!

W A R N IN G

FAILURE TO FOLLOW CAUTIOUS

OPERATING PRACTICES CAN RESULT IN

SERIOUS OPERATOR INJURY.

!

CAUTION

1. Keep all shields, guards and safety devices (especially grass

discharge system) in place and in proper working condition.

2. Stop engine and remove spark plug wire(s) or remove

key before adjusting, servicing, or performing maintenance.

3. When mower deck becomes clogged, stop engine and remove

spark plug wire(s) or remove key before cleaning blockage.

4. Keep hands, feet, and clothing away from power driven parts.

5. Keep off mower unless seat platform is provided.

6. Keep others off mower.

!

WARNING

The engine exhaust from this product contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

!

HEALTH WARNING

GASOLINE

Harmful or fatal if swallowed. Long-term exposure to vapors has caused cancer in laboratory animals.

.

.

.

.

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.

Failure to use caution may cause serious injury or illness.

IMPORTANT

When mower is used or operated on any California forest, brush or grass covered land, a working order spark arrester must be attached to muffler. If not, the operator is violating state law, Section 442 Public Resource Code. To acquire a spark arrester for your unit, see your Engine Service Dealer.

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.

i

EXMARK PARTS PLUS PROGRAM

EFFECTIVE DATE: September 1, 1995

Program

If your Exmark dealer does not have the Exmark part in stock,

Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!!

How the Program Works

1.

If dealer does not have part in stock for a "down" unit at the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark

Parts Plus shipment of six (6) line items or less.

2.

Distributor ships part(s) to dealer or customer, as requested by dealer, same day, overnight UPS

Distributor bills dealer for part and freight charges where applicable.

3.

4.

5.

6.

If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus central time, with an Exmark Parts Plus order of six (6) line items or less.

order, he contacts Exmark by 3:00 p.m.,

If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.

The customer pays for the part and freight if it is shipped under the Exmark Parts Plus accordance to the program.

and if it arrives in

Who pays for the part and freight if it fails to arrive overnight in accordance to the program?

A. Under any circumstance the customer does not pay.

B. If the part does not arrive overnight due to:

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

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

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

order

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

Exmark pays for the part and freight.

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

The following restrictions apply -- The Exmark Parts Plus Program is available only through participating Exmark

Dealers and applies only to orders submitted on this program Monday through Thursday. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on

Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts

Plus orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less.

Exclusions from the Exmark Parts Plus Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.

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

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

ii

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.

OPERATOR'S MANUAL

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

BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS

ENTIRETY.

By following the operating, maintenance and safety instructions, you will prolong the life of your mower, maintain its maximum efficiency and promote safe operation.

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

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.

iii

TABLE OF CONTENTS

1. SAFETY PAGE

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

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

1.3 Preparation .....................................1-2

1.4 Operation .......................................2-3

1.5 Maintenance & Storage .............................4

1.6 Riding Attachments ................................4

1.7 Safety Signs ....................................4-6

2. SPECIFICATIONS

2.1 Model Numbers .....................................6

2.2 Engine ............................................6

2.3 Fuel System .......................................6

2.4 Safety Interlock System ...........................7

2.5 Steering/Brake Control ............................7

2.6 Transmission ......................................7

2.7 Wheel Drive System ................................7

2.8 Tires .............................................7

2.9 Deck ............................................7-8

2.10 Dimensions ........................................8

2.11 Bolt Torque Requirements ..........................8

3. ASSEMBLY INSTRUCTIONS

3.1 to 3.12 Assembly ................................8-15

4. OPERATION INSTRUCTIONS

4.1 Controls ......................................15-17

4.2 Pre-Start .....................................17-18

4.3 Operating Instructions ........................18-19

4.4 Transporting .....................................20

5. MAINTENANCE & ADJUSTMENTS

5.1 Periodic Maintenance ..........................20-26

5.2 Adjustments ...................................26-31

6.

TROUBLE SHOOTING

6.1 Mower Tracks Left or Right .......................32

6.2 Mower Cuts Unevenly ..............................32

6.3 Blades Do Not Stop ...............................32

6.4 Engine Will Not Start .........................32-33

7.

BELT ROUTING (MOWER DECKS)

.........................33

8.

WIRING DIAGRAMS

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

9

.

WARRANTY

..........................................35-36 iv

1.

SAFETY

1.1 SAFETY ALERT SYMBOL

THIS SAFETY ALERT SYMBOL IS USED BOTH IN THIS MANUAL AND ON

THE MACHINE TO IDENTIFY IMPORTANT SAFETY MESSAGES WHICH MUST BE

FOLLOWED TO AVOID ACCIDENTS. THIS SYMBOL MEANS:

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

The safety alert symbol appears above information which alerts you of unsafe actions or situations and will be followed by the word DANGER, WARNING, or CAUTION.

When used with the word DANGER: IT DENOTES THAT AN EXTREME HAZARD

EXISTS WHICH WOULD RESULT IN HIGH PROBABILITY OF DEATH OR

IRREPARABLE INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.

When used with the word WARNING: IT DENOTES THAT A HAZARD EXISTS WHICH

CAN RESULT IN INJURY OR DEATH IF PROPER PRECAUTIONS ARE NOT TAKEN.

When used with the word CAUTION: IT DENOTES A REMINDER OF SAFETY

PRACTICES OR DIRECTS ATTENTION TO UNSAFE PRACTICES WHICH COULD

RESULT IN PERSONAL INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.

1.2 TRAINING

1.2.1

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

1.2.2

Read the instructions carefully. Familiarize yourself with the controls and the proper use of the equipment.

1.2.3

Never allow children, teenagers, or people unfamiliar with these instructions to use the mower.

1.2.4

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

1.3 PREPARATION

1.3.1

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

1.3.2

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

1.3.3

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

- 1 -

••••

•••• Store fuel in containers specifically designed for this purpose.

••••

Fuel is Highly Flammable. DO NOT smoke while refueling. Refuel only in a well ventilated area, or refuel outdoors.

••••

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.

Never fill the fuel tank so that the fuel level rises above a level that is 1/2” below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage.

•••• If fuel is spilled, DO NOT attempt to start the engine. Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated.

1.4 OPERATION

1.4.1

Give complete, undivided attention to the job at hand.

1.4.2

Mow only in daylight or in good artificial light. DO NOT operate the mower when children or others are in the area.

1.4.3

When feasible, avoid operating the equipment in wet grass.

1.4.4

Use EXTREME caution when mowing and/or turning on slopes as loss of traction and/or control could occur. Mow across slopes with walk behind mowers, never up and down. 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 and sustaining serious injury. Drive slower on slopes. DO NOT operate on slopes greater than 20 degrees. Watch for ditches, holes, rocks, dips, and rises which can cause erratic handlebar movement and loss of footing. Keep away from dropoffs and steep banks. Avoid sudden starts. Look down and behind you before and while moving backwards. DO NOT mow slopes when grass is wet - slippery conditions create hazardous footing, affect steering, and reduce traction and braking. The operator is responsible for safe operation on slopes. See inside back cover to determine the approximate slope angle of the area to be mowed.

1.4.5

Stop the blades when crossing surfaces other than grass, if mower must be tilted for transportation, and when transporting the mower to and from the area to be mowed.

1.4.6

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

1.4.7

Do Not change the engine governor settings or overspeed the engine. Operating an engine at excessive speed may increase the hazard of personal injury.

1.4.8

Place transmission in neutral, disengage blades, and latch drive levers in “park brake” position before starting engine.

- 2 -

1.4.9

Start the engine carefully with feet well away from the blades.

1.4.10 Keep hands, feet and clothing away from rotating parts while the mower is being operated.

1.4.11 Stop the engine and disconnect the spark plug wire(s)and/ or remove key: a) Before checking, cleaning or working on the mower.

b) After striking a foreign object (inspect the mower for

damage and make repairs before restarting and

operating the mower).

1.4.12 Stop the engine: a) Before clearing blockages.

b) Before removing the grass catcher.

c) Whenever you leave the mower.

d) Before refueling.

e) Before making height adjustments.

1.4.13 Before stopping the engine, return the throttle control to the idle position for 30 seconds to allow the engine to cool down.

1.4.14 The fuel system is provided with a shut-off valve. The fuel shut-off valve is used to shut off the fuel when: a) The machine will not be used for a few days b) During transport to and from the job c) When parking inside a building

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

1.4.16 Do Not mow without the grass deflector or entire grass collection system in place and in proper working condition.

•••• DO NOT operate the engine in a small confined area where dangerous carbon monoxide fumes can collect.

•••• Failure to follow safety instructions and cautious operating practices can result in serious injury.

•••• Although hazard control and accident prevention partially are dependent upon the design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence and proper training of the personnel involved in the operation, transport, maintenance and storage of the equipment. It is essential that all

Operator Safety Mechanisms be connected and in operating condition prior to use for mowing.

- 3 -

1.5 MAINTENANCE AND STORAGE

1.5.1

For engine maintenance, follow the engine manufacturer's recommendations precisely as stated in the engine manual.

1.5.2 If carburetor adjustment is necessary, stand to one side and keep feet and hands clear while making adjustments.

1.5.3

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.

1.5.4

Store fuel in a container specifically designed for this purpose. Store the fuel container in a cool, dry place.

1.5.5

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

1.5.6

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

1.5.7

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

1.5.8. Check all bolts often to maintain proper tightness.

1.5.9. Keep all guards, shields and all safety devices in place and in safe working condition.

1.5.10 Frequently check for worn or damaged components that could create a hazard.

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

1.6 RIDING ATTACHMENTS

Use only Exmark riding attachments. The use of other than

Exmark riding attachments may create a hazardous condition resulting in injury.

1.7 SAFETY SIGNS

1.7.1

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

1.7.2

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

1.7.3

When new components are installed, be sure that current safety signs are affixed to the replaced components.

1.7.4

New safety signs may be obtained from your authorized

Exmark equipment dealer or distributor or from Exmark

Mfg. Co. Inc.

1.7.5

Safety signs can 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.

1.7.6

Familiarize yourself with the following safety signs and instruction labels. They are critical to the safe operation of your Exmark commercial mower.

- 4 -

PART NO. 323688

LOCATION: Console

PART NO. 403005

LOCATION: Front Corners of Deck

PART NO. 323550

LOCATION: Upper Handles

(Both Sides)

PART NO. 303508

LOCATION: Right Rear Corner of Deck

PART NO. 303517

LOCATION: Left Side, Rear Surface

Engine Deck

KAWASAKI,KOHLER & 10.5 HP B&S

PART NO. 323689

LOCATION: RH Side of Console

- 5 -

8.5 HP B&S

PART NO. 543631

LOCATION: Upper Handle

Console

PART NO. 403162

LOCATION: 48” Decks

PART NO. 323427

LOCATION: 32” & 36” Decks

PART NO. 303293

LOCATION: Top Right Side

Fuel Tank

PART NO. 403143

LOCATION: Right Rear of Engine Deck

PART NO. 303518

LOCATION: Transmission Shifter Plate

PART NO. 513746

LOCATION: Engine Blower

Housing Next to Muffler

2. SPECIFICATIONS

2.1 MODEL NUMBER:

Serial No.s 150,000 and Higher

M3213KA; M3613KA; M3613KC;

M3614KA; M3615KC; M4814KA;

M4815KC.

Serial No.s 150,000 –189,999

M329B; M3213KC

Serial No.s 190,000 and Higher

M3211B

2.2 ENGINE

2.2.1

Engine Specifications: See your engine owner's manual.

2.2.2 RPM (No Load): 3600 rpm

2.3 FUEL SYSTEM

2.3.1

Capacity: 5 gal. (18.9 liter)

2.3.2

Type of Fuel: Use only clean, fresh, regular grade, unleaded gasoline with the pump sticker octane rating of

87 or higher. In countries using the research method, it should be 90 octane minimum.

- 6 -

2.3.3

Fuel Filter: Replaceable in-line

2.3.4

Fuel Shut Off Valve: in-line, 1/4 turn

2.4 SAFETY INTERLOCK SYSTEM

Operator must have the transmission in neutral and blades disengaged to start engine. Release of Operator Presence

Control (OPC) levers will cause engine to stop if transmission

is not in neutral and/or blade drive is engaged.

2.5 STEERING/BRAKE CONTROL

Fingertip drive control levers provide independent control of traction, braking and neutral to each drive wheel for moving, stopping & power turning. Parking brakes are engaged by locking drive control levers in the “brake” position.

2.6 TRANSMISSION

2.6.1

Peerless 700-061, five speeds forward and one reverse.

2.6.2

Speed range:

1st 2.0 mph (3.22 km/h) 4th 4.1 mph (6.60 km/h)

2nd 2.7 mph (4.35 km/h) 5th 6.2 mph (9.98 km/h)

3rd 3.5 mph (5.63 km/h) Rev 3.1 mph (4.99 km/h)

2.7 WHEEL DRIVE SYSTEM

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" Model)

2.8 TIRES

Drive Front Caster

Size........ 13 x 6.50 - 6 ...........9 x 3.50 - 4

(32" Model) . 13 x 5.00 - 6 ...........9 x 3.50 - 4

Quantity...........2 ...................... 2

Tread.......... Turf Saver/Turf Master ..... Smooth

Ply................4 ...................... 4

Pressure.... 14 psi (97 kPa).......... 22 psi (152 kPa)

Bearings.... Replaceable Ball ........ Replaceable Roller

2.9 DECK

2.9.1

Cutting Width:

Model 32 ......31.75 in. (80.7 cm)

Model 36 ......35.38 in. (89.9 cm)

Model 48 ......47.63 in. (120.98 cm) S/N 150,000 - 159,999

Model 48 ......47.25 in. (120.0 cm) S/N 160,000 & higher

2.9.2

Discharge: Right Side

2.9.3

Blade Size:

Model 32 ......16.25 (41.3 cm) - Qty. 2

Model 36 ......18.00 (45.7 cm) - Qty. 2

Model 48 ......16.25 (41.3 cm) - Qty. 3

2.9.4

Type of Drive: Manual engagement of belt with overcenter lock. Blade belt tension is adjustable via turnbuckle. The 48 in. units have an additional belt which is also adjustable.

2.9.5

Deck Mounting: Bolted directly to engine deck

- 7 -

2.9.6

Cutting Height: Adjusts in 1/4" (.63 cm) or smaller increments by various adjustments of caster spacers, blade spacers and axle height, from 1” to 4 1/4”

(2.5 cm - 10.8 cm).

2.10 DIMENSIONS

2.10.1 Overall Width:

Discharge chute down

32" 36"

42.45 in.

46.1 in.

107.8 cm 117.1 cm

Up

(transport only)

32.75 in.

36.4 in.

83.2 cm 92.5 cm.

Overall Length

32" 36"

78 in.

78 in.

198.1 cm 198.1 cm

48"

♦ 48”◊◊◊◊

58.1 in.

147.6 cm

58.2 in.

148.0 cm

48.4 in.

122.9 cm

48.1 in.

122.2 cm

48"

♦

74.7 in.

189.7 cm

48”

◊◊◊◊

73.0 in.

185.4 cm

Overall Height 40.0 in.

40.0 in.

40.0 in.

101.6 cm 101.6 cm.

101.6 cm

40.0 in.

101.6 cm

Tread Width

∗∗∗∗ 32.05 in.

35.6 in.

81.4 cm 90.4 cm

35.6 in.

90.4 cm

35.6 in.

90.4 cm

Curb Weight

∗∗∗∗∗∗∗∗ 374 lbs

170 kg

391 lbs

177 kg

431 lbs

196 kg

439 lbs

199 kg

∗∗∗∗

∗∗∗∗∗∗∗∗

To outside of tires.

Weights will vary slightly depending on engine option.

♦

◊◊◊◊ For Serial No.s 160,000 and higher.

2.11 TORQUE REQUIREMENTS

BOLT LOCATION TORQUE

Blade/Cutter Housing Spindle Bolt ........ 75-80 ft-lbs.

Caster Bracket Mounts .................... 30-35 ft-lbs.

Cutter Deck/Engine Deck Mount ............ 30-35 ft-lbs.

Engine Mounting Bolts

Briggs & Stratton ................. 15-20 ft-lbs.

Kohler & Kawasaki ................. 25-30 ft-lbs.

Transmission Shifter Lever ............... 30-35 ft-lbs.

3. ASSEMBLY INSTRUCTIONS

3.1

Uncrate unit, leaving it on the pallet, place upper handle assembly, fuel tank, and shifter lever at the rear of the machine. Place casters at the front of the unit.

3.2

Place a length of 4" x 4" block between the front of the cutter deck and the pallet.

3.3

Remove the bolt bag from the top of the fuel tank support.

3.4

Refer to Parts Manual to help you identify and locate parts and their proper position.

- 8 -

3.5

Install casters to front of deck using appropriate hardware from the bolt bag (eight 3/8 x 3/4" bolts and eight 3/8" whizlock nuts); tightening the lower four bolts first, then the top four.

3.6

Loosen the 5/16" hardware at the two (2) discharge deflector hinge points so that the deflector is snug, but can be moved up and down freely.

3.7

Mount the fuel tank on the tank support.

Apply retaining adhesive Fel-Pro Pro-Lock ‘Retaining Type I or

Retaining II’ or Loctite RC 609 or 680 on the two threaded studs from the bolt bag and install into the two left holes underneath fuel tank. Install the fuel tank on top of the fuel tank support with the studs going through the slots in the support. Install two 5/16 x 3/4 screws with a 5/16” flatwasher and 5/16” lockwasher into the threaded holes in the right side of the fuel tank. Do not over tighten. Place a 5/16” flatwasher, then a spring, and a 5/16 nyloc nut over each of the studs. Completely tighten nyloc nut then back off a 1/2 turn. This will allow for normal fuel expansion and contraction with changes in temperature and fuel levels.

Do not over tighten.

3.8

Install Handle Assembly

Position the lower end of the handle assembly on the outside of the upper rear section of the fuel tank & handle support. Install one 3/8-16 x 1" bolt (from the outside in) in the upper hole on each side of the handle.

Loosely secure each screw with a 3/8" nyloc nut. The handle can now be pivoted to allow positioning in one of the three holes allowing various adjustments for operator comfort (See Figures 1 & 2). Once a proper position is found, install one 3/8 x 1" bolt in the bottom mounting holes on each side of the handle.

Secure each bolt with a 3/8" nyloc nut. Tighten all hardware.

FIG. 1

UPPER HANDLE MOUNTING

IMPORTANT: If the mower has been completely assembled and the handle position is changed, it will be necessary to readjust the drive and brake linkage.

- 9 -

FIG. 2

UPPER HANDLE

HEIGHT ADJUSTMENT

3.8.1 Attach throttle cable to engine.

For Kohler, Kawasaki, and B&S 10.5 hp Engines with "positive" detents in throttle cable for both idle and full throttle positions.

a) Position the throttle control lever (on console) in the full throttle (but not choke) position. You will feel a detent when the throttle control lever is approximately 3/4" from the upper end of the slot -- this is the full throttle position.

b)Route the throttle cable along the right side of the upper handle, under the fuel tank support and to the left side of the engine.

c)Loosen clamp on engine control plate. (See Figures

3, 4 and 5). Attach inner wire of the throttle cable to the control plate lever and position cable under clamp, do not tighten clamp.

FIG 3

KOHLER SPEED CONTROL

(THROTTLE CABLE HOOK-UP)

- 10 -

FIG 4

KAWASAKI SPEED CONTROL

(THROTTLE CABLE HOOK-UP)

FIG 5

B&S 10.5 hp SPEED CONTROL

(THROTTLE CABLE HOOK-UP) d) Pull cable upward (rearward for B&S) until alignment holes in control plate lever and control plate line up.

For Kawasaki a 15/64 drill bit can be inserted through these two holes to align them. For Kohler use a 19/64 drill bit. For B&S 10.5 hp use a 1/8” drill bit. Once holes are aligned, tighten clamp onto throttle cable.

e) Check that the choke adjusting screw just comes in contact with the choke lever when throttle control is in the full throttle position. (B&S 10.5 hp does not have a choke adjusting screw.) Choke link should not move when throttle control is moved to the full throttle position. Be sure choke is fully closed when throttle lever is moved fully forward to the

"CHOKE" position.

f) This step needs to be done after the unit has been assembled and the engine has been started. Refer to Section 4 (Operation Instructions). Check the engine "STOP" position by moving throttle control fully to the rear. (Note: There is a detent toward the lower end of the slot in the console for "IDLE"

"STOP" position is rearward from this detent). For

Kohler, if engine continues to run in the "STOP" position, turn kill switch adjusting screw inward until engine stops, then give it an additional 1/2 to 3/4 turn to assure it will always function properly.

(Kawasaki and B&S 10.5 hp kill switchs are not adjustable).

- 11 -

For B&S 8.5 hp Engines, a) Position the throttle control lever (on console)

1/8" from the lower end of the slot. Route the throttle cable along the right side of the upper handle, under the fuel tank support, and position the cable on the left side of the engine.

b) Attach the inner wire to the appropriate throttle control slider on the engine. Loosen the cable clamp on the engine, place the cable behind it and push ahead on the cable to move the throttle linkage to the "stop" position. Tighten the cable clamp screw.

3.8.2

Attach the fuel tank hose to the tank fitting and secure with the clamp provided.

3.8.3

Install the blade engagement linkage to the bell crank on the Left Hand side of the engine deck. Insert rod through the hole from the outside and fasten with cotter hairpin.

3.8.4

Install and adjust shifter lever.

a) Remove the 3/8" nyloc nut and spring disc washer from the stud on top of the transmission. Install the shifter lever through slot in shifter lever plate and onto the stud on top of transmission. Be sure the square-hole washer remains between the lever and transmission. Replace the spring disc washer and nyloc nut (See Figure 6). Torque the 3/8" nut to

35 ft. lbs. (47 N

⋅m).

b) Shift lever to second gear and check alignment of lever in slot of shifter plate. Clearance between top of lever and the top of the slot should be about equal to the clearance between bottom of the lever and the bottom of the slot (See Figure 7).

If it is not, remove lever and bend it slightly to adjust. DO NOT bend lever while it is attached to transmission. Reinstall lever and tighten hardware.

c) Shift to neutral position. Lever should not contact the left edge of the upper slot. Push lever down. Lever should not contact the right edge of the bottom slot

(See Figure 8). Shifter plate can be adjusted

S ide to

side to adjust position of lever relative to the slot in plate. Loosen the two bolts securing the shifter plate to the shifter lever legs. Adjust shifter plate and retighten bolts.

- 12 -

FIG. 7

THIS CLEARANCE SHOULD BE EQUAL

FIG. 6

SHIFTER LEVER

TO TRANSMISSION

FIG. 8

THIS CLEARANCE SHOULD BE EQUAL

3.8.5 Install and adjust wheel drive linkages.

a) Screw threaded end of drive linkages into swivels in wheel drive idler arms.

b)

Insert clevis pin from bolt bag through drive linkage, lever and slot in the neutral lock/park brake latches (See

Figure 9). Make proper adjustments before adding hairpins.

Neutral Lock/Park Brake Latch

Clevis Pin

Drive Linkage

Drive Lever

FIG. 9

LEVER AND ROD

ADJUSTMENT c) Adjust drive linkage length by threading into or out of the swivel until there is a 3/16" to 1/4" clearance between the linkage assembly and the bottom of the slot in the neutral lock/park brake latch (See Figure 10).

- 13 -

3/16” TO 1/4”

Neutral Lock /

Park Brake Latch

Drive Linkage

FIG. 10

NEUTRAL LOCK

LEVER CLEARANCE

NOTE: Neutral lock/park brake latch clearance should be checked when there is a slight upward force placed on the drive levers to remove any "slack" in the linkage.

After clevis pin has been inserted, install hairpin into hole on the clevis pin between the neutral lock/park brake latch and drive lever (See Figure 11). Repeat procedure on

opposite side of unit.

Drive Linkage

Clevis Pin

Drive

Lever

Left Side

Shown

Hairpin

Neutral Lock /

Park Brake Latch

FIG. 11

Drive Lever Hardware Location

3.8.6

Adjust brakes by adjusting wingnut on the upper end of each brake rod. Position the wingnut so the brakes will engage when the drive levers are squeezed enough to place the neutral lock/park brake latches into the “park brake” position.

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.

3.8.7

Squeeze the drive levers and move both neutral lock/park brake latches to the rear into the neutral lock position. Mower should move forward and backward freely, if not, readjust the brakes.

Squeeze the drive levers and move the neutral lock/park brake latches to the front into the park brake position. Mower should not move forward and backward freely, if it does, readjust the brakes.

- 14 -

3.8.8

Route the long, unattached wiring harness lead up the left hand side of the handle and connect the two leads, in any order, to the operator presence control switch terminals on the inside of the control console. Fasten the lead to the handle with two large wire ties, from bolt bag, one at the upper end of the handle next to the console and one at the very lower end of the handle where it attaches to the fuel tank support.

3.9 If the unit is shipped without the muffler attached, install with hardware provided.

3.10 Service Engine: Follow the recommendations in the Engine

Operators Manual.

3.11 Grease unit.

NOTE: UNIT IS NOT GREASED AT THE FACTORY! Refer to Section

5.1.12 for locations and grease amounts.

3.12 Follow pre-start instructions as outlined in Section 4.2.

4. OPERATION INSTRUCTIONS

4.1 CONTROLS

4.1.1

Familiarize yourself with the controls and operation of the unit.

Carefully read the following information about the controls and their operation.

4.1.2

Drive Levers:

Located on each side of the upper handle assembly directly below the handle grips. These levers individually control clutching action of the wheel drive belts and brakes. When the drive levers are all the way down, the wheel drive belts engage and the brakes disengage. Squeezing the left or right hand drive lever causes the left hand or right hand wheel to slow down or stop, which makes the machine turn to the left or right respectively. The sharpness of the turn varies by how much the lever is squeezed. If both levers are squeezed all the way back, both brakes will engage and the machine will stop. For straight ahead motion, smoothly release both drive levers to engage both drive wheels simultaneously.

4.1.3

Neutral Lock/Parking Brake Latches:

Located directly above the drive levers. The purpose of these latches is to 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. To lock the drive levers in neutral, squeeze the drive levers back, place thumbs on the upper portion of the neutral lock/park brake latches and move them to the rear. Release drive levers. To lock the drive levers in “park brake” position, squeeze the drive levers back, place thumbs on the upper portion of the neutral lock/park brake latches and move them ahead. Release drive levers as stated in 4.1.2. (See Figure 12).

Apply parking brakes whenever leaving the operators position.

- 15 -

Rotate Forward for

Park Brake Position

Rotate Back for

Neutral Lock Position

Park

Brake

Latch is in the drive position

Full Speed

Forward

Neutral

Lock

NEUTRAL - Hold in this position

FORWARD - Release Drive Lever

REVERSE - Squeeze Drive Lever

FIG. 12

DRIVE LEVER, NEUTRAL LOCK/PARK BRAKE LATCH OPERATION

4.1.4

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 blade clutch is engaged.

4.1.5

Blade Engagement Lever:

Located on the left side of the upper handle. To engage the blades, push the lever forward, or away from the operator, until the turnbuckle locks over-center. To disengage the blades, pull the lever to the rear, or towards the operator, until the bell crank, located at the rear of the engine deck, contacts the deck.

4.1.6

Throttle-Choke Control:

Kawasaki,Kohler, and B&S 10.5 hp Engines:

The throttle-choke control lever is located on the control console right side. Choke aids in starting a cold engine. The choke control is a part of the throttle control and activates by moving the throttle control lever to the full forward position. You will notice a detent at the "full throttle" position (approximately 3/4" from top of slot) continue pushing forward into the "choke" position.

Once the engine has started, move the throttle control lever to the midway point and allow the engine to warm-up before going to full throttle.

All Kawasaki, Kohler, and B&S 10.5 hp engines are equipped with "throttle kill" as a standard feature. Moving the throttle control lever to the full rear position will kill the engine. You will notice the control lever will fall into

- 16 -

a detent at the "idle" position, continuing rearward past this detent will shut off the engine

.

B&S 8.5 hp Engines:

For the B&S 8.5 hp engine the choke control is located on the left side of the engine (from operator's position). Pull the choke lever outward and to the rear (counter-clockwise from top).

Once the engine has started, move the choke control to the off position and move the throttle control to about medium throttle position to allow engine to warm-up before going to full throttle.

To stop the engine, move the throttle control lever to the full rearward position.

4.1.7

Transmission Shift Lever:

Located under the control console and behind the fuel tank. 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.

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.

4.1.8

Fuel Shut-Off Valve:

Installed on the fuel line midway between the fuel tank and the engine. The fuel shut off valve shuts off the flow of fuel when the machine will not be used for a few days, when parking inside a building, and during transport to and from the job.

Rotate the valve 1/4 turn clockwise to shut off fuel. Rotate

the valve 1/4 turn counter-clockwise to turn on fuel.

4.2 PRE-START

4.2.1

Refer to the Maintenance Section 5.1 and perform all of the necessary inspection and maintenance steps.

••••

••••

Fuel is highly flammable. Add fuel before starting the engine. Refuel outdoors or in a well ventilated area.

DO NOT smoke when refueling or operating the equipment. Never remove the cap of the gas tank while engine is hot or when engine is running.

4.2.2

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 add oil to gasoline.

Do not overfill fuel tank. Never fill the fuel tank so that the fuel level rises above a level that is ½” below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage.

- 17 -

•••• If fuel is spilled, DO NOT attempt to start the engine.

Move away from the spill and avoid creating any source of ignition until fuel vapors have dissipated.

4.3 OPERATING INSTRUCTIONS

4.3.1

Read the Engine Owner's Manual carefully for detailed operating instructions and maintenance regarding the engine.

Before attempting to operate the unit, refer to Section 1

(Safety) and follow all safety, operating, and preparation guidelines as stated in that section.

4.3.2

Starting Engine

Position mower on a level surface. Disengage blade drive and place transmission in neutral.

Open fuel shut-off valve.

NOTE: Always engage the left and right neutral lock/park brake

latches in the “park brake” position when starting the

engine (See Section 4.1.3).

•••• DO NOT operate the engine in a confined area where exhaust fumes can collect.

Carbon monoxide present in the exhaust is an odorless and deadly gas. Provide proper ventilation.

With a cold engine (Kawasaki, Kohler, and B&S 10.5 hp) place the throttle in the full "choke" position. With a warm engine, place the throttle midway between the "slow" and "fast" position.

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

Pull recoil rope to start engine. After engine starts, move throttle control out of the choke position.

For the B&S 8.5 hp (cold engine) place throttle in full forward position and move the choke control, on the left side of engine, fully to engaged position. Pull the recoil rope to start the engine. After engine starts, move choke control to the disengaged position.

When engine is warm do not engage the choke control.

4.3.3

Stopping Engine:

Disengage blade drive, shift transmission to neutral and lock the drive levers in “park brake” position. Move throttle to "slow" position.

Allow engine to idle for 30 seconds to allow cool down then:

Move throttle to full rear position to stop the engine.

- 18 -

Close fuel shut-off valve if machine will not be

used for a few days; when parking inside a building;

or when transporting the unit.

4.3.4

Drive Lever/Neutral Lock/Park Brake Latch Operation:

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 drive levers (See Figure 12).

To lock the levers in “park brake”, squeeze the drive levers back to the brake position. Place thumbs on the upperportion of the neutral lock/park brake latches and move them to the front. Release drive levers (See Figure 12).

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.

4.3.5

Drive Wheel Engagement and Turning:

With drive levers in the “park brake” position, shift transmission into desired gear. Squeeze both drive levers and move both neutral lock/park brake latches from the “park brake” position.For straight ahead motion, smoothly release both drive levers to engage drive wheels.

Squeeze right hand drive lever to turn right and left hand drive lever to turn left (See Section 4.1.2).

4.3.6

To Stop:

Squeeze drive levers all the way back to engage brakes.

Move neutral lock/park brake latches into the the “park brake” position and shift transmission into neutral.

4.3.7

Blade Engagement:

•••• DO NOT put hands or feet under the mower or mower deck when blades are engaged.

Be sure that all persons are clear of mower deck and discharge area before engaging the blades. Set throttle to "midway" (half throttle) position. Push the blade engagement lever forward to engage blades. Accelerate to full throttle to begin mowing. (See Section 4.1.5).

4.3.8

Blade Disengagement

Pull the blade engagement lever to the full rearward position to disengage the blades (See Section 4.1.5)

4.3.9

Changing Gears

When changing gears, always squeeze drive levers and/or engage neutral lock latches or “park brakes”. The shift lever may be moved with a knee or by hand.

NOTE: Reverse gear is reverse assist only, the operator must pull the unit backwards.

- 19 -

4.4 TRANSPORTING

••••

••••

If loading with ramps, be sure ramps are properly supported and strong enough to support the unit.

If necessary, use assistance when loading or unloading. Keep feet and legs out from under the unit when loading and unloading

Be sure fuel shut-off valve is closed.

Use a heavy duty trailer to transport the machine. Engage

the park brakes and block wheels. After the wheels have been properly blocked, securely fasten the machine to the trailer with straps, chains, cables or ropes. Be sure that the trailer has all necessary lighting and marking as required by law and use a safety chain.

NOTE: When transporting machine, be sure to engage the park brakes.

Failure to do so can result in damage and/or premature wear

to drive train.

Do not rely solely on the parking brake to hold machine on

trailer.

5. MAINTENANCE AND ADJUSTMENTS

5.1 PERIODIC MAINTENANCE

•••• Disengage blade clutch, shut off engine and remove spark plug wire(s) before any adjusting, servicing, or cleaning

•••• The engine can become very hot. Always allow the engine to cool before servicing or making repairs around the engine area.

5.1.1

Check engine oil level.

Service Interval: See Engine Owner's Manual a) Make sure engine is stopped and on a level surface.

b) Check with engine cold.

c) Clean area around dipstick. Remove dip stick and wipe off oil. Reinsert the dipstick and:

Screw dipstick into place for the B&S engines.

Do not screw into place for Kawasaki or Kohler engines.

Remove dipstick and check oil level.

d) If the oil level is low, add oil as specified in the engine owners manual to bring the oil level up to the

"F" mark on the dipstick. DO NOT OVERFILL.

IMPORTANT: Do Not operate the engine with oil level below the "L" mark on the dipstick or over the "F" mark.

- 20 -

5.1.2

Clean engine air cooling system.

Service Interval: See Engine Owner's Manual a) Stop engine and remove spark plug wire(s).

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

5.1.3

Clean grass build-up under deck and check mower blades.

Service Interval: Daily

•••• When it is necessary to raise the deck or the mower, DO NOT rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

a) Disengage blades.

b) Stop engine and remove spark plug wire(s).

c) Raise deck, support properly using safety precautions.

d) Clean out any grass build-up from underside of deck and in deck discharge chute.

e)

Inspect blades and sharpen or replace as required.

f)

If blade removal is necessary, be careful for the sharp cutting edges of the blades.

g)

Re-install the blades (if they were removed) and torque blade bolts to 75-80 ft/lbs. Be sure the spring disc washer cone is installed toward the bolt head (See Figure

13).

h)

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

FIG. 13

BLADE BOLT INSTALLATION

5.1.4

Check safety interlock system.

Service Interval: Daily a) For your safety, your Exmark mower is equipped with

Operator Presence Controls, referred to as (OPC). When

- 21 -

either the mower blades are engaged, or the transmission shifter lever is not in neutral and the operator removes both hands from the handles, the mower engine must stop.

b) 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, shift the transmission into gear and release the OPC levers - the

engine MUST stop.

Again, run the engine at one-third throttle, move the

transmission shifter lever to neutral, engage the blade

clutch and release the OPC levers - the engine MUST stop.

If the mower engine does not stop under any of the above mentioned conditions, DO NOT OPERATE. Contact your authorized Exmark service dealer.

•••• It is essential that all Operator Safety

Mechanisms, be in place and in proper operating condition prior to mowing.

5.1.5

Check Brake and Wheel Drive Linkage Adjustment.

Service Interval: Daily

Refer to Sections 3.8.5 and 3.8.6. Note any bent linkage or hardware which may need servicing or replacing.

5.1.6

Check for loose hardware.

Service Interval: Daily a) Stop engine and remove spark plug wire(s).

b) Visually inspect machine for any loose hardware or any other possible problem. Tighten or replace any hardware before operating.

5.1.7

Service pre-cleaner element and air cleaner.

Service Interval: See Engine Owners Manual a) Stop engine and remove spark plug wire(s).

b) See engine owners manual for cleaning instructions.

5.1.8

Change engine oil.

Service Interval: See Engine Owner's Manual

NOTE: Change oil after first five (5) hrs. of operation. Follow engine manufacturer's recommendations for future oil changes.

a) Disengage blades.

b) Stop engine and remove spark plug wires(s).

c) Drain oil while engine is warm from operation or if oil is to be changed after the unit has been sitting for awhile, run engine for a few minutes to get it warm.

•••• Do Not service or make repairs near the engine area when the engine is hot.

d) Remove the oil drain plug from the right hand side of the engine. Allow oil to drain, replace drain plug.

e) Replace the oil filter per the engine owners manual

(Kohler and Kawasaki only, there is no filter on B&S

- 22 -

engines). 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.

f) Clean around oil fill cap and remove. Fill to specified capacity and replace cap. Refer to Engine Owner's

Manual for correct oil level and the SAE Grade recommended by the manufacturer.

Do Not overfill.

g) Start the engine and check for leaks. Stop engine and recheck oil levels.

5.1.9

Check tire pressures.

Service Interval: 40 hrs.

a)

Stop engine and remove spark plug wire(s). Check air pressure in tires; recommended tire pressure is: rear,

12 to 16 psi; pneumatic casters, 22 psi.

b) Inflate tires to pressures stated above. Measure circumference of each drive tire. Adjust tire pressures within the above range to try to make tire circumferences match as closely as possible.

Note: Front caster tires have permanent tire sealant installed.

5.1.10 Check grease level, input and output shaft bearing wear on Peerless Transmission. (Replace gearbox grease yearly)

Service Interval: 160 hrs.

a)

Stop engine and remove spark plug wire(s).

b) Place drive levers and neutral lock/park brake latches in the neutral lock position.

c) Remove shifter lever from top of transmission.

d) Remove shifter plate from top of transmission and the two leads from the neutral start switch.

e) Release the tension on the transmission belt.

f) Check for side play caused by bearing wear on the input and output shafts of the transmission. Replace bearings if necessary.

g) Remove the six bolts that fasten the upper case to the lower case and carefully remove the upper case half.

h) Check the grease level in the lower case. The grease level should be approximately 1-1/2" to 1-3/4" from the gearbox bottom. If necessary, fill to proper level with Peerless grease (Part No. 788067).

I) Reinstall upper case half and fasten in place with six bolts previously removed.

j) Reinstall all parts removed in Steps c and d. Install drive belt and adjust tension as stated in Section 5.2.3.

- 23 -

5.1.11 Inspect belt wear.

Service Interval: 40 hrs. a) Stop engine and remove spark plug wire(s).

b) Remove the cutter deck belt shield to check mower primary and secondary blade drive belt condition.

NOTE: A Secondary blade drive belt is used on 48" units.

c) Look under engine deck to check the transmission drive belt condition.

d) Inspect wheel drive belt conditions.

e) Check all idler arms to be sure they pivot freely.

Disassemble, clean and grease pivot bushings if necessary.

5.1.12 Lubrication:

Service Interval: Refer to Chart a) Stop engine and remove spark plug wire(s).

b) Lubricate fittings with one to two pumps of SAE No. 2 multi-purpose gun grease.

Refer to the following chart for fitting locations and lubrication schedule.

LUBRICATION CHART

FITTING

LOCATIONS

1. Caster Wheel Bearings

2. Caster Pivots

INITIAL

PUMPS

12

2

FITTING QUANTITY

32" 36" 48"

2

2

2

2

2

2

SERVICE

INTERVAL

Daily

Daily

3. Drive Wheels

4. Drive Wheel Idler Arm

18

2

2 2 2

2 2 2

Daily

Daily

5. Brake Lever 2 2 2 2 Weekly

6. Trans. Output Shaft Coupler

7. Cutter Deck Idler Pivots

8.

Cutter Spindles

S/N 150,000 to 159,999

2

2

10

2

1

2

2

1

2

2

2

3

Under severe cutting conditions, two pumps of grease

twice weekly may be more beneficial.

Weekly

Weekly

Weekly

No.8 (Cutter Spindle)

S/N 150,000 to 159,999 only

Located Under Deck

No.6 (Trans. Coupler)

Located Below

Fuel Tank Support

No. 4 & 7 (Idler Arm Pivots)

Dissasemble and grease once a

Month under a “No Load” condition

48” Deck Shown for

Reference Only

- 24 -

c)

Replace 5-speed gearbox grease yearly. Use 18 oz. Of

Peerless grease (Part No. 788067). See Section 5.1.10.

d) Lubricate pivot points with a spray penetrating lubricant as directed below.

SPRAY LUBRICANT CHART

PIVOT POINTS

1. Blade Engagement Bellcrank

NO. of PLACES

32" 36" 48"

1 1 1

SERVICE INTERVAL

Weekly

5.1.13 Remove engine shrouds and clean cooling fins.

Service Interval: See Engine Owner's Manual a) Stop engine and remove spark plug wire(s).

b) Remove cooling shrouds from engine and clean cooling fins. Also clean dust, dirt and oil from external surfaces of engine that can cause improper cooling.

c) Make sure cooling shrouds are properly reinstalled.

Operating the engine without cooling shrouds will cause engine damage due to overheating.

Service Interval: See Engine Owner's Manual

Remove spark plug, check condition and adjust plug gap, or replace with new plug (See Engine Owner’s Manual).

5.1.15 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.

5.1.16 Engine maintenance.

Service Interval: See Engine Owner's Manual

Refer to the Engine Owner's Manual regarding maintenance required for the engine.

5.1.17 Check all safety signs for visibility. Replace as needed.

5.1.18 Thread locking adhesives Fel-Pro Pro-Lock "Nut-Type" or

Loctite Threadlocker "242" are used on the following: a) All belt drive pulley setscrews.

b) OPC lever setscrews.

c) Shoulder bolt for blade engagement assist arm.

Adhesives such as Loctite "RC/609" or "RC/680" or

Fel-Pro Pro-Lock "Retaining I" or "Retaining II" are used on the following: a) Transmission drive pulley on engine crankshaft.

b) OPC lever hubs and cross-shaft.

NOTE: When applying any locking adhesives, care must be used not to bond the bearing (next to each OPC hub) to the crossshaft. This could cause binding of the OPC levers and erratic operation.

- 25 -

5.1.19 An anti-seize compound is used on the blade drive pulley hub, located on the engine PTO shaft (this allows for ease of removal of the pulley).

5.1.20 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact.

5.2 ADJUSTMENTS

5.2.1

Adjusting cutting height with blade spacers.

Blades may be adjusted for cutting height by using the four 1/4" spacers found on the blade spindle bolts

(factory setting is two above and two below). This allows a 1" range in 1/4" 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.).

For the best cut and discharge, place a minimum of two spacers between the blade and spindle shaft.

For the highest quality cut, place all four spacers between the blade and the spindle shaft.

If the mulching kit is installed, the highest quality cut can be obtained with 3 spacers between the blade and spindle (minimum is 1 for a good cut).

If you need to cut higher or lower than what the spacers will allow, it will be necessary to adjust the rear axle height and caster position. See Section 5.2.2 below.

5.2.2

Axle height and caster position.

Desired cutting height range can be obtained by adjusting the rear axle and placing caster spacers above or below the caster arm (See Figures 14 and 15). It may be necessary to readjust wheel drive and brake linkages.

To adjust rear axle: a) Stop engine and remove spark plug wire(s).

b) Place the drive levers in the neutral lock position.

c) Remove mower deck belt shield for access to axle adjustment belts.

d) Loosen but do not remove the two (2) axle pivot bolts and the two (2) axle adjustment bolts (See Figure 15).

e) Place a jack under the rear center of the engine deck.

f) Raise the back end of the engine deck up enough to remove the two (2) axle adjustment bolts.

g) With the jack, raise or lower the back end of the engine deck so that two (2) axle adjustment bolts can be reinstalled in desired hole location. A tapered punch can be used to help align the holes.

h) Retighten all four (4) bolts, lower unit and remove jack.

i) Install mower deck belt shield.

j) Adjust wheel drive and brake linkages as required.

(See Sections 3.8.5 and 3.8.6).

k) Using the appropriate chart for your unit, adjust the caster spacers as directed to match with the axle hole selected. (See Figure 15)

- 26 -

Refer to the charts and illustrations on the following pages to properly adjust for desired cutting height.

Axle Pivot Bolt

Place Jack

Here

Axle

Adjustment

Holes

Pos. A

Pos. B

Pos. C

Pos. D

Pos. E

Axle Adjustment Holes are actually in the side of the rear deck.

FIG. 14 FIG. 15

CASTER HEIGHT ADJUSTMENT AXLE HEIGHT ADJUSTMENT

These models have five (5) axle positions; four (4) 1/2" caster spacers; one (1) 3/16" caster spacer, and four (4) blade spacers.

- 27 -

NOTE: The axle positions are in 1/2" increments and the large caster spacers are 1/2" thick. Therefore, by adjusting the same number of 1/2" caster spacers as axle hole positions the blades will retain the same front-to-back tip (rake).

CUTTING HEIGHT ADJUSTMENT (1" to 4 1/4")

AXLE

POSITION

(FIG. 10)

A

A

A

C

C

C

C

B

B

B

B

E

E

E

D

D

D

D

3

4

4

3

4

2

3

1

2

2

3

NO. OF SPACERS

BELOW CASTER

1/2" 3/16"

0 0

0

1

1

0

1

2

0

1

1

0

1

0

1

0

1

1

0

1

0

1

0

1

0

NUMBER OF 1/4" BLADE SPACERS

BELOW SPINDLE

4 3 2 1 0

1" 1 1/4" 1 1/2" 1 3/4" 2"

1 1/8" 1 3/8" 1 5/8" 1 7/8" 2 1/8"

1 3/8" 1 5/8" 1 7/8" 2 1/8" 2 3/8"

1 3/8" 1 5/8" 1 7/8" 2 1/8" 2 3/8"

1 5/8" 1 7/8" 2 1/8" 2 3/8" 2 5/8"

1 3/4"

2"

2"

2 1/4"

2 1/4"

2 1/2"

2 1/2"

2 3/4"

2 3/4"

3"

1 7/8" 2 1/8" 2 3/8" 2 5/8" 2 7/8"

2 1/8" 2 3/8" 2 5/8" 2 7/8" 3 1/8"

2 1/4" 2 1/2" 2 3/4" 3" 3 1/4"

2 ½" 2 3/4" 3" 3 1/4" 3 1/2"

2 3/8" 2 5/8" 2 7/8" 3 1/8" 3 3/8"

2 1/2" 2 3/4" 3" 3 1/4" 3 1/2"

2 3/4"

3"

3"

3 1/4"

3 1/4"

3 1/2"

3 1/2"

3 3/4"

3 3/4"

4"

2 7/8" 3 1/8" 3 3/8" 3 5/8" 3 7/8"

3 1/8" 3 3/8" 3 5/8" 3 7/8" 4 1/8"

3 1/4" 3 1/2" 3 3/4" 4" 4 1/4"

IMPORTANT: To achieve the highest quality of cut, the blades should be level with the ground, or tipped slightly down at the front.

5.2.3

Transmission belt adjustment.

a) Stop engine and remove spark plug wire(s).

b) To tighten transmission belt, loosen the 3/8" nyloc nut on transmission belt idler pulley. Slide bolt inward in slot and retighten nyloc nut.

c) When properly adjusted, the belt should have 1/2" of deflection with three pounds of pressure on the belt midway between the transmission and engine pulley.

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5.2.4

Wheel drive belts and scrapers.

a) If wheel traction appears to be slipping, drive lever rods may be touching bottom of neutral lock/park brake latch slot. To adjust, refer to directions in Section

3.8.5.

NOTE: There are three (3) adjustment holes for the wheel

drive spring tension bolt (Refer to Section 5.2.15).

b) 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.

5.2.5

Engine to cutter deck belt.

a) Stop engine and remove spark plug wire(s).

b) For proper adjustment of lower blade drive linkage, lengthen or shorten linkage. When properly adjusted, there should be 1/16" to 1/8" of clearance between bell-crank and transmission output shaft when belt is engaged.

c) Check belt guides under rear engine and front mower deck to see that they are properly set. (See Section

5.2.7).

d) Belt must be tight enough to not slip during heavy loads while cutting grass. Overtensioning will reduce belt and spindle bearing life. To adjust belt tension, loosen the 5/16" 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 16).

Check belt tension after the first hour of operation and at least twice during the first 24 hours of operation. Adjust as necessary.

48” Deck

Used For

Reference Only

FIG. 16

CUTTER DECK BELT ADJUSTMENT e) Proper belt tension will require about 10 lbs. side pull on belt, halfway between pulleys (See Figure 16, Point A) to deflect belt 1/2”.

- 29 -

5.2.6

Secondary belt (48" only).

a)

Stop engine and remove spark plug wire(s).

b)

The secondary drive belt is adjusted via the belt tension rod (See Figure 16). The 5/16" nyloc adjustment nut is located at the rear, right corner of engine deck.

c)

Proper belt tension (for the secondary belt) will require about 10 lbs. side pull on belt, halfway between pulleys

(See Figure 16, Point B) to deflect belt 1/2”.

5.2.7

Belt Guide Adjustment a) Stop engine and remove spark plug wire(s).

b) Engage the blade drive belt.

c) Check belt guide clearance on the mower deck. The four welded belt guides on the mower deck should be located 1/8" from belt. Adjust if necessary.

d)

Check belt guides under the engine deck for proper adjustment (See Figures 17 and 18). Adjust as necessary.

The disengaged belt should not drag or fall off pulley when guides are properly adjusted.

NOTE: Belt guides are not installed on the same bolts on the 32" and 36" models as on the 48" models.

NOTE : These drawings are viewed from

FIG. 17 underneath engine deck.

BELT GUIDE LOCATION

FIG. 18

BELT GUIDE LOCATION

32" & 36" 48"

5.2.8 Brake adjustment - See 3.8.6.

5.2.9 Wheel drive linkage adjustment - See 3.8.5.

5.2.10 Shifter lever adjustment - See 3.8.4.

5.2.11 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

- 30 -

turn setscrew all the way in then back out 1-1/2 turns.

IMPORTANT: Screwing setscrew in too far will prevent the

transmission from shifting.

5.2.12

Blade safety switch.

a) Stop engine and remove spark plug wire(s).

b) 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".

c) Be sure the bellcrank does not contact the switch body to prevent damage to the switch.

d) Retighten switch mounting hardware.

5.2.13 Handle height adjustment. See Section 3.8.

IMPORTANT: When the handle height adjustment is changed, it will be necessary to readjust the wheel drive and brake linkage (See Sections 3.8.5 and

3.8.6).

5.2.14

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.

a) Stop engine and remove spark plug wire(s).

b) Disengage neutral lock/park brake latches and release drive levers to lower spring force.

c) Remove the 5/16-18 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 19).

FIG. 19

DRIVE BELT TENSION

ADJUSTMENT POSITIONS

5.2.15

Adjust throttle lever tension (B&S Engines only).

a) Stop engine.

b) Tension in throttle levers can be increased or decreased by adjusting the tightness of the lever pivot bolt which is located under the console.

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6. TROUBLE SHOOTING

6.1 MOWER PULLING LEFT OR RIGHT.

a) Check idler arm pulleys and drive sheaves for mud and/or grass buildup. Check for proper scraper position. See 5.2.4.

b) Check to be sure idler arms pivot freely, if not, lubricate idler pivots.

c) Check for worn drive belts.

NOTE: Wheel drive belts should be replaced as a set. A new belt should not be mixed with a worn belt.

d) Check drive linkage adjustment - See 3.8.5.

e) Check for proper tire pressure in drive tires.

Recommended tire pressure for the drive tires is 12 to

16 psi. Higher pressures may be used in the tire on the side that it pulls to (up to 28 psi).

Note: Different pressures may make mower cut unevenly.

6.2 MOWER CUTS UNEVENLY.

a) Check the drive tire pressure and tire circumference. See

5.1.9.

A more uniform cutting height may be obtained with higher tire pressure on rough terrain. A lower tire pressure provides more flotation.

b) Check blade spacers, axle positions, and front caster spacers. They must be equal on each blade.

c) Check caster mounting brackets to be sure all bolts are tight.

d) Check blades tip to tip for straightness. (They should be within 3/16" or one blade width from being in line.)

6.3 BLADES DO NOT STOP WHEN DISENGAGED.

Check belt guides to see that they are properly set.

See Belt Guide Adjustment 5.2.7.

6.4 ENGINE WILL NOT START.

a) Refer to Section 4.3.2 and follow directions to make sure engine is being properly choked.

b) Make sure transmission is in "true neutral" position.

See Sections 3.8.4(c).

c) Check that the blades are disengaged and the blade switch is depressed (See Section 5.2.12).

d) Check that there is fuel in the tank and that the fuel valve is open.

e) Check that the spark plug wire(s) is/are properly connected.

f) Check for loose or faulty wiring connections.

g) Check for corrosion at all wiring connections. Even

minor corrosion may cause a faulty connection. Clean connector terminals thoroughly, apply dielectric grease and reconnect.

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NOTE: After carefully checking the previous steps, attempt to start the engine. If it does not start, contact your authorized Exmark service dealer.

ENGINE TROUBLESHOOTING

When a problem occurs, do not overlook the simple causes. For example, starting problems could be caused by an empty fuel tank, key switch not

"ON" etc. The following tables list some common causes of troubles.

Do not attempt to service or replace major items or any items that call for special timing or adjustment procedures (governor, valves, etc.). Have this work done by your Engine Service Dealer.

ENGINE TROUBLESHOOTING TABLE 1

PROBLEM

Will not start

Hard starting

Stops suddenly

Lacks power

Operates erratically

Knocks or pings

Skips or misfires

Backfires

Overheats

High fuel consumption

X

X

X

NO

FUEL

IMPROPER

FUEL

X

X

X

DIRT

IN FUEL

LINE

X

X

X

X

X

DIRTY

AIR

FILTER

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

FAULTY

SPARK

PLUG

X

X

X

X

X

X

X

ENGINE

OVER-

LOADED

X

X

X

X

X

X

X

X

X

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

X

X

X

X

X

X

X

DIRTY

AIR

SCREEN

X

X

X

X

X

X

X

X

7. MOWER DECK BELT ROUTING

FIG. 20

32" and 36" MOWER DECK

- 33 -

FIG. 21

48” MOWER DECK

8. WIRING DIAGRAMS

- 34 -

9. WARRANTY

Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg. Co. Inc.

("Exmark") warrants on the terms and conditions herein, that it will repair, replace or adjust any part manufactured by Exmark and found by

Exmark(in the exercise of its reasonable discretion)to be defective in factory material or workmanship.

This warranty is limited to one year from the date of original retail purchase (90 days for rental use) for any Exmark mower that is used for commercial or any other income producing purpose. The Blade Spindle assemblies will be warranted for three years, one year parts and labor with an additional two years parts only, form date of original retail purchase against defects in materials or workmanship. The hydrostatic traction drive system, excluding hoses will be warranted for two full years from date of original retail purchase against defects in materials or workmanship. Exmark Mfg. will extend the Peerless 5-speed transmission manufacturer's warranty from 90 days to one year. Belts and tires are warranted for 90 days against defects in materials or workmanship.

The engine warranty is covered by its respective engine manufacturer.

Please refer to the engine manufacturers warranty statement that is included in the literature packet. Exmark is not authorized to handle warranty adjustments on engines. Engine warranties should be referred to the nearest authorized service outlet of the engine manufacturer.

This warranty extends only to the original retail purchaser of the equipment. The warranty may not be assigned or transferred without the prior express written consent of Exmark. The warranty commences upon the date of the original retail purchase.

The Exmark turf equipment, including any defective part, must be returned to an authorized Exmark service dealer within the warranty period. The warranty shall extend to cost to repair or replace(as determined by

Exmark) the defective part, including labor. The expense of delivering the mower to the dealer for warranty work and the expense of returning it back to the owner after repair or replacement will be paid for by the owner. Exmark's responsibility in respect to claims is limited to making the required repairs or replacements, and no claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower. Proof of purchase may be required by the dealer to substantiate any warranty claim. All warranty work must be performed by an authorized Exmark service dealer.

This warranty extends only to turf equipment operated under normal conditions and properly serviced and maintained. The warranty expressly does not cover: (i) any defects, damage or deterioration due to normal use, wear and tear, or exposure; (ii) normal maintenance services, such as oil change, cleaning, lubrication; adjustment; (iii) replacement of service items, such as oil, lubricants, spark plugs, belts, rubber hoses or other items subject to normal service replacement; (iv) damage or defects arising out of or relating to misuse, neglect, alteration, negligence or accident; (v) repair or replacement arising from operation of or use of the turf equipment which is not in accordance with operating instructions as specified in the operator's manual or other operational

- 35 -

instructions provided by Exmark; (vi) repair or replacement arising as a result of any operation from turf equipment that has been altered or modified so as to, in the determination of Exmark, adversely affect the operation, performance or durability of the equipment or that has altered, modified or affected the turf equipment so as to change the intended use of the product; (vii) repair or replacement necessitated by 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; (viii) repairs or replacements resulting from parts or accessories which have adversely affected the operation, performance or durability of the turf equipment; or (ix) damage or defects due to or arising out of repair of turf equipment by person or persons other than an authorized Exmark service dealer or the installation of parts other than genuine Exmark or Exmark recommended parts.

As a condition to this warranty, customer shall have read the operator's manual and shall have returned to Exmark, within the prescribed time, the enclosed warranty registration card.

The sole liability of Exmark with respect to this warranty shall be repair and replacement as set forth herein. Exmark shall have no liability for any other cost, loss or damage, including but not limited to, any incidental or consequential loss or damage. In particular,

Exmark shall have no liability or responsibility for: (i) expenses relating to gasoline, oil or lubricants; (ii) loss, cost or expense relating to transportation or delivery of turf equipment from the location of owner or location where used by owner to or from any authorized Exmark service dealer; (iii) travel time, overtime, after hours time or other extraordinary repair charges or charge relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark service dealer; (iv) rental of like or similar replacement equipment during the period of any warranty, repair or replacement work; (v) any telephone or telegram charges or travel charges; (vi) loss or damage to person or property other than that covered by the terms of this warranty; (vii) any claims for lost revenue, lost profit or additional cost as a result of a claim of breach of warranty; or (viii) attorney's fees.

There are no representations or warranties which have been authorized and provided to the buyer of the turf equipment, other than as set forth in this warranty. Any and all statements or representations made by any seller of this equipment, including those set forth in any sales literature or made orally by any sales representative, are superseded by the terms of this warranty. Any affirmation of fact or promise made by

Exmark or any of its representatives to the buyer which relates to the goods that are the subject of this warranty shall not be regarded as part of the basis of the bargain and shall not be deemed to create any express warranty that such goods shall conform to the affirmation or promise.

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES,

EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED TO ANY REGARDING THE

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), NOT SPECIFIED HEREIN,

RESPECTING THE EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY.

This warranty applies to all Exmark turf equipment sold in the United States and Canada and intended to be used for commercial purposes.

- 36 -

Date

SERVICE RECORD

Description of Work Done Service Done By

- 37 -

ALIGN THIS EDGE WITH A VERTICAL SURFACE

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

E

P

O

L

0°

H

T

H

T

P

O

E

5°

A

E

P

O

L

0°

H

T

- 38 -

SEE EXMARK’S COMPLETE

LINE OF PRODUCTS FOR TURF CARE

LAZER Z

™

LAZER Z

™

HP

EXPLORER

®

TURF RANGER

®

TURF TRACER

®

TURF TRACER

®

HP

VIKING HYDRO

METRO

™

METRO

™

HP

SELF STEERING SULKY

GRASS CATCHER

MICRO-MULCH

™

ACCESSORY

©1997,1998 EXMARK MFG. CO. INC. PART NO. 850610 Rev. B

INDUSTRIAL PARK BOX 808 (402) 223-6300

BEATRICE, NE 68310 FAX (402) 223-5489

ALL RIGHTS RESERVED PRINTED IN U.S.A.

M F G . C O . IN C .

®