Owner`s manual | Exmark 4500-352 Lawn Mower User Manual

METRO
®
For Serial Nos.
790,000 & Higher
Part No. 4500-352 Rev. A
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
Important: When the mower is used or operated
on any California forest, brush or grass covered
land, a working spark arrester must be attached
to the muffler. If not, the operator is violating
state law, Section 4442 Public Resource Code. To
acquire a spark arrester for your unit, see your
Engine Service Dealer.
This spark ignition system complies with Canadian
ICES-002 Ce système d’allumage par ètincelle de
vèhicule est conforme à la norme NMB-002 du
Canada
The enclosed Engine Owner’s Manual is
supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and
the California Emission Control Regulation of
emission systems, maintenance and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become
damaged or illegible, replace immediately.
Replacements may be ordered through the
engine manufacturer.
Exmark reserves the right to make changes or
add improvements to its products at any time
without incurring any obligation to make such
changes to products manufactured previously.
Exmark, or its distributors and dealers, accept
no responsibility for variations which may be
evident in the actual specifications of its products
and the statements and descriptions contained
in this publication.
© 2009—Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
2
Contact us at www.Exmark.com.
Printed in the USA
All Rights Reserved
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
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
1. Model and serial number location
Model No.
If additional information is needed, or should you
require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
Serial No.
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
Contents
Belt Guide Adjustment .................................. 29
Brake and Wheel Drive Linkage
Adjustment ............................................... 30
Shifter Lever Adjustment............................... 31
Shifter Detent Adjustment............................. 32
PTO Safety Switch Adjustment...................... 32
Handle Height Adjustment ............................ 32
Wheel Drive Spring Tension
Adjustment ............................................... 33
Cleaning ........................................................... 34
Clean Engine and Exhaust System
Area .......................................................... 34
Remove Engine Shrouds and Clean Cooling
Fins........................................................... 34
Clean Debris From Machine .......................... 34
Clean Grass Build-Up Under Deck ................ 34
Waste Disposal .............................................. 34
Troubleshooting ................................................... 35
Schematics ........................................................... 37
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ....................... 9
Specifications ....................................................... 12
Model Numbers ............................................ 12
Systems ......................................................... 12
Dimensions................................................... 13
Torque Requirements .................................... 13
Product Overview ................................................ 14
Operation ............................................................. 14
Controls ........................................................ 14
Pre-Start........................................................ 16
Operating Instructions .................................. 16
Transporting ................................................. 18
Maintenance ......................................................... 19
Recommended Maintenance Schedule(s) ........... 19
Periodic Maintenance ....................................... 20
Check Engine Oil Level ................................. 20
Check Mower Blades ..................................... 20
Check Safety Interlock System ....................... 21
Check for Loose Hardware ............................ 21
Service Pre-Cleaner Element and Air
Cleaner...................................................... 21
Change Engine Oil ........................................ 21
Check Tire Pressures ..................................... 22
Check Condition Of Belts.............................. 22
Lubricate Grease Fittings............................... 22
Check Spark Plugs ......................................... 23
Check Grease Level, Input and Output
Shaft Bearing Wear on Peerless
Transmission............................................. 23
Thread Locking Adhesives............................. 24
Mobil HTS Grease (Or Food-Grade
Anti-seize)................................................. 24
Copper-Based Anti-seize .............................. 24
Dielectric Grease........................................... 24
Adjustments ..................................................... 24
Adjusting the Cutting Height ......................... 24
Adjusting the Axle Position............................ 26
Adjusting the Number of Spacers below
Caster Support Hub................................... 27
Adjusting the Cutting Height with Blade
Spacers...................................................... 27
Transmission Belt Adjustment ....................... 27
Wheel Drive Belt Pulley Scrapers ................... 28
Engine to Mower Deck Belt........................... 28
Blade Brake Adjustment ................................ 29
4
Safety
Safety
• Never let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.
Safety Alert Symbol
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
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
Preparation
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
• Evaluate the terrain to determine what accessories
and attachments are needed to properly and
safely perform the job. Only use accessories and
attachments approved by Exmark.
• Wear appropriate clothing including safety glasses,
substantial footwear, long trousers, and hearing
protection. Do Not operate when barefoot or
when wearing open sandals. Long hair, loose
clothing or jewelry may get tangled in moving
parts.
Figure 2
1. Safety alert symbol
The safety alert symbol appears above information
which alerts you to unsafe actions or situations
and will be followed by the word DANGER,
WARNING, or CAUTION.
CAUTION
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
This machine produces sound levels in
excess of 85 dBA at the operator’s ear and
can cause hearing loss through extended
periods of exposure.
WARNING: Black lettering / Orange background.
Indicates a potentially hazardous situation which, if
not avoided, Could result in death or serious injury.
Wear hearing protection when operating this
machine.
CAUTION: Black lettering / Yellow background.
Indicates a potentially hazardous situation which, if
not avoided, May result in minor or moderate injury.
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
Safe Operating Practices
Training
• Read the Operator’s Manual and other training
material. If the operator(s) or mechanic(s) can
not read English it is the owner’s responsibility to
explain this material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
5
Safety
DANGER
DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.
A fire or explosion from gasoline can burn
you, others, and cause property damage.
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.
• Fill the fuel tank outdoors in an open
area, when the engine is cold. Wipe up
any gasoline that spills.
• Always place gasoline containers on the
ground away from your vehicle before
filling.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• Do Not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the
loss of any static charge.
• Do Not fill the fuel tank completely
full. Add gasoline to the fuel tank until
the level is 1/4 to 1/2 inch (6–13 mm)
below the bottom of the filler neck. This
empty space in the tank allows gasoline
to expand.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• Never smoke when handling gasoline,
and stay away from an open flame or
where gasoline fumes may be ignited by
spark.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• Store gasoline in an approved container
and keep it out of the reach of children.
• If a gasoline dispenser nozzle must be
used, keep the nozzle in contact with the
rim of the fuel tank or container opening
at all times until fueling is complete.
• Add fuel before starting the engine.
Never remove the cap of the fuel tank or
add fuel when engine is running or when
the engine is hot.
WARNING
• If fuel is spilled, Do Not attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors has caused
cancer in laboratory animals. Failure to use
caution may cause serious injury or illness.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Keep away from eyes and skin.
• Never siphon by mouth.
• Check that the operator’s presence controls,
safety switches, and shields are attached and
functioning properly. Do Not operate unless they
are functioning properly.
6
Safety
Operation
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
damage and make repairs before restarting
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:
– Before refueling.
– Before dumping the grass catcher.
– Before making height adjustments.
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.
• Allow engine parts, especially the muffler,
to cool before touching.
• Remove accumulated debris from muffler
and engine area.
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
WARNING
Hands, feet, hair, clothing, or accessories can
become entangled in rotating parts. Contact
with the rotating parts can cause traumatic
amputation or severe lacerations.
WARNING
• Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
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.
• DO NOT operate the mower when people,
especially children, or pets are in the area.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• Stop the blades, slow down, and use caution when
crossing surfaces other than grass and when
transporting the mower to and from the area to
be mowed.
• Be aware of the mower discharge path and direct
discharge away from others.
• Do Not operate the mower under the influence
of alcohol or drugs.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
• Operate only in daylight or good artificial light,
keeping away from holes and hidden hazards.
• Be sure all drives are in neutral and parking brake
is engaged before starting engine.
• Never raise deck with blades running.
• Never operate the mower with damaged guards,
shields, or covers. Always have safety shields,
guards, switches and other devices in place and in
proper working condition.
• Never mow with the discharge deflector raised,
removed or altered unless there is a grass
collection system or mulch kit in place and
working properly.
• Do Not change the engine governor setting or
overspeed the engine.
Slope Operation
• Stop engine, wait for all moving parts to stop,
remove key and engage parking brake:
Use Extreme caution when mowing and/or turning
on slopes as loss of traction and/or tip-over could
occur. The operator is responsible for safe operation
on slopes.
– Before checking, cleaning or working on the
mower.
7
Safety
spark plug wire. Wait for all movement to stop
before adjusting, cleaning or repairing.
DANGER
Operating on wet grass or steep slopes can
cause sliding and loss of control. Loss of
control and/or loss of operator’s footing
could result in a fall with an arm or leg
getting under the mower or engine deck
which may result in serious injury, death or
drowning.
• Keep engine and engine area free from
accumulation of grass, leaves, excessive grease
or oil, and other debris which can accumulate
in these areas. These materials can become
combustible and may result in a fire.
• Let engine cool before storing and Do Not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Mow across slopes, never up and down.
• Do Not mow slopes when grass is wet.
• Do Not mow near drop-offs or near water.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
• Do Not mow slopes greater than 20
degrees.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Reduce speed and use extreme caution
on slopes.
• Use jack stands to support components when
required.
• Avoid sudden turns or rapid speed
changes.
• Carefully release pressure from components with
stored energy.
• 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.
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
• Be aware that operating on wet grass, across steep
slopes or downhill may cause the mower to lose
traction. Loss of traction to the drive wheels may
result in sliding and a loss of braking and steering.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
• Keep hands and feet away from moving parts.
If possible, Do Not make adjustments with the
engine running.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Check all bolts frequently to maintain proper
tightness.
• Frequently check for worn or deteriorating
components that could create a hazard.
• All replacement parts must be the same as
or equivalent to the parts supplied as original
equipment.
Maintenance and Storage
• Disengage drives, lower implement, set parking
brake, stop engine and remove key or disconnect
8
Safety
Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.
• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• 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.
• Familiarize yourself with the following safety signs
and instruction labels. They are critical to the safe
operation of your Exmark commercial mower.
1-303508
1-323427
32 inch and 36 inch Units Only
1-303517
1-323550
Pistol Grip Handle Units Only
1-303518
1-403005
9
Safety
1-403143
103-2076
98-5954
103-2244
ECS Units Only
103-1623
ECS Units Only
103-2245
ECS Units Only
103-1798
10
Safety
103-5626
48 inch Units Only
103-1967
Pistol Grip Units Only
11
Specifications
Specifications
Model Numbers
Serial Nos: 790,000 and Higher
M15KA322P; M15KA362P; M15KA483P; M15KA362; M15KA483; M17KA322PCA; M17KA362CA;
M17KA483CA;
Systems
Transmission
Engine
• Peerless 700-070A, five speeds forward and one
reverse.
• Engine Specifications: See your Engine Owner’s
Manual
• Speed range:
– 1st: 2.0 mph (3.22 km/hr)
• RPM: Full Speed: 3600 (No Load)
– 2nd: 2.7 mph (4.35 km/hr)
Fuel System
– 3rd: 3.5 mph (5.63 km/hr)
• Capacity: 5.0 gal. (18.9 L)
– 4th: 4.1 mph (6.60 km/hr)
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher.
– 5th: 6.2 mph (9.98 km/hr)
– Reverse: 3.1 mph (4.99 km/hr)
• Fuel Filter: Replaceable In-line
Wheel Drive System
• Fuel Shut-Off Valve: 1/4 turn increments
Banded double A-Section V-belts, single top-side
idlers and replaceable bolt-on drive sheaves and brake
drums. (Single B-Section V-belts for the 32 inch
Model)
Safety Interlock System
Operator must have the transmission in neutral and
PTO disengaged to start engine. Release of Operator
Presence Control (OPC) levers will cause engine to
stop if transmission is not in neutral and/or PTO
is engaged.
Tires & Wheels
Drive
Steering/Brake Controls
Pneumatic (Air-Filled)
Fingertip drive control levers provide independent
control of traction, braking, and neutral to each drive
wheel for moving, stopping, and power turning.
Parking brakes are engaged by locking drive control
levers in the “brake” position.
12
Front
Caster
SemiPneumatic
32
36 & 48
All Decks
Quantity
2
2
2
Tread
Turf Saver
Turf Master Smooth
Size
13 x 5.00-6
13 x 6.50-6
Ply Rating
4
4
Pressure
14 psi
(97 kPa)
14 psi
(97 kPa)
Bearings
Replaceable
Ball
Replaceable
Ball
9 x 3.50-4
Replaceable
Roller
Specifications
Cutting Deck
Overall Length:
• Cutting Width:
32 inch
Deck
36 inch
Deck
48 inch
Deck
Standard
Pistol Grip
Handles
78.0 inches
(198.1 cm)
78.0 inches
(198.1 cm)
73.0 inches
(185.4 cm)
ECS
Handles
77.3 inches
(196.3 cm)
77.3 inches
(196.3 cm)
72.3 inches
(183.6 cm)
– 32 inch Deck: 31.75 inches (80.7 cm)
– 36 inch Deck: 35.38 inches (89.9 cm)
– 48 inch Deck: 47.25 inches (120.0 cm)
• Discharge: Side
• Blade Size:
– 32 inch Deck: 16.25 inches (41.3 cm) —
Quantity: 2
Overall Height:
– 36 inch Deck: 18.00 inches (45.7 cm)—
Quantity: 2
– 48 inch Deck: 16.25 inches (41.3 cm)—
Quantity: 3
Standard Pistol Grip
Handles
40.0 inches (101.6 cm)
ECS Handles
42.1 inches (106.9 cm)
Tread Width: (Outside to Outside of
Tires, Widthwise)
• Deck Drive: Manual engagement of belt with
over-center lock. Blade belt tension is adjustable
via turnbuckle.
• Blade Brake: When the blade engagement control
is moved to the disengaged position a friction
brake pad stops the rotation of the blades.
32 inch
Deck
36 inch
Deck
48 inch
Deck
32.1 inches
(81.4 cm)
35.6 inches
(90.4 cm)
35.6 inches
(90.4 cm)
32 inch
Deck
36 inch
Deck
48 inch
Deck
Standard
Pistol Grip
Handles
420 lb
(191 kg)
430 lb
(195 kg)
475 lb
(215 kg)
ECS
Handles
435 lb
(197 kg)
446 lb
(202 kg)
490 lb
(222 kg)
Standard
Pistol Grip
& ECS
Handles
• Deck Mounting: Bolted directly to engine deck.
• Deck Depth:
Curb Weight:
– 32 inch Deck: 5.0 inches (12.7 cm)
– 36 inch Deck: 5.0 inches (12.7 cm)
– 48 inch Deck: 5.0 inches (12.7 cm)
• Cutting Height Adjustment:
Adjusts from 1 inch (2.5 cm) to 4 1/4 inches (10.8
cm) in 1/4 inch (6.4 mm) or smaller increments
by various adjustments of caster spacers, blade
spacers, and axle height.
Torque Requirements
Dimensions
Overall Width:
Bolt Location
Torque
Blade/Cutter Housing
Spindle Bolt
75-80 ft-lb (102-109 N-m)
Caster Bracket Mounts
30-35 ft-lb (41-48 N-m)
32 inch
Deck
36 inch
Deck
48 inch
Deck
Deflector
Up
32.7 inches
(83.1 cm)
36.4 inches
(92.5 cm)
48.1 inches
(122.2 cm)
Mower Deck/Engine
Deck Mount
30-35 ft-lb (41-48 N-m)
Deflector
Down
43.3 inches
(110.0 cm)
47.0 inches
(119.4 cm)
57.9 inches
(147.1 cm)
Engine Mounting Bolts
15-20 ft-lb (20-27 N-m)
Transmission Shifter Lever 30-35 ft-lb (41-48 N-m)
Nut
13
Operation
Product Overview
Operation
Note: Determine the left and right sides of the
machine from the normal operating position.
Controls
Operator Presence Control (OPC)
Levers
Located on the upper handle assembly directly above
the handle grips.
When these levers are depressed, the OPC system
senses that the operator is in the normal operator’s
position. When the levers are released, the OPC
system senses that the operator has moved from the
normal operating position and will kill the engine if
either the transmission shift lever is not in the neutral
position or the PTO is engaged (see Figure 4 and
Figure 5).
Figure 3
1. Controls
2. Fuel Cap
3. Pistol Grip Handles
4. ECS Handles
5. Blade Spacers
Figure 4
Pistol Grip Handle
1. Neutral Lock/Park Brake
Latch
2. Rotate latch forward for
park brake position
3. Rotate latch back for
neutral lock position
14
4. OPC Lever
5. Drive Lever
Operation
The latches allow the operator to lock the drive levers
in a “neutral” position where neither the wheel drive
belts nor the brakes engage or in a “park brake”
position where the wheel drive belts are not engaged
and the park brake is engaged (see Figure 4 and
Figure 5).
Choke Control
Located on the front left corner of the fuel tank
support.
Choke is used to aid in starting a cold engine. The
choke control is pulled out to be in the “ON” position
and pushed in to be in the “OFF” position. Do Not
run a warm engine with choke in the “ON” position.
Figure 5
ECS Handle
1. OPC Lever
2. Rotate latch for neutral
lock and park brake
positions
Throttle Control
Located on the on the control console right side.
3. Neutral Lock Latch/Park
Brake Latch
4. Drive Lever
The throttle is used to control engine speed. Moving
the throttle control forward will increase engine
speed and moving it to the rear will decrease engine
speed. Moving the throttle forward into the detent
is full position.
Drive Levers
Transmission Shift Lever
Located on each side of the upper handle assembly
ahead of and below the handle grips (see Figure 4
and Figure 5).
Located under the control console and behind the
fuel tank.
These levers individually control clutching action of
the wheel drive belts and brakes. When the drive
levers are all the way down, the brakes disengage and
the wheel drive belts engage
It shifts the 5-speed transmission into five forward
gears, neutral and reverse. Shift transmission only
when drive levers are in the neutral position. Shifting
without drive levers in neutral may cause damage to
the transmission.
Gradually squeezing the left or right hand drive lever
disengages the wheel drive belts, causing the left hand
or right hand wheel to slow down until they reach
neutral or stop. This makes the machine turn to the
left or right respectively. Squeezing further engages
the park brakes. The sharpness of the turn varies by
how much the lever is squeezed. For straight ahead
motion, smoothly release both drive levers to engage
both drive wheels simultaneously.
Note: Reverse is “reverse assist” only, meaning when
the transmission is in reverse, the operator has to pull
the unit backward to “assist” with the movement of
the unit.
“Off-Run” Switch
Located on the control console.
Neutral Lock/Park Brake Latches
Turn the key to the “Run” position to allow the
engine to be started. Turn the key to the “Off ”
position to shut engine off.
• For Pistol Grip Handles: Located on handles
ahead of the grips.
Fuel Shut-Off Valve
• For ECS Handles: Located on the upper handle
assembly on the ends of the handle grips.
Located in the fuel line midway between the tank
and engine.
15
Operation
Note: Kawasaki engines generally need to be
“choked” even when warm.
The fuel shut-off valve is used to shut off the
flow of fuel when parking inside a building, during
transportation to and from the job sites, and when
the machine will not be used for a few days.
PTO Engagement
Rotate valve 1/4 turn clockwise to shut fuel off.
Rotate valve 1/4 turn counterclockwise to turn fuel
on.
DANGER
The rotating blades under the mower deck
are dangerous. Blade contact can cause
serious injury or kill you.
Pre-Start
Fill fuel tank. For best results use only clean, fresh
regular grade unleaded gasoline with an octane rating
of 87 or higher. Regular grade leaded gasoline may
also be used; however, combustion chamber and
cylinder head will require more frequent service. See
Engine Owner’s Manual.
Do Not put hands or feet under the mower
or mower deck when the blades are engaged.
DANGER
Do Not add oil to gasoline.
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.
Do Not overfill fuel tank. Never fill the fuel tank so
that the fuel level rises above a level that is 1/2 inch
below the bottom of the filler neck to allow for fuel
expansion and prevent fuel spillage.
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.
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
The PTO switch engages the cutting blades. Be sure
that all persons are clear of mower deck and discharge
area before engaging the PTO.
1. Set throttle to “MIDWAY” position.
2. Push the PTO lever forward to engage blades.
3. Place the throttle in the “FAST” position to begin
mowing.
Operating Instructions
Open the Fuel Shut-Off Valve
Rotate the valve 1/4 turn counterclockwise to turn
fuel on.
Starting the Engine
Disengaging the PTO
Note: Always engage the left and right neutral
lock/park brake latches in the “park brake” position
when starting the engine
1. On a cold engine, place the throttle midway
between the “Slow” and “Fast” positions and
place the choke in the “On” position. On a warm
engine, place the throttle lever midway between
“Slow” and “Fast” positions and leave the choke
in the “Off ” position.
2. Turn ignition switch to “Run” position. Pull the
recoil rope to start engine.
3. On a cold engine, gradually return choke to the
“Off ” position after engine starts and warms up.
1. Set throttle to “MIDWAY” position.
2. Pull the blade engagement lever to the full
rearward position to disengage the blades
Stopping the Engine
1.
2.
3.
4.
5.
16
Bring the unit to a full stop.
Lock drive levers in “park brake” position.
Disengage the PTO.
Move transmission shift lever to “neutral”.
Place the throttle midway between the “SLOW”
and “FAST” positions.
Operation
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.
7. Remove the key to prevent children or other
unauthorized persons from starting engine.
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 the Machine
Drive Lever/Neutral Lock/Park Brake Latch
Operation
Figure 6
• For Pistol Grip Handles
1. Latch is in the drive
position
2. Rotate forward for park
brake position
3. Rotate back for neutral
lock position
4. Park brake
To lock the drive levers in “neutral”, squeeze the
drive levers back to the neutral position. Place
thumbs on the upper portion of the neutral
lock/park brake latches and move them to the
rear. Release the drive levers.
6. Neutral lock
7. Forward — release drive
lever
8. Neutral —hold in this
position
9. Reverse—squeeze drive
lever
5. Full speed forward
To lock the levers in “park brake”, squeeze the
drive levers back to the brake position. Place
thumbs on the upper portion of the neutral
lock/park brake latches and move them to the
front. Release the drive levers (see Figure 6)
• For ECS Handles
To lock the drive levers in “neutral lock”, squeeze
the drive levers to the “neutral” position. See
Figure 7 position 2. Place thumbs on the inner
thumb lobe of the neutral lock /park brake latches
and rotate them to the “neutral” position. See
Figure 7 position 3. Release the drive levers.
CAUTION
If the neutral lock/park brake latches are not
completely engaged the drive levers could
unexpectedly slip into the forward drive
position. If the drive levers slip into the drive
position, the unit could lurch forward and
cause injury or property damage.
To lock the drive levers in “park brake”, squeeze
the drive levers farther to the “brake” position.
Place thumbs on the inner thumb lobe of the
neutral lock/park brake latches and rotate them
to the “park” position. See Figure 7 position 4.
Release drive levers.
Be sure the pins protruding through the slots
of each neutral lock latch are completely
engaged in the rear slot of each latch.
CAUTION
To place the drive levers in the drive position,
firmly hold the drive levers, place thumbs on the
upper portion of the neutral lock/park brake
latches and move them out of the “neutral” or
the “park brake” position. Slowly and smoothly
release the drive levers.
If the neutral lock/park brake latches are not
completely engaged the drive levers could
unexpectedly slip into the forward drive
position. If the drive levers slip into the drive
position, the unit could lurch forward and
cause injury or property damage.
Be sure the drive levers are securely seated at
the bottom of the “neutral” or “park” areas
of the neutral lock latches.
17
Operation
Smoothly release both drive levers to engage drive
wheels.
To place the drive levers in the “drive” position,
slightly squeeze the drive levers while placing
thumbs on the outer thumb lobe of the neutral
lock/park brake latches (or the index finger on
the front lobe) and rotate them from under the
drive levers. Slowly and carefully release the drive
levers. See Figure 7 position 1.
Pull the unit backward to “assist” with the movement
of the unit.
To stop, squeeze drive levers all the way back to
engage the brakes. Move the neutral lock latches into
the “park brake” position and release drive levers.
Move the speed control lever to the neutral position.
Changing Gears
When changing gears, always squeeze drive levers to
the neutral position. The shift lever may be moved
with a knee or by hand (engage the neutral lock
latches if shifting by hand).
Note: Reverse gear is “reverse assist” only, the
operator must pull the unit backwards.
Transporting
Figure 7
1. Drive Lever in drive
position
2. Drive Lever in neutral
position
Transporting a Unit
3. Drive Lever locked in
neutral position
4. Drive Lever locked in
park position
WARNING
Loading the mower onto a trailer without
strong enough or properly supported ramps
could be dangerous. The ramps could
collapse causing the unit to fall, which could
cause injury.
Driving Forward
1. With drive levers in the “neutral” or “park brake”
position, shift transmission into desired gear.
2. Squeeze both drive levers and move both neutral
lock/park brake latches from the “neutral” or
“park brake” position to the “drive” position.
• Use proper ramps that are secured to the
truck or trailer.
• Keep feet and legs out from under the
unit when loading and unloading.
3. To move forward in a straight line, smoothly
release both drive levers to engage drive wheels.
• If necessary, use assistance when loading.
To turn left or right, squeeze the right hand drive
lever to turn right and the left hand drive lever
to turn left.
Be sure the fuel shut-off valve is closed.
Squeeze drive levers all the way back to engage
brakes. Move neutral lock/park brake latches into
the “park brake” position and release drive levers.
Shift transmission into neutral.
Use a heavy duty trailer to transport the machine.
Engage neutral lock latches and park brake, then
block wheels.
Driving in Reverse
Securely fasten the machine to the trailer with straps,
chains, cables, or ropes.
Note: Reverse gear is reverse assist only, the operator
must pull the unit backwards.
Do Not rely solely on the parking brake to hold the
machine on the trailer.
To move rearward, squeeze the drive levers to neutral
position and move the shifter to the “R”.
Be sure that the trailer has all necessary lighting and
marking as required by law and use a safety chain.
18
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
Interval
Maintenance Procedure
After the first 5 hours
• Change the engine oil.
Before each use or daily
•
•
•
•
•
•
•
•
•
•
•
Check the engine oil level.
Check the mower blades.
Check the safety interlock system.
Check for loose hardware.
Grease the front caster wheel bearings.
Grease front caster pivots.
Grease the drive wheels.
Grease the drive wheel idler arm.
Clean the engine and exhaust system area.
Clean the grass and debris build-up from the machine and cutting deck.
Clean the grass build-up from under the deck.
Every 25 hours
• Service the air cleaner. (May need more often under severe conditions. See the Engine
manual for additional information.)
Every 40 hours
•
•
•
•
•
Every 80 hours
• Remove engine shrouds and clean cooling fins.
Every 100 hours
• Change the engine oil. (May need more often under severe conditions.)
Every 160 hours
• Check the spark plugs.
• Check grease level, input and output shaft bearing wear on Peerless Transmission.
Yearly
Check the tire pressures.
Check the condition of the belts.
Grease the brake arm.
Grease the transmission output shaft coupler
Grease the mower deck idler pivots
• Replace gearbox grease.
19
Maintenance
Periodic Maintenance
Check Engine Oil Level
Service Interval: Before each use or daily
1. Stop engine and wait for all moving parts to stop.
Make sure unit is on a level surface.
2. Check with engine cold.
3. Clean area around dipstick. Remove dipstick and
wipe oil off. Reinsert the dipstick and push it all
the way down into the tube. Do Not screw into
place. Remove the dipstick and read the oil level.
4. If the oil level is low, wipe off the area around the
oil fill cap, remove cap and fill to the “FULL”
mark on the dipstick. Use oil as specified in
Engine Owner’s Manual. Do Not overfill.
Figure 8
2. Blade bolt torque to
1. Spring disc washer
75-80 ft-lb (102-109
(cone towards bolt head)
N-m).
Important: Do Not operate the engine with the
oil level below the “LOW” (or “ADD”) mark on
the dipstick, or over the “FULL” mark.
Replacing the Discharge
Deflector
Check Mower Blades
Service Interval: Before each use or daily
Service Interval: As required
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
DANGER
2. Lift deck and secure in raised position as stated
in the Clean Grass Build-Up Under Deck
procedure.
An uncovered discharge opening could allow
the lawn mower to throw objects in the
operator’s or bystander’s direction and result
in serious injury. Also, contact with the blade
could occur.
3. Inspect blades and sharpen or replace as required.
4. Re-install the blades (if they were removed) and
torque blade bolts to 75-80 ft-lb (102-109 N-m).
Be sure the spring disc washer cone is installed
toward the bolt head (see Figure 8).
Never operate the lawn mower unless you
install a mulch plate, discharge deflector, or
grass collection system.
1. To remove a damaged or worn discharge
deflector, lift the leg of the spring with the loop
out of the notch in the discharge deflector and
slide the rod out of the discharge deflector
brackets, and discharge deflector.
2. To install new discharge deflector, orient the
spring on the rod as shown in Figure 9. Slide the
rod through the front discharge deflector bracket,
discharge deflector, and rear deflector bracket.
20
Maintenance
shift the transmission into gear and release the
OPC levers–the engine must stop.
3. Again, run the engine at on-third throttle, move
the transmission shifter lever to neutral, engage
the PTO and release the OPC levers–the engine
must stop.
Note: If machine does not pass any of these tests,
do not operate. Contact your authorized EXMARK
SERVICE DEALER.
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
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.
Figure 9
1. Rod
2. Spring
3. Discharge deflector
4. Mower deck
5. Discharge deflector
bracket
6. Assembled view
2. Visually inspect machine for any loose hardware
or any other possible problem. Tighten hardware
or correct the problem before operating.
Service Pre-Cleaner Element
and Air Cleaner
3. Hook the bent end of the rod around the front
discharge deflector bracket to retain it from
sliding out. Place the leg of the spring with the
loop in the notch in the discharge deflector to
hold the discharge deflector in the down position
(see Figure 9).
Service Interval: Every 25 hours—Service
the air cleaner. (May
need more often under
severe conditions. See
the Engine manual for
additional information.)
Important: The discharge deflector must be
spring loaded in the down position. Lift the
deflector up to test that it snaps to the full
down position.
1. Stop engine, wait for all moving parts to stop, and
remove key or spark plug wire(s). Engage parking
brake.
Check Safety Interlock
System
2. See the Engine Owner’s Manual for cleaning
instructions.
Service Interval: Before each use or daily
1. For your safety, your Exmark mower is equipped
with Operator Presence Controls, referred to as
(OPC). When either the PTO is engaged, or the
transmission shifter lever is not in neutral and the
operator removes both hands from the handles,
the mower engine must stop.
2. To determine if the OPC is in operating condition,
clear area of bystanders. Run the engine at
one-third throttle, then with the drive levers and
neutral lock latches in the “park brake” position,
Change Engine Oil
Service Interval: After the first 5 hours
Every 100 hours (May
need more often under
severe conditions.)
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Drain oil while engine is warm from operation.
21
Maintenance
Lubricate Grease Fittings
3. Remove the oil drain plug from the right hand
side of the engine. Allow oil to drain, replace
drain plug.
4. Replace the oil filter per the engine owner’s
manual. Clean around oil filter and unscrew filter
to remove. Before the new filter is installed,
apply a thin coating of oil on the surface of the
rubber seal. Turn filter clockwise until rubber seal
contacts the filter adapter, then tighten filter an
additional 2/3 to 3/4 turn.
5. Clean around oil fill cap and remove cap. Fill to
specified capacity and replace cap.
6. Use oil recommended in engine owner’s manual.
Do Not overfill. Start the engine and check for
leaks. Stop engine and recheck oil level.
7. Wipe up any spilled oil from engine deck
mounting surfaces.
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 NGLI grade #2
multi-purpose gun grease.
Refer to the following chart for fitting locations
and lubrication schedule.
Lubrication Chart
Fitting
Initial
Locations Pumps
Check Tire Pressures
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Check tire pressure in drive tires.
3. Inflate drive tires to 12–16 psi (83–110 kPa).
4. Inflate tires to pressures stated above. Measure
the circumference of each drive tire. Adjust tire
pressures within the above range to try to make
tire circumferences match as closely as possible.
5. Semi-pneumatic caster tires Do Not need to be
inflated.
Note: A more uniform cutting height may be
obtained with higher tire pressure on rough terrain.
A lower tire pressure provides more flotation.
Check Condition Of Belts
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Remove the mower deck belt shield to check
mower blade drive belt condition.
3. Look under engine deck to check the transmission
drive belt condition.
4. Inspect wheel drive belt conditions.
5. Check all idler arms to be sure they pivot freely.
Disassemble, clean and grease pivot bushings if
necessary.
22
Number of Places
32 inch
Deck
36 inch
Deck
48 inch
Deck
Service
Interval
1. Front
Caster
Wheel
Bearings
12
2
2
2
Daily
2. Front
Caster
Pivots
2
2
2
2
Daily
3. Drive
Wheels
18
2
2
2
Daily
4. Drive
Wheel
Idler Arm
2
2
2
2
Daily
5. Brake
Arm
2
2
2
2
40
hours
6. Transmission
Output
Shaft
Coupler
2
2
2
2
40
hours
7. Mower
Deck
Idler
Pivots
2
1
1
1
40
hours
Maintenance
Change Fuel Filter
Service Interval: As required
A fuel filter is installed in the fuel line between the
fuel tank and the engine. Replace when necessary.
Check Grease Level,
Input and Output Shaft
Bearing Wear on Peerless
Transmission
Service Interval: Every 160 hours—Check
grease level, input and
output shaft bearing
wear on Peerless
Transmission.
48 inch Deck Shown for Reference Only
Number 4 and 7 (Idler Arm Pivots) Disassemble and
grease once a month under a “No Load” condition
Yearly—Replace gearbox
grease.
Number 6 (Transmission Coupler) Located
below fuel tank support
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake. Remove key
or spark plug wire(s).
3. Replace 5-speed gearbox grease yearly. Use 18 oz.
of Peerless grease (Part No. 788067). See Check
Grease Level, Input and Output Shaft Bearing
Wear on Peerless Transmission section for
special lubrication instructions.
2. Place drive levers and neutral lock/park brake
latches in neutral lock position
3. Remove shifter lever from top of transmission.
4. Lubricate pivot points with a spray penetrating
lubricant as shown in the Spray Lubricant Chart.
4. Remove shifter plate from top of transmission
and the two leads from the neutral start switch.
Spray Lubricant Chart
5. Release the tension on the transmission belt.
Number of Places
Pivot Points
32 inch
Deck
36 inch
Deck
48 inch
Deck
Service
Interval
1. Blade
Engagement
Bellcrank
1
1
1
40 hours
6. Check for side play caused by bearing wear on
the input and output shafts of the transmission.
Replace bearings if necessary.
7. Remove the six bolts that fasten the upper case
to the lower case and carefully remove the upper
case half
8. Check the grease level in the lower case. The
grease level should be approximately 1 1/2 inch
to 1 3/4 inch (3.8 to 4.4 cm) from the gearbox
bottom. If necessary, fill to proper level with
Peerless grease (Part No. 788067).
Check Spark Plugs
Service Interval: Every 160 hours
Remove spark plugs, check condition and reset gaps,
or replace with new plugs. See Engine Owners
Manual.
9. Reinstall upper case half and fasten in place with
six bolts previously removed.
10. Reinstall all parts removed in steps 3 and 4. Install
drive belt and adjust tension as stated in the
Transmission Belt Adjustment section.
23
Maintenance
Thread Locking Adhesives
Adjustments
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
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.
• All belt drive pulley setscrews.
• OPC lever setscrews.
Adjusting the Cutting Height
• Pulley retaining bolt in end of engine crankshaft.
The cutting height of the mower deck is adjusted
from 1 inch to 4 1/4 inches (2.54 cm to 11.4 cm) in
1/4 inch (.64 cm) increments by adjusting the axle
position, number of spacers below the caster hub,
and number of spacers between blade and spindle.
• Fuel tank bulkhead fitting threads
Adhesives such as “Loctite RC/609 or RC/680” or
“Fel-Pro Pro-Lock Retaining I or Retaining II” are
used on the following:
• OPC lever hubs and cross-shaft
Refer to the Cutting Height Adjustment table and
select a cutting height range in the left hand column
which corresponds to the range of cutting heights
you will most often be using. Adjustments within this
range can then be made by adjusting the number of
blade spacers between the blade and the bottom of
the spindle (this is a much easier adjustment to make
than adjusting axle position and number of spacers
below caster support hub).
Note: Care must be used not to bond the
bearing, next to each OPC hub, to the cross-shaft
which could cause binding of the OPC levers and
erratic operation.
• Fuel tank studs, where studs are inserted into tank.
Mobil HTS Grease (Or
Food-Grade Anti-seize)
Note that:
• For the best cut and discharge, place a minimum
of two spacers between the blade and the spindle.
Mobil HTS grease (or food-grade anti-seize) is used
in the following locations:
• For highest quality cut, place all four spacers
between the blade and the spindle.
• Between the cutter housing spindle and bearings.
• Between the cutter housing spindle and sheave.
Copper-Based Anti-seize
• If mulching kit is installed, the highest quality cut
can be obtained with 3 spacers between the blade
and the spindle (minimum is 1 for a good cut).
Copper-based anti-seize is used in the following
locations:
• When mulching leaves it is best to have fewer
spacers between blade and spindle.
• Between the blade drive and transmission drive
pulleys and engine crankshaft.
Refer to the table and select desired cutting height
range. Refer to Adjusting the Axle Position,
Adjusting the Number of Spacers below Caster
Support Hub, and Adjusting the Cutting
Height with Blade Spacers and sections to make
adjustments make adjustment to obtain specific
cutting height.
• Between the transmission drive pulley and
transmission drive shaft.
• Between the bearings and sheaves and
transmission output shafts.
Dielectric Grease
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
24
Maintenance
Cutting Height Adjustment Table (1 inch to 4 1/4 inches (2.5 cm-10.8 cm))
Cutting
Height
Range
Axle
Position
(Figure 10)
Number Of Spacers
Below Caster
Support Hub
1/2
inch
3/16
inch
Number of 1/4 inch Blade Spacers Below Spindle
4
3
2
1
0
1–2 inches
(2.5–5.0 cm)
A
0
0
1 inch
(2.5 cm)
1 1/4 inch
(3.2 cm)
1 1/2 inch
(3.5 cm)
1 3/4 inch
(4.4 cm)
2 inch
(5.0 cm)
1 1/8–
2 1/8 inches
(2.9–5.4 cm)
A
0
1
1 1/8 inch
(2.9 cm)
1 3/8 inch
(3.5 cm)
1 5/8 inch
(4.1 cm)
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
1 3/8–
2 3/8 inches
(3.5–6.0 cm)
A
1
0
1 3/8 inch
(3.5 cm)
1 5/8 inch
(4.1 cm)
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
1 3/8–
2 3/8 inches
(3.5–6.0 cm)
B
0
1
1 3/8 inch
(3.5 cm)
1 5/8 inch
(4.1 cm)
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
1 5/8–
2 5/8 inches
(4.1–6.7 cm)
B
1
0
1 5/8 inch
(4.1 cm)
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
2 5/8 inch
(6.7 cm)
1 3/4–
2 3/4 inches
(4.4–7.0 cm)
B
1
1
1 3/4 inch
(4.4 cm)
2 inch
(5.0 cm)
2 1/4 inch
(5.7 cm)
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
2–3 inches
(5.0–7.6 cm)
B
2
0
2 inch
(5.0 cm)
2 1/4 inch
(5.7 cm)
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
1 7/8–
2 7/8 inches
(4.8–7.3 cm)
C
1
1
1 7/8 inch
(4.8 cm)
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
2 5/8 inch
(6.7 cm)
2 7/8 inch
(7.3 cm)
2 1/8–
3 1/8 inches
(5.4–7.9 cm)
C
2
0
2 1/8 inch
(5.4 cm)
2 3/8 inch
(6.0 cm)
2 5/8 inch
(6.7 cm)
2 7/8 inch
(7.3 cm)
3 1/8 inch
(7.9 cm)
2 1/4–
3 1/4 inches
(5.7–8.3 cm)
C
2
1
2 1/4 inch
(5.7 cm)
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
2 1/2–
3 1/2 inches
(6.4–8.9 cm)
C
3
0
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
2 3/8–
3 3/8 inches
(6.0–8.6 cm)
D
2
1
2 3/8 inch
(6.0 cm)
2 5/8 inch
(6.7 cm)
2 7/8 inch
(7.3 cm)
3 1/8 inch
(7.9 cm)
3 3/8 inch
(8.6 cm)
2 1/2–
3 1/2 inches
(6.4–8.9 cm)
D
3
0
2 1/2 inch
(6.4 cm)
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
2 3/4–
3 3/4 inches
(7.0–9.5 cm)
D
3
1
2 3/4 inch
(7.0 cm)
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
3 3/4 inch
(9.5 cm)
3–4 inches
(7.6–10.1 cm)
D
4
0
3 inch
(7.6 cm)
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
3 3/4 inch
(9.5 cm)
4 inch
(10.1 cm)
2 7/8–
3 7/8 inches
(7.3–9.8 cm)
E
3
1
2 7/8 inch
(7.3 cm)
3 1/8 inch
(7.9 cm)
3 3/8 inch
(8.6 cm)
3 5/8 inch
(9.2 cm)
3 7/8 inch
(9.8 cm)
25
Maintenance
Cutting Height Adjustment Table (1 inch to 4 1/4 inches (2.5 cm-10.8 cm)) (cont'd.)
Cutting
Height
Range
Axle
Position
(Figure 10)
Number Of Spacers
Below Caster
Support Hub
1/2
inch
3/16
inch
Number of 1/4 inch Blade Spacers Below Spindle
4
3
2
1
0
3 1/8–
4 1/8 inches
(7.9–10.5 cm)
E
4
0
3 1/8 inch
(7.9 cm)
3 3/8 inch
(8.6 cm)
3 5/8 inch
(9.2 cm)
3 7/8 inch
(9.8 cm)
4 1/8 inch
(10.5 cm)
3 1/4–
4 1/4 inches
(8.3–10.8 cm)
E
4
1
3 1/4 inch
(8.3 cm)
3 1/2 inch
(8.9 cm)
3 3/4 inch
(9.5 cm)
4 inch
(10.1 cm)
4 1/4 inch
(10.8 cm)
Important: Always adjust the Number of Spacers below Caster Hub to correspond to the Axle
Position as shown in table to obtain proper “rake” (blades should always be level to the ground
or tipped slightly down at the front).
Adjusting the Axle Position
10. Install mower deck belt shield.
Desired cutting height range can be obtained by
adjusting the rear axle and placing caster spacers
above or below the caster arm (See Figure 10 and
Figure 11 along with the Cutting Height Adjustment
Chart). It may be necessary to readjust wheel drive
and brake linkages.
11. Adjust wheel drive and brake linkages as
required (see Brake and Wheel Drive Linkage
Adjustment section).
To adjust rear axle:
1. Stop the machine and move the drive levers to
the neutral lock position.
2. Disengage the PTO.
3. Place the drive levers in the neutral lock position.
4. Remove mower deck belt shield for access to axle
adjustment bolts.
Figure 10
1. Axle Pivot Bolt
2. Axle Adjustment Holes
(Located in the side of
the rear deck.)
3. Position A
4. Position B
5. Loosen but do not remove the two axle pivot
bolts and the two axle adjustment bolts (see
Figure 10).
6. Place a jack under the rear center of the engine
deck.
5. Position C
6. Position D
7. Position E
8. Place jack here
Note: The axle positions are in 1/2 inch (1.3 cm)
increments and the large caster spacers are 1/2
inch (1.3 cm) thick. Therefore, by adjusting the
same number of 1/2 inch (1.3 cm) caster spacers as
axle hole positions the blades will retain the same
front-to-back tip (rake).
7. Raise the back end of the engine deck up enough
to remove the two axle adjustment bolts.
8. With the jack, raise or lower the back end of the
engine deck so that two axle adjustment bolts can
be reinstalled in desired hole location. A tapered
punch can be used to help align the holes.
9. Retighten all four bolts, lower unit and remove
jack.
26
Maintenance
Adjusting the Number
of Spacers below Caster
Support Hub
5. Blades may be adjusted for cutting height by using
the four 1/4 inch (.64 cm) spacers found on the
blade spindle bolts (factory setting is two above
and two below). This allows a 1 inch (2.5 cm)
range in 1/4 inch (.64 cm) increments of cutting
height in any axle position. The same number
of blade spacers must be used on all blades to
achieve a level cut (two above and two below, one
above and three below, etc.).
1. Stop the machine and move the drive levers to
the neutral lock position.
2. Disengage the PTO.
3. Place the drive levers in the “park brake” position.
4. Push down on handles to lift front casters off the
ground.
5. Support with jackstands.
6. Remove “quick pin” from one caster and remove
caster from hub (see Figure 11.).
6. Raise front of deck and support with jack stands.
7. Hold blade bolt on bottom and loosen spindle
nut on top.
8. Adjust number of spacers between bottom of
spindle and blade as indicated in the Cutting
Height Adjustment Table and notes in the
Adjusting the Cutting Height section.
9. Install unused spacers between top of spindle and
spindle nut.
10. Torque bolt to 75–80 ft-lb (102–109 N-m) (see
Figure 12).
Figure 11
1. Four 1/2 inch (127 mm)
spacers
2. Quick Pin
3. 3/16 inch (4.8 mm)
spacer
4. Caster support
7. Adjust the number of 1/2 inch spacers between
bottom of hub and caster yoke to obtain the
desired cutting height from the Cutting Height
Adjustment Table in the Adjusting the Cutting
Height section.
8. Install remaining spacers on top of hub.
9. Install “quick pin”.
10. Repeat for other caster.
Figure 12
2. Blade bolt torque to
1. Spring disc washer
75–80 ft-lb (102–109
(cone towards bolt head)
N-m)
Adjusting the Cutting Height
with Blade Spacers
1. Stop the machine and move the drive levers to the
neutral locked position.
2. Disengage the PTO.
3. Engage the park brake.
4. Stop the engine, remove the key and wait for all
moving parts to stop.
Transmission Belt
Adjustment
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
27
Maintenance
2. To tighten transmission belt, loosen the 3/8 inch
nyloc nut on transmission belt idler pulley. Slide
bolt inward in slot and retighten nyloc nut.
For 48” Decks: If there is no adjustment left in
the turnbuckle and the belt is still loose, the rear
idler pulley can be repositioned in the front hole
(See Figure 12). The belt guide located next to
the pulley must also be repositioned in the front
hole when the pulley is moved. The turnbuckle
will need to be readjusted.
3. When properly adjusted, the belt should have 1/2
inch (1.3 cm) of deflection with three pounds
of pressure on the belt midway between the
transmission and engine pulley.
Check belt tension after the first hour of operation
and at least twice during the first 24 hours of
operation. Adjust as necessary.
Wheel Drive Belt Pulley
Scrapers
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. Be sure mud and grass scraper, on each side,
is adjusted properly and centered in the pulley
grooves. The pointed part of the scraper should
be centered and as deep in the pulley groove as
possible without rubbing at any point.
Figure 13
48 inch Deck Shown for Reference Only
Engine to Mower Deck Belt
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
1. Pulley location for Metro
2. Pulley can be moved to the front position to tighten the
belt when there is no adjustment left in the turnbuckle
(48 inch deck only)
3. Belt guide must be moved to the front position if the
pulley is moved. (48 inch deck only)
4. Turnbuckle
5. 5/16 inch (.79 cm) minimum engagement
6. 5/16 inch whizlock nut
7. Rear Assist Arm Stop
8. Assist Arm
9. Front Assist Arm Stop
10. Point “A”
2. Check the adjustment of the lower blade drive
linkage located between the bellcrank on the
engine deck and assist arm on the mower deck.
Lengthen or shorten the linkage. When properly
adjusted, there should be 1/16 inch to 1/8 inch
(2–3 mm) of clearance between bell-crank and
transmission output shaft when belt is engaged.
Make sure the assist arm is against the rear assist
arm stop on the deck (see Figure 13). Push the
lever down to the disengaged position. The assist
arm should contact the front assist arm stop on
the deck. If it does not contact, readjust so that
the bellcrank is closer to the transmission output
shaft.
4. Proper belt tension will require about 10 lb (4.5
kg) side pull on belt, halfway between pulleys (see
Figure 13, item 10–Point A) to deflect belt 1/2
inch (12 mm).
5. Check belt guide under the engine deck to see that
it is properly set (see Belt Guide Adjustment
section). Also check the blade brake adjustment
(see Blade Brake Adjustment section).
3. Belt must be tight enough to not slip during heavy
loads while cutting grass. Over-tensioning will
reduce belt and spindle bearing life. To adjust
belt tension, loosen the 5/16 inch whizlock nut
on turnbuckle and rotate the turnbuckle; rotate
turnbuckle toward rear of mower to tighten, and
toward front of mower to loosen belt tension (see
Figure 13). Leave a minimum of 5/16 inch (.79
cm) of the eyebolt threads engaged on both ends
of the turnbuckle.
28
Maintenance
Mower Deck Belt Routings:
distance should be between 1/8 inch and 3/16
inch (3–5 mm) (see Figure 16).
5. Engage the blade control and check to make sure
the blade brake pad clears the sheave.
Figure 14
32 inch and 36 inch Mower Deck
Figure 16
Shown with Blades Disengaged
1. Blade Brake Rod
3. 1/8 inch to 3/16 inch (3–5
mm)
2. Spring Mounting Bolts
Belt Guide Adjustment
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. Engage the blade drive belt.
3. Check belt guide under the engine deck for proper
adjustment (See Figure 17 and Figure 18). Adjust
as necessary.
Figure 15
48 inch Mower Deck
The disengaged belt should not drag or fall off
pulley when guides are properly adjusted.
Blade Brake Adjustment
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. Disengage blades.
3. Make sure the blade brake pad rests against
the sheave. Adjust the spring mounting bolts
to properly align the pad on the sheave (see
Figure 16).
Figure 17
32 inch and 36 inch Belt Guide Location
(Viewed from underneath the deck)
4. Check the distance between the spacer and the
nut at the end of the blade brake rod. The
1. 1 1/4 inch (3.1 cm)
29
Maintenance
A. For wheel drive linkage adjustment,
remove the hairpin between the neutral
lock latch and drive lever (Figure 19).
Figure 18
48 inch Belt Guide Location
(Viewed from underneath the deck)
1. 1 3/8 inch (3.5 cm)
Figure 19
Left Side Shown
Brake and Wheel Drive
Linkage Adjustment
1. Drive Lever
1. Check for correct brake adjustment:
2. Clevis Pin
3. Drive Linkage
Place the drive levers in the “park brake”
position. The mower should not move forward
or backward. If it does, tighten the wingnuts.
4. Neutral Lock/Park Brake
Latch
5. Hairpin
B. Adjust drive linkage length by threading
into or out of the swivel until there is
a 3/16 inch to 1/4 inch (.47-.64 cm)
clearance between the linkage assembly
and the bottom of the slot in the neutral
lock/park brake latch (see Figure 20).
Place the drive levers in the “neutral lock”
position. The mower should move forward and
backward freely. If it does not, brake adjustment
is necessary
2. Adjust brakes by adjusting wingnut on the upper
end of each brake rod. Tighten the wingnut
until the brakes engage when the drive levers are
squeezed enough to allow the neutral lock/park
brake latches to be placed into the “park brake”
position.
See Figure 6 for Standard Pistol Grip handles and
Figure 7 for ECS handles.
Note: The neutral lock/park brake latches must
be able to be moved into the park brake position,
if not, the brake linkages must be adjusted again.
3. Check for correct wheel drive linkage adjustment.
• For Pistol Grip Handles
Figure 20
Allow drive levers to drop into the full forward
position: The clevis pin should rest in the
neutral lock latch with approximately 3/16
inch to 1/4 inch (4.7–6.4 mm) clearance from
the bottom of the slot (see Figure 19). Adjust
if necessary.
1. 3/16 inch to 1/4 inch (.47 cm-.64 cm)
2. Neutral Lock/Park Brake Latch
3. Drive Linkage
Note: Neutral lock/park brake latch
clearance should be checked when there is
To adjust the wheel drive linkage:
30
Maintenance
a slight upward force placed on the drive
levers to remove any "slack" in the linkage.
C. Re-install hairpin into hole on the clevis
pin between the neutral lock/park brake
latch and drive lever (See Figure 19).
Repeat procedure on opposite side of unit.
• For ECS Handles:
Allow drive levers to drop into the full forward
position: the flat edge of the drive lever
should align with the bottom roller notch (See
Figure 21). Adjust if necessary
Figure 22
Right Side of Unit Shown
1. Wingnut
2. Transmission Lever in
neutral
3. 5/16–18 inch nyloc nut
4. Drive Levers in neutral
5. 5/16–18 x 1 3/4 inch hex
capscrew
6. Drive Lever Linkage
7. Swivel
8. Brake Rod
Figure 21
1. Notch in Neutral
Lock/Park Brake Latch
2. Drive Lever
Shifter Lever Adjustment
To adjust the wheel drive linkage:
The shifter lever in neutral should not contact the
upper or lower edge of the slot or the left edge of
the upper slot or the right edge of the bottom slot
(See Figure 23 and Figure 24). The clearance should
be equal. Adjust the shifter lever and shifter plate
if necessary.
A. Locate a drive lever linkage on one side
of the unit and remove the 5/16-18 x 1
3/4 inch hex cap screw and 5/16-18 inch
nyloc nut (see Figure 22).
B. Thread drive lever linkage into or out of
the swivel located on the wheel drive idler
arm until the flat edge of the drive lever
aligns with bottom of the roller notch
in the neutral lock/park brake latch (see
Figure 22).
C. Re-install the 5/16-18 x 1 3/4 inch hex
cap screw and secure with the 5/16-18
inch nyloc nut. Repeat for the other side
(see Figure 22).
Figure 23
1. Equal distance
2. Shifter Lever
31
3. Shifter Plate
Maintenance
Shifter Detent Adjustment
Transmission shifter detent can be adjusted
by adjusting the setscrew on the back side of
transmission located just behind the neutral start
switch. Turn setscrew in (clockwise) to hold the
transmission shifter more positively in each gear and
to increase the force on the lever required to shift
gears.
Turn setscrew out (counterclockwise) to decrease
force on lever required to shift gears. Factory setting
is to turn setscrew all the way in then back out 1 1/2
turns.
Figure 24
3. Adjustment slot
1. Shifter Lever
2. Equal distance
Important: Screwing setscrew in too far will
prevent the transmission from shifting.
• To adjust the shifter lever:
1. Remove the 3/8 inch nyloc nut and spring
disc washer from the stud on top of the
transmission (See Figure 25).
PTO Safety Switch
Adjustment
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. With the blades disengaged and the bellcrank
touching the engine deck, adjust the blade safety
switch (if needed) until the bellcrank depresses
the plunger by 1/4 inch (.64 cm).
3. Be sure the bellcrank does not contact the switch
body to prevent damage to the switch.
4. Retighten switch mounting hardware.
Figure 25
1. Shifter Lever
2. Square Holed Washer
Handle Height Adjustment
3. Transmission
The handle can be pivoted to allow positioning in
one of the three holes allowing various adjustments
for operator comfort (see Figure 26).
2. Remove the shifter lever and bend it slightly.
Do Not bend the lever while it is attached to
the transmission.
To adjust the handle height:
1. Remove the bottom mounting hardware on each
side of the handle.
3. Re-install lever and torque the 3/8 inch nyloc
nut to 35 ft-lb (47 N-m).
2. Pivot the handle to one of the three positions.
• To adjust shifter plate:
3. Re-install hardware and tighten.
Note: The square-hole washer must be between the
lever and the transmission.
Important: If the handle height position is
changed, it will be necessary to readjust the
drive and brake linkage (see Check Brake and
Wheel Drive Linkage Adjustment section in
Operation.)
Place shifter lever in the neutral position. Loosen the
two bolts securing the shifter plate to the shifter lever
legs. Adjust shifter plate and retighten bolts.
32
Maintenance
Figure 26
1. Upper Handle
2. Upper Hole
3. Adjustment Holes
4. Fuel Tank Support
Figure 27
1. More traction applied as
bolt moves down
2. Position A–Normal
Conditions
3. Position B–More Severe
Note: Adjustment Holes are actually in the side
of the fuel tank support.
Wheel Drive Spring Tension
Adjustment
It may be necessary to increase wheel drive belt
tension under certain operating conditions such as,
wet grass, hilly terrain, or while pulling a sulky.
1. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
2. Disengage neutral lock/park brake latches and
release drive levers to lower spring force.
3. Remove the 5/16-18 inch whizlock nut securing
the adjustment bolt to the drive wheel shield.
Locate bolt assembly in the desired position as
follows:
• Position A-Normal Conditions
• Position B-More Severe
• Position C-Most Severe
Note: Lever force is lowest with bolt assembly
in Position A and will increase in Positions B and
C (see Figure 27).
33
4. Position C–Most Severe
5. Front of Unit
Maintenance
Clean Debris From Machine
Cleaning
Service Interval: Before each use or daily
Clean Engine and Exhaust
System Area
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.
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
conditions.)
Clean Grass Build-Up Under
Deck
CAUTION
Excessive debris around engine cooling air
intake and exhaust system area can cause
engine and exhaust system area to overheat
which can create a fire hazard.
Service Interval: Before each use or daily
1. Disengage PTO.
2. Stop engine and wait for all moving parts to stop.
Engage parking brake. Remove key or spark plug
wire(s).
Clean all debris from engine and exhaust
system area.
3. Raise deck and support unit using jack stands or
equivalent support.
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.
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.
3. Wipe up any excessive grease or oil around the
engine and exhaust system area
Remove Engine Shrouds and
Clean Cooling Fins
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
Service Interval: Every 80 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake. Remove key
or spark plug wire(s).
4. Clean out any grass build-up from underside of
deck and in discharge chute.
2. Remove cooling shrouds from engine and clean
cooling fins. Also clean dust, dirt, and oil from
external surfaces of engine which can cause
improper cooling.
Waste Disposal
Motor Oil Disposal
3. Make sure cooling shrouds are properly
reinstalled. Operating the engine without
cooling shrouds will cause engine damage due to
overheating.
Engine oil is a pollutant to the environment. Dispose
of used oil at a certified recycling center or according
to your state and local regulations.
34
Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused
by an empty fuel tank.
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.
Problem
Engine will not start, starts hard, or fails to
keep running.
Possible Cause
1. Fuel tank is empty.
1. Fill the fuel tank.
2. Fuel shutoff valve is closed.
3. The throttle and choke are not in the
correct position.
2. Open the fuel shutoff valve.
3. Be sure the throttle control is midway
between the “SLOW” and “FAST”
positions, and the choke is in the “ON”
position for a cold engine or the “OFF”
position for a warm engine.
4. Replace the fuel filter.
5. Contact an Authorized Service Dealer.
4. Dirt in fuel filter.
5. Dirt, water, or stale fuel is in the fuel
system.
6. Air cleaner is dirty.
7. Electrical connections are corroded, loose
or faulty.
8.
9.
10.
11.
12.
Relay or switch is defective.
Faulty spark plug.
Spark plug wire is not connected.
PTO is engaged.
Transmission is not in true neutral
position.
13. OPC levers are released.
Engine loses power.
Engine overheats.
Corrective Action
6. Clean or replace the air cleaner element.
7. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
8. Contact an Authorized Service Dealer.
9. Clean, adjust or replace spark plug.
10. Check the spark plug wire connection.
11. Disengage the PTO.
12. Ensure the shifter lever is in the neutral
position.
13. Depress OPC levers.
1. Engine load is excessive.
1. Reduce the ground speed.
2. Air cleaner is dirty.
3. Oil level in the crankcase is low.
4. Cooling fins and air passages for the
engine are plugged.
5. Vent hole in the fuel cap is plugged.
6. Dirt in fuel filter.
7. Dirt, water, or stale fuel is in the fuel
system.
2. Clean or replace the air cleaner element.
3. Add oil to the crankcase.
4. Remove the obstructions from the cooling
fins and air passages.
5. Clean or replace the fuel cap.
6. Replace the fuel filter.
7. Contact an Authorized Service Dealer.
1. Engine load is excessive.
1. Reduce the ground speed.
2. Oil level in the crankcase is low.
2. Add oil to the crankcase.
35
Troubleshooting
Problem
Mower pulls left or right (with levers fully
forward).
Possible Cause
1. Idler arm pulleys and drive sheaves are
dirty.
1. Remove mud and/or grass buildup.
2. Wheel drive belt pulley scrapers
adjustment is not correct
3. Idler pivot arms cannot pivot freely
4. Drive belts are worn.
2. Correct adjustment.
5. Drive linkage adjustment is not correct.
6. Tire pressure in drive tires not correct.
Machine does not drive.
Uneven cutting height.
1. Change the belt.
2. Transmission drive belt is off a pulley.
2. Change the belt.
1. Blade(s) not sharp.
1. Sharpen the blade(s).
2. Cutting blade(s) is/are bent.
3. Mower deck is not level.
2. Install new cutting blade(s).
3. Level mower deck from side-to-side and
front-to-rear.
4. Clean the underside of the mower.
5. Adjust tire pressure in the drive tires.
6. Contact an Authorized Service Dealer.
7. Replace blades, spindles and (or) check
for damage to mower deck.
Underside of mower is dirty.
Tire pressure in drive tires not correct.
Blade spindle bent.
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.
8. Caster mounting brackets are loose.
Blades do not rotate.
Blades do not stop when disengaged.
3. Lubricate ilder pivots.
4. Replace drive belts as a set. (Do Not mix
a new belt with a worn drive belt.)
5. Correct adjustment.
6. Adjust tire pressure in the drive tires.
1. Transmission drive belt is worn, loose or
broken.
4.
5.
6.
7.
Abnormal vibration.
Corrective Action
8. Tighten hardware.
1. Cutting blade(s) is/are bent or unbalanced.
1. Install new cutting blade(s).
2. Blade mounting bolt is loose.
3. Engine mounting bolts are loose.
4. Loose engine pulley, idler pulley, or blade
pulley.
5. Engine pulley is damaged.
6. Blade spindle is bent.
7. Belt is damaged.
2. Tighten the blade mounting bolt.
3. Tighten the engine mounting bolts.
4. Tighten the appropriate pulley.
5. Contact an Authorized Service Dealer.
6. Contact an Authorized Service Dealer.
7. Install new belt.
1. Deck belt is worn, loose or broken.
1. Install new deck belt.
2. Deck belt is off pulley.
2. Install deck pulley and check the idler
pulley, idler arm and spring for correct
position and function.
1. Blade brake is not adjusted properly.
1. Adjust blade brake.
2. Belt guide is not properly set
3. PTO engagement is not properly set.
2. Adjust belt guide to proper position.
3. Check the PTO engagement position.
36
Schematics
Schematics
KEY
SWITCH
OPC
SWITCH
N.O.
TO SAFETY
INTERLOCK
MODULE
GREEN
BLACK
DK BLUE
ORANGE
BROWN
RED
PTO
SWITCH
N.O.
YELLOW
TRANSMISSION
N.C.
AB C D E F
ENGINE GROUND
BLACK
RED
ENGINE KILL
TERMINAL
CONNECTORS ARE VIEWED FROM WIRE END
N.C. = NORMALLY CLOSED
N.O. = NORMALLY OPEN
37
G006816
Exmark Commercial Turf Equipment
2 Year Limited Warranty
If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:
Exmark Customer Service Department
The Exmark Warranty Company
2101 Ashland Avenue
Beatrice, NE 68310
402-223-6375 or
service@exmark.com
Conditions and Products Covered
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty
Company, pursuant to an agreement between them, jointly
warrant on the terms and conditions herein, that we will repair,
replace or adjust any part on these products and found by us
(in the exercise of our reasonable discretion) to be defective in
factory materials or workmanship for a period of two years.
This warranty applies to Exmark commercial turf equipment
sold in the U.S. or Canada. This warranty may only be
assigned or transferred to a second (or third) owner by an
authorized Exmark dealer. The warranty period commences
upon the date of the original retail purchase.
Warranty Exceptions
• Bags, Belts and Tires
• Battery
• Engine
Owner’s Responsibilities
The Exmark turf equipment, including any defective part,
must be returned to an authorized Exmark service dealer
within the warranty period. This warranty extends only to turf
equipment operated under normal conditions. You must read
the operator’s manual. You must also properly service and
maintain your Exmark product as described in the operator’s
manual. Such routine maintenance, whether performed by a
dealer or by you, is at your expense.
Warranty Period
90 days
1 Year Prorated
2 years*
* The Engine warranty is covered by the engine manufacturer.
Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet.
General Conditions
The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair or replacement of
defective components as set forth herein. Neither Exmark
nor Exmark Warranty Company shall be liable for any
incidental or consequential loss or damage.
This warranty only includes the cost of parts and labor.
Items and Conditions Not Covered
This warranty does not cover the following:
• Pickup and delivery charges to and from any authorized
Exmark Service Dealer.
• Any damage or deterioration due to normal use, wear and
tear, or exposure.
• Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune-up parts, and adjustments.
• Any product or part which has been altered or misused or
required replacement or repair due to normal wear,
accidents, or lack of proper maintenance.
• Any repairs necessary due to use of parts, accessories or
supplies, including gasoline, oil or lubricants, incompatible
with the turf equipment or other than as recommended in
the operator's manual or other operational instructions
provided by Exmark.
Such damages include but are not limited to:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other
extraordinary repair charges or charges relating to repairs or
replacements outside of normal business hours at the place
of business of the authorized Exmark Service Dealer.
• Rental of like or similar replacement equipment during the
period of any warranty, repair or replacement work.
• Any telephone or telegram charges or travel charges.
• Loss or damage to person or property other than that
covered by the terms of this warranty.
• Any claims for lost revenue, lost profit or additional cost as
a result of a claim of breach of warranty.
• Attorney's fees.
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.
No Claim of breach of warranty shall be cause for cancellation
or rescission of the contract of sale of any Exmark mower.
All implied warranties of merchantability (that the
product is fit for ordinary use) and fitness for use (that the
product is fit for a particular purpose) are limited to the
duration of the express warranty.
Some states do not allow exclusions of incidental or
consequential damages, or limitations on how long an
implied warranty lasts, so the above exclusions and
limitations may not apply to you.
Instructions for Obtaining Warranty Service
The product must be registered with original proof of purchase
by an Exmark Service Dealer before obtaining any warranty
service.
Contact any Exmark Service Dealer to arrange service at their
dealership. To locate a dealer convenient to you, access our
website at www.exmark.com. U.S. or Canada customers may
also call 402-223-6375.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
G4500-425
38
39
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS
MID-MOUNT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
OPERATOR CONTROLLED DISCHARGE
FULL SUSPENSION SEAT
ROLL OVER PROTECTION SYSTEM (ROPS)
DECK LIFT ASSIST KIT
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
TURF STRIPER
12V POWER PORT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
OUT-FRONT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
SNOW BLADE
DUAL-TAIL WHEEL
SNOWBLOWER
FLOOR PAN EXTENDER
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
WEATHER CAB
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
TURF STRIPER
MICRO-MULCH SYSTEM
STANDON
Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Model No.
Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Serial No.
© 2009 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
All Rights Reserved
Part No. 4500-352 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com
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