the  
motion control levers are in the full forward position,  
adjust the cover plates.  
10. Place the machine into the “operating” position.  
Refer to the Drive Wheel Release Valves section  
in Operation.  
1. Loosen the screws on a cover plate (see Figure 30).  
2. Slide the cover plate backward or forward to  
adjust the travel of the lever and tighten the  
screws.  
Motion Control Handle  
Adjustment  
3. Drive the machine and check the full forward  
tracking.  
Adjusting the height:  
The motion control levers can be adjusted higher or  
lower for maximum operator comfort.  
4. Repeat steps 1 through 3 until desired tracking  
is obtained.  
1. Remove the hardware holding the control lever to  
the control arm shaft (Figure 29).  
Figure 29  
1. Bolts  
2. Washer  
4. Control arm shaft  
5. Slotted hole  
3. Control lever  
Figure 30  
1. Control arm shaft  
2. Tracking plate nut  
3. Tracking plate  
2. Move the control lever to the next set of holes.  
Secure the lever with the hardware.  
3. Repeat the adjustment for the opposite control  
lever.  
Motion Control Linkage  
Adjustment  
Adjusting the Tilt  
The motion control levers can be tilted fore or aft for  
maximum operator comfort.  
Located on either side of the unit, below the seat are  
the pump control linkages. Rotating the turnbuckle  
38  
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Maintenance  
with a 1/2 inch wrench allows fine tuning adjustments  
so that the machine does not move in neutral. Any  
adjustments should be made for neutral positioning  
only.  
WARNING  
Engine must be running and drive wheels must  
be turning so adjustments can be performed.  
Contact with moving parts or hot surfaces may  
cause personal injury.  
Keep fingers, hands, and clothing clear of  
rotating components and hot surfaces.  
1. Prior to starting the engine, push the deck lift  
pedal and remove the height of cut pin. Lower  
deck to the ground.  
2. Raise the rear of machine up and support with  
jack stands (or equivalent support) just high  
enough to allow drive wheels to turn freely.  
Figure 31  
4. Control plate  
1. Nut  
2. Turnbuckle  
3. Stationary plate  
5. Return to neutral plate  
6. Tabs touching return to  
neutral plate  
3. Remove the electrical connection from the seat  
safety switch, located under the bottom cushion  
of the seat. The switch is a part of the seat  
assembly.  
8. Tighten nuts.  
4. Temporarily install a jumper wire across the  
terminals in the connector of the main wiring  
harness.  
9. Shut off unit. Remove jumper wire from wire  
harness and plug connector into seat switch.  
10. Remove the jack stands.  
5. Start engine. Brake must be engaged and  
motion control levers out to start engine.  
Operator does not have to be in the seat. Run  
engine at full throttle and release brake.  
11. Raise the deck and re-install the height of cut pin.  
12. Check that the machine does not creep in neutral  
with the park brake disengaged.  
6. Run the unit at least 5 minutes with the drive  
levers at full forward speed to bring hydraulic oil  
up to operating temperature.  
Adjusting the Seat Ride  
Suspension  
The number of seat springs can be changed to  
maximize rider comfort. More springs should be used  
with heavier operators and on rough terrain. Fewer  
springs should be used with lighter operators and  
when mowing smooth, well established lawns. Always  
keep the number of springs on the left and right side  
the same when adding and removing springs.  
Note: The motion control lever needs to be in  
neutral while making any necessary adjustments.  
7. Bring the motion control levers into the neutral  
position. The control plate tabs should touch the  
return to neutral plates on the hydros. Adjust  
pump control rod lengths by loosening the nuts  
and rotating the turnbuckle in the appropriate  
direction until the wheels slightly creep in reverse  
(Figure 31). Move the motion control levers to the  
reverse position and while applying slight pressure  
to the lever allow the reverse indicator springs to  
bring the levers back to neutral. The wheels must  
stop turning or slightly creep in reverse.  
39  
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Maintenance  
3. Check the condition of the wire harness leads,  
connectors, and terminals. Clean or repair as  
necessary.  
4. Verify that 12V is present at the clutch connector  
when the PTO switch is engaged.  
5. Measure the gap between the rotor and armature.  
If the gap is greater than .04 inch (1 mm), proceed  
with the following steps:  
A. Loosen both brake mounting bolts one-half  
to one full turn (see Figure 34).  
Note: Do Not remove the brake pole from  
the field shell/armature. The brake pole has  
worn to match the armature and needs to  
continue to match after the shim is removed  
to ensure proper brake torque.  
Figure 32  
3. Nut  
1. Bolt  
2. Spring  
4. Additional mounting  
holes  
Up to five springs can be secured to the seat box with  
a nut and bolt, see Figure 32.  
Refer to the Parts Manual for spring and hardware  
part numbers.  
Electric Clutch Adjustment  
Figure 34  
1. Brake mounting bolt  
2. Shim  
B. Using needle nose pliers, or by hand, take  
hold of the tab and remove the shim (Do Not  
discard the shim until proper clutch function  
has been confirmed).  
Figure 33  
1. Armature  
2. Field shell  
3. Rotor  
5. Brake spacer  
6. Re-gap shim  
7. Brake pole  
C. Using a pneumatic line, blow out any debris  
from under the brake pole and around the  
brake spacers.  
4. Brake mounting bolt  
D. Re-torque each bolt (M6 x 1) to 10 ft-lb (13  
N-m) +/-0.5 ft-lb (0.7 N-m).  
Removing the Shim:  
E. Using a 0.010 inch thick feeler gauge, verify  
that a gap is present between the rotor and  
armature face on both sides of the brake pole  
as shown. (Due to the way the rotor and  
armature faces wear (peaks and valleys) it is  
sometimes difficult to measure the true gap.)  
1. Stop engine, wait for all moving parts to stop,  
and remove key. Engage parking brake. Allow  
the machine to cool completely before starting  
these instructions.  
2. Using a pneumatic line, blow out any debris  
from under the brake pole and around the brake  
spacers.  
40  
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Maintenance  
Cleaning  
Clean Engine and Exhaust  
System Area  
G011733  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
1
Figure 35  
conditions.)  
1. Feeler gauge  
CAUTION  
Excessive debris around engine cooling air  
intake and exhaust system area can cause engine,  
exhaust area, and hydraulic system to overheat  
which can create a fire hazard.  
Clean all debris from engine and exhaust system  
area.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean all debris from rotating engine air intake  
screen, around engine shrouding, and exhaust  
system area.  
Figure 36  
1. Feeler gauge  
3. Wipe up any excessive grease or oil around the  
engine and exhaust system area.  
• If the gap is less than 0.010 inch, then  
reinstall the shim and reference the  
Troubleshooting section.  
Remove Engine Shrouds and  
Clean Cooling Fins  
• If the gap is sufficient, proceed to the  
safety check in step F.  
Service Interval: Every 100 hours  
F. Perform the following safety check:  
a. Sit on the seat and start the engine.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
b. Make sure the blades Do Not engage  
with the PTO switch “off ” and the clutch  
disengaged.  
2. Remove cooling shrouds from engine and clean  
cooling fins. Also clean dust, dirt and oil from  
external surfaces of engine which can cause  
inadequate cooling.  
If the clutch does not disengage,  
reinstall the shim and reference the  
Troubleshooting section.  
3. Make sure cooling shrouds are reinstalled.  
Operating the engine without cooling shrouds  
will cause engine damage due to overheating.  
c. Engage and disengage the PTO switch  
ten consecutive times to ensure the clutch  
is functioning properly. If the clutch  
does not engage properly, reference the  
Troubleshooting section.  
Clean Hydro Fan Cooling  
Fins  
Service Interval: Before each use or daily  
Removing debris from the hydro fan cooling fins will  
allow the hydro system to run cooler and improve the  
life of the hydro system.  
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Maintenance  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
recycling center or according to your state and local  
regulations.  
2. Slide seat all the way forward.  
Battery Disposal  
DANGER  
3. Remove accumulated debris from the hydro fan  
cooling fins and upper surfaces.  
Battery electrolyte contains sulfuric acid, which  
is poisonous and can cause severe burns.  
Swallowing electrolyte can be fatal or if it touches  
skin can cause severe burns.  
Clean Debris From Machine  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean off any oil, debris, or grass build-up on the  
machine and cutting deck, especially under deck  
belt shields, around the fuel tank, around engine  
and exhaust area.  
• Wear safety glasses to shield eyes, and rubber  
gloves to protect skin and clothing when  
handling electrolyte.  
• Do Not swallow electrolyte.  
• In the event of an accident, flush with water  
and call a doctor immediately.  
Clean Grass Build-Up Under  
Deck  
Federal law states that batteries should not be placed  
in the garbage. Management and disposal practices  
must be within relevant federal, state, or local laws.  
Service Interval: Before each use or daily  
1. Park the machine on a level surface and disengage  
the blade control switch.  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Raise deck to the transport (5 inch (12.7 cm)  
cutting height) position. Lift the front of unit  
and support unit using jack stands or equivalent  
support.  
If a battery is being replaced or if the unit containing  
the battery is no longer operating and is being  
scrapped, take the battery to a local certified recycling  
center. If no local recycling is available return the  
battery to any certified battery reseller.  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
4. Clean out any grass build-up from underside of  
deck and in discharge deflector.  
Waste Disposal  
Motor Oil Disposal  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
42  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused  
by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do not attempt to service or replace major  
items or any items that call for special timing of adjustment procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.  
Problem  
Starter does not crank  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
2. Parking brake is not engaged.  
2. Set the parking brake.  
3. Drive levers are not in neutral lock  
position.  
3. Ensure the drive levers are in the neutral  
lock position.  
4. Battery does not have a full charge.  
4. Charge the battery. See Check  
Battery Charge and Recommended  
Jump Starting Procedure sections in  
Maintenance.  
5. Electrical connections are corroded, loose 5. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
6. Fuse is blown.  
7. Relay or switch is defective.  
8. Faulty module.  
6. Replace the blown fuse.  
7. Contact an Authorized Service Dealer.  
8. Replace module.  
Engine will not start, starts hard, or fails to  
keep running  
1. Fuel tank is empty.  
1. Fill the fuel tank.  
2. Fuel shutoff valve is closed.  
3. Oil level in the crankcase is low.  
2. Open the fuel shutoff valve.  
3. Add oil to the crankcase.  
4. The throttle and choke are not in the  
correct position.  
4. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions, and the choke is in the “ON”  
position for a cold engine or the “OFF”  
position for a warm engine.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
7. Air cleaner is dirty.  
7. Clean or replace the air cleaner element.  
8. Seat switch is not functioning properly.  
8. Check the seat switch indicator. Replace  
seat if needed.  
9. Electrical connections are corroded, loose 9. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
10. Relay or switch is defective.  
11. Faulty spark plug.  
12. Spark plug wire is not connected.  
13. Faulty module.  
10. Contact an Authorized Service Dealer.  
11. Clean, adjust or replace spark plug.  
12. Check the spark plug wire connection.  
13. Replace module.  
43  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Engine loses power  
1. Engine load is excessive  
1. Reduce the ground speed.  
2. Air cleaner is dirty.  
3. Oil level in the crankcase is low.  
2. Clean or replace the air cleaner element.  
3. Add oil to the crankcase.  
4. Cooling fins and air passages for the  
engine are plugged.  
4. Remove the obstructions from the cooling  
fins and air passages.  
5. Dirt in fuel filter.  
5. Replace the fuel filter.  
6. Dirt, water, or stale fuel is in the fuel  
system.  
6. Contact an Authorized Service Dealer.  
Mower pulls left or right (with levers fully  
forward)  
1. Tire pressure in drive tires not correct.  
1. Adjust tire pressure in the drive tires.  
Machine does not drive  
1. Drive release handle not in “operating”  
position.  
1. Position handle in “operating” position;  
see Drive Wheel Release Valves section  
in Operation.  
2. Drive or pump belt is worn, loose or  
broken.  
2. Change the belt.  
3. Drive or pump belt is off a pulley.  
4. Broken or missing idler spring.  
5. Hydraulic fluid level is low or too hot.  
3. Change the belt.  
4. Replace the spring.  
5. Add hydraulic fluid to reservoir or let it  
cool down.  
Uneven cutting height.  
1. Blade(s) not sharp.  
1. Sharpen the blade(s).  
2. Install new cutting blade(s).  
3. Level mower deck from side-to-side and  
front-to-rear.  
2. Cutting blade(s) is/are bent.  
3. Mower deck is not level.  
4. Underside of mower is dirty.  
5. Tire pressure in drive tires not correct.  
6. Blade spindle bent.  
4. Clean the underside of the mower.  
5. Adjust tire pressure in the drive tires.  
6. Contact an Authorized Service Dealer.  
7. Tips of adjacent blades are at an uneven  
cutting height. Blades tips should be even  
within 3/16 inch which is approximately  
one blade thickness.  
7. Replace blades, spindles and (or) check  
for damage to mower deck.  
Abnormal vibration  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Engine mounting bolts are loose.  
4. Loose engine pulley, idler pulley, or blade  
pulley.  
2. Tighten the blade mounting bolt.  
3. Tighten the engine mounting bolts.  
4. Tighten the appropriate pulley.  
5. Engine pulley is damaged.  
6. Blade spindle is bent.  
5. Contact an Authorized Service Dealer.  
6. Contact an Authorized Service Dealer.  
Blades do not rotate.  
1. Drive belt is worn, loose or broken.  
1. Check the belt tension.  
2. Install new deck belt.  
3. Install belt on clutch and deck pulleys,  
idlers, and tensioning idler per routing  
decal on deck.  
2. Deck belt is worn, loose or broken.  
3. Deck belt is off pulley.  
4. Broken or missing idler spring.  
5. Drive belt not routed correctly.  
4. Replace the spring.  
5. Refer to belt routing decal on deck.  
44  
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Schematics  
Schematics  
Electrical Diagram  
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Schematics  
Electrical Logic Schematic  
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Pioneer S-Series Turf Equipment  
2Year Limited Commercial Warranty  
4Year or 500 Hours Limited Consumer Warranty  
General Warranty Conditions and Products Covered  
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.  
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.  
Contact any Exmark Service Dealer to arrange service at their dealership.  
To locate a dealer convenient to you, access our website at  
402-223-6375.  
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.  
If for any reason you are dissatisfied with the Service Dealer’s analysis or  
with the assistance provided, contact us at:  
Commercial Warranty Conditions  
This warranty applies to Exmark Pioneer S-Series turf equipment sold in  
the U.S. or Canada for a period of two years for commercial usage.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
This warranty includes the cost of parts and labor for a period of two  
years. This warranty does not cover pickup and delivery charges to and  
from any authorized Exmark Service Dealer.  
Beatrice, NE 68310  
402-223-6375 or  
Consumer Warranty Conditions  
This warranty applies to Exmark Pioneer S-Series turf equipment sold in  
the U.S. or Canada for a period of four years or 500 hours (whichever  
occurs first) for residential usage.  
Owner’s Responsibilities  
If your product requires warranty service it 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.  
Residential usage means use of the product on the same lot as your home.  
Use at more than one location is considered commercial use, and the  
commercial use warranty detailed above would apply.  
This warranty only includes the cost of parts and labor. For the first  
warrantable service repair, Exmark will cover up to $45 for associated  
pick-up and delivery charges to and from any authorized Exmark Service  
Dealer. Additional transportation charges may apply, contact your Dealer  
for details.  
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.  
Warranty Exceptions  
Such damages include but are not limited to:  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
*
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.  
• Engine  
* The Engine warranty is covered by the engine manufacturer. Please  
refer to the engine manufacturer’s warranty statement that is included in  
the literature packet.  
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.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• 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.  
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.  
• 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.  
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.  
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.  
This warranty gives you specific legal rights, and you may also have  
other rights which vary from state to state.  
G4500-748_A  
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Notes:  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
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Figure 37  
This page may be copied for personal use.  
1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope indicator to determine the  
degree of slope of hills before operating. Do Not operate this machine on a slope greater than 15 degrees. Fold  
along the appropriate line to match the recommended slope.  
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.  
3. Example of how to compare slope with folded edge.  
51  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
©2011 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-898 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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