Exmark Metro HP User's Manual
Contents
1. 1 3 TA Operation 3 6 1 5 Maintenance amp SiOlag 6 6 16 Riding Attachments auras asin anesthesia 6 1 Salley SIGNS tank a 6 8 2 SPECIFICATIONS 2 1 Model Number 9 212 9 2 a gl 9 2 4 Safety Interlock System sence es 9 2 5 Steering Brake 9 PA eA SIM SSIONN 9 2 7 Wheel Drive System 9 28 7169 R 9 2 DOGS T AEEA 9 2AN a a ed 10 2 11 Torque 10 3 ASSEMBLY INSTRUCTIONS el UO ss Assembly Sect cat tak cata 10 14 4 OPERATION INSTRUCTIONS AA CONOS rane Seatac Aare ae Nenad nese daa ag eases tee eae 14 15 4 2 Pre Slant E ER 15 16 4 3 Operation INStruUctionS tact 16 18 AA TRANS eee eater 18 5 MAINTENANCE amp ADJUSTMENTS 51 19 25 5 2 A2. CONGRATULATIONS the purchase of your new Exmark mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor If you need to order replacement parts from your dealer always give the model number and serial number of your mower as well as the part number description and quantity of the part needed For Serial Nos 540 000 amp Higher 7 A QO MFG CO INC The Serial No plate is located next to the fuel tank on the top left hand side of the fuel tank support For ease of ordering and reference we suggest that you record the information requested in the following identification table Place Model No and Serial No Label Here Included in Literature Pack or Fill in Below Model No Serial No Engine Model No and Spec No Code Engine Serial No E No Date Purchased Part No 103 9184 A WARNING POTENTIAL HAZARD This product is a piece of power equipment WHAT CAN HAPPEN Failure to follow safe operating practices can result in serious operator injury or even death HOW TO AVOID THE HAZARD Keep all shields guards and safety devices especially the grass discharge syste
3. 3 If distributor does not have the part s in stock to satisfy Exmark Parts Plus order he contacts Exmark by 3 00 p m central time with an Exmark Parts Plus order of six 6 line items or less 4 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 5 The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrives in accordance to the program 6 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 If the part does not arrive overnight due to 1 The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1 00 p m the dealer pays for the part and freight 2 The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 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
4. OF UNIT SHOWN a os je 7 0012 8 FIGURE 7 DRIVE LEVER LINKAGE INSTALLATION lt D K O NOTCH IN NEUTRAL LOCK PARK BRAKE LATCH DRIVE LEVER FIGURE 8 DRIVE LEVER SETTING 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 allow the neutral lock park brake latches to be placed into the park brake position See Figure 7 Check for correct adjustment Place the drive levers in the park brake position The mower should not move forward or backward If it does tighten the wingnuts Place the drive levers in the neutral lock position The mower should move forward and backward freely If it does not loosen the wingnuts NOTE The neutral lock park brake latches must be easily moved into the park brake position if not the brake linkages must be adjusted again zaas 3 12 3 13 3 14 3 15 3 16 3 17 Route the long unattached wiring harness lead up left hand side of the handle and connect the connector on the end of the shorter lead to the key switch Connect the two flag terminals that are on the longer lead in any order to the operator presence control switch terminals underneath the control console Fasten the lead to the handle with two small wire ties from the bolt bag one at the upper end of the handle next to the console and one at the very lower
5. SPRING DISC WASHER CONE TOWARDS NUT FOR CUTTING HEIGHTS ABOVE 3 5 8 89 cm SE THE BOTTOM HOLE GUTTING REISE FRONT LEFT ROLLER THE ROLLERS WILL STILL BE INCHES mm MOUNTING BRACKET EFFECTIVE AGAINST SCALPING 15 38 TORQUE CUTTING HEIGHT O 20 51 45 ft lbs 54 61N m INCHES mm 2 5 64 30 76 2 0 51 O 3 o 76 4 0 102 3 5 90 45 114 40 45 ft lbs 54 61N m ANTI SCALP ROLLER MOUNTING BRACKET DECK ANTI SCALP ROLLER ANTI SCALP ROLLER SUPPORT CUTTER HEIGHT INSTALLATION ADJUSTMENT PIN ADJUSTMENT FIGURE 13 60280 ANTI SCALP ROLLER BOLT INSTALLATION ANTI SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT c Adjust anti scalp rollers for Normal Operating Conditions Stop engine and wait for all moving parts to stop Place rollers in one of the positions shown in Figure 13 Rollers will maintain 3 4 in 19 mm clearance to the ground to minimize gouging and roller wear or damage For Maximum Deck Flotation place rollers one hole position lower Rollers should maintain 1 4 in 6 4 mm minimum clearance to ground Do Not adjust rollers to support the deck Be sure the spring disc washer is installed with the cone towards the nut Tighten nuts properly d When operating in extremely rough conditions it may be necessary to position the anti scalp rollers one or two holes higher than described in b to prevent damage to the rollers and or bolt failure See Figure 13 NOTE When anti scalp r
6. Do not mow near drop offs or near water Do not mow slopes greater than 20 degrees Reduce speed and use extreme caution on slopes Avoid sudden turns or rapid speed changes 4 1 4 5 1 4 6 1 4 7 1 4 8 1 4 9 1 4 10 1 4 11 1 4 12 1 4 13 1 4 14 1 4 15 1 4 16 e See inside the back cover to determine the approximate slope angle of the area to be mowed e Progressively greater care is needed as the slope increases e Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope e Be aware that loss of traction may occur going downhill Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine e Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles e Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control Use EXTREME caution when backing up LOOK BEHIND YOU 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 Never operate the mower with defective guards shields or cover
7. adjeng sordiino r cieaning Avoid blades unless blades and PART NO 103 2245 Use extreme caution when operating on slopes engine are stopped LOCATION RH Side of Console Do NOT operate on slopes greater than 20 Mow across slope NOT up and down Do NOT mow wet slopes A CAUTION Hearing protection recommended Do NOT park on slope unless park ENHANCED CONTROL SYSTEM THIS UNIT WHEN COVER 15 IN PLACE PART NO 98 5954 LOCATION Under Mower Deck Belt Shield s brake is engaged PART NO 103 1623 LOCATION Console 2 SPECIFICATIONS 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 MODEL NUMBER MHP3615KAC MHP4815KAC ENGINE 2 2 1 Engine Specifications See your Engine Owner s Manual 2 2 2 3600 RPM No Load FUEL SYSTEM 2 3 1 Capacity 5 0 gal 18 9 L 2 3 2 Type of Fuel Regular unleaded gasoline 87 octane or higher In countries using the research method it should be a 90 octane minimum 2 3 3 Fuel Filter Replaceable in line 2 3 4 Fuel Shut Off Valve 1 4 turn SAFETY INTERLOCK SYSTEM Operator must have transmission in neutral and PTO disengaged to start engine Release of OPC levers will cause the engine to stop if transmission is not in neutral and or PTO is engaged STEERING BRAKE CONTROL Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving stopping and power
8. 148 0 48 1 122 2 cm 2 10 2 Overall Length 36 48 77 0 196 cm 73 0 185 cm 2 10 3 Curb Weight 36 48 517 lbs 234 kg 565 Ibs 256 kg x Weights will vary slightly depending on engine option 2 10 4 Overall Height 36 48 44 1 112 cm 44 1 112 cm 2 10 5 Tread Width to outside of tires 36 48 35 2 89 4 cm 35 2 89 4 cm 2 11 TORQUE REQUIREMENTS BOLT LOCATION TORQUE Blade Mounting Bolt 55 60 ft lbs 75 81 N m Cutter Housing Spindle 140 145 ft lbs 190 197 N m Mower Deck Support Engine Deck 30 35 ft lbs 40 47 N m Engine Mounting Bolts 15 HP Kawasaki 15 20 ft lbs 20 27 N m Transmission Shifter lever 30 35 ft lbs 40 47 N m Anti Scalp Roller 40 45 ft lbs 54 61 N m Wheel Lug Nuts oes 90 95 ft lbs 122 129 N m 3 ASSEMBLY INSTRUCTIONS 3 1 Uncrate unit and remove upper handle assembly fuel tank and linkages from top of crate 3 2 Remove and open the bolt bag 3 3 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 4 Refer to Parts Manual to help you identify and locate parts and their proper position
9. 2 5 16 18x1 3 4 hex head cap screws and 2 5 16 18 nyloc nuts in the bolt bag NOTE During set up at the factory L or R may have been marked the flats of the balljoints If the balljoints are marked assemble accordingly If the balljoints are not marked they may be assembled on either side Thread the linkage into the swivel located on the wheel drive idler arm Thread in until the flat edge of the drive lever aligns with the bottom of the roller notch in the neutral lock park brake latch when the cap screw is inserted through the hole in the drive lever and the hole in the ball joint Secure with a nyloc nut Tighten nyloc nut Repeat for the other side See figures 7 and 8 12 b The bend in the drive lever linkages should be positioned downward and slightly outward If adjustment is needed loosen jam nut below balljoint and rotate linkage Tighten jam nut Shift transmission lever to fifth gear Insure that bend in right hand linkage is rotated outward enough that linkage clears shifter lever If linkage is rotated too far out ball joint may bind when drive lever is released into the drive position Insure that this does not happen DRIVE LEVERS IN NEUTRAL 5 6 18 1 3 4 HH CAPSCREW _ 318 24 JAM NUT 56 18 NYLOC NUTS DRIVE LEVER LINKAGE BALLJOINT VUAN A J swveL TRANSMISSION LEVER WINGNUT IN NEUTRAL ___ BRAKE ROD RIGHT SIDE
10. dealer e Rental of like or similar replacement equipment during the period of any warranty repair or replacement work e 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 claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower There are no understandings agreements representations or warranties express or implied including but not limited to any regarding the merchantability that product is fit for ordinary use or fitness for use that product is fit for a particular purpose not specified herein respecting the equipment which is the subject of this warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state NOTES SERVICE RECORD Date Description of Work Done Service Done By ALIGN THIS EDGE WITH A VERTICAL SURFACE TREE BUILDING FENCE POST POLE ETC THIS IS A 5 SLOPE Wh as FOLD ALONG APPROPRIAT
11. 3 5 Apply retaining adhesive Fel Pro Retaining or Retaining 11 or Loctite RC609 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 18 x 3 4 screws with a 5 16 SAE flat washer and 5 16 lock washer into the threaded holes in the right side of the fuel tank Do not over tighten Place a 5 16 SAE flat washer then a spring over each of the studs and fasten with a 5 16 nyloc nut Tighten 5 16 nyloc nut fully then back off a 1 2 turn This is to allow for normal fuel tank expansion with changes in temperature and fuel levels 3 6 Attach the fuel tank hose to the tank fitting and secure with the clamp provided 3 7 Position the lower end of the handle assembly on the outside of the upper rear section of the fuel tank and handle support Install four 3 8 16 x 1 bolts with four spring disk washers against the head of each bolt from the outside in Secure using four 3 8 whizlock nuts on the inside of each handle support and tighten until the spring disk washers are flat See Figure 1 10 UPPER HANDLE FUEL TANK SUPPORT D J amp ja FIGURE 1 UPPER HANDLE MOUNTING 3 8 Route the throttle cable along the right side of the upper handle through the clip under the fuel tank support and positi
12. 5 hours of operation Follow engine manufacturer s recommendations for future oil changes 21 f Stop engine and wait for all moving parts to stop Remove key or spark plug wire s Drain oil while engine is warm from operation The oil drain valve is located on left hand side of engine Place pan under machine to catch oil and turn valve counter clockwise with a 10 mm wrench to open valve Allow oil to drain then turn valve clockwise to close Replace the oil filter as per Engine Owner s Manual Clean around oil filter and unscrew filter to remove Before reinstalling new filter 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 Clean around oil fill cap and remove cap Fill to the specified capacity and replace cap Use oil as specified in Engine Owners Manual Do not overfill Start the engine and check for leaks Stop engine and recheck oil levels 5 1 10 Check grease level input and output shaft bearing wear on Peerless Transmission Replace gearbox grease yearly Service Interval 160 hrs 5 1 11 5 1 12 Stop engine wait for all moving parts to stop and remove key or spark plug wire s Place drive levers and neutral lock park brake latches in the neutral lock position Remove shifter lever from top of transmission Remove shifter plate from top of transmission and t
13. DO NOT USE WRENCH HERE FOR BLADE INSTALLATION THIS NUT HAS BEEN TORQUED TO 140 145 ft lbs 190 197 N m AND SECURED WITH THREADLOCKER _ SPLINED BUSHING X TOWARDS BOLT HEAD INSTALL BUSHING IN BLADE PRIOR TO INSTALLING Sd BUSHING IN SPINDLE NN BLOCK OF WOOD BETWEEN FRONT OR REAR BIS BAFFLES amp BLADE 75 81N m G0259 FIGURE 11 BLADE BOLT INSTALLATION IMPORTANT DO NOT use components other than the original blade blade bushing spring disc washer and blade bolt supplied with the unit Failure to use all original components and assembled as shown will increase the risk of a blade bolt becoming loose or weak after striking a foreign object 20 5 1 5 5 1 7 CAUTION POTENTIAL HAZARD Operating a mower deck with loose or weakened blade bolts can be dangerous WHAT CAN HAPPEN loose or weakened blade bolt could allow a blade rotating at a high speed to come out from under the deck causing serious injury or property damage HOW TO AVOID THE HAZARD Always re install original Exmark blades blade bushings spring disc washers and blade bolts in the correct positions as shown Check safety interlock system Service Interval Daily a For your safety your Exmark mower is equipped with Operator Presence Controls OPC When either the PTO is engaged or the transmission shift lever is not in neutral and both hands are removed from th
14. Me y ON cass eee aay HOLIMS 240 eg aa D N3349 MOTISA SA QH S ama al JINGOW YOOTHSLNI ALSaVS ON HOLMS Old A ON HOLIMS 30 9 2 Year Limited Warranty Exmark Turf Equipment For units purchased on or after October 1 2004 Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part manufactured by Exmark and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship for a period of two years This warranty applies to Exmark turf equipment purchased on or after October 1 2004 sold in the US or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Products Warranty Period e All Products except as noted below 2 years e All Attachments and Accessories 1 year e Metro 21 Series 1 year e Belts and Tires 90 days 1 Year Prorated Warranty is covered by engine manufacturer e Battery e Engine Please refer to the engine manufacturer s warranty statement that is included in the literature packet We are
15. area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land WARNING POTENTIAL HAZARD Hands feet hair clothing or accessories can become entangled in rotating parts WHAT CAN HAPPEN Contact with rotating parts can cause traumatic amputation or severe lacerations HOW TO AVOID THE HAZARD Do not operate the machine without guards shields and safety devices in place and working Keep hands feet hair jewelry or clothing away from rotating parts 141 Give complete undivided attention to the job at hand 1 4 2 Mow only in daylight or good artificial light keeping away from holes and hidden hazards Do Not operate the mower when children or others are in the area 1 4 3 When feasible avoid operating the equipment in wet grass 1 4 4 Use EXTREME caution when mowing and or turning on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation on slopes DANGER POTENTIAL HAZARD Mowing on wet grass or steep slopes can cause sliding and loss of control WHAT CAN HAPPEN Loss of control and or loss of 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 or death HOW TO AVOID THE HAZARD Mow across slopes never up and down Do not mow slopes when grass is wet
16. end of the handle where it attaches to the fuel tank support Fasten the lead to the small hole in the channel under the console using another small tie from the bolt bag If machine is shipped without muffler installed install muffler with hardware provided Service Engine Refer to Engine Owner s Manual GREASE UNIT NOTE UNIT 15 NOT GREASED AT THE FACTORY Refer to 5 1 13 for locations and grease amounts Follow pre start instructions as outlined in 4 2 Perform any needed adjustments as outlined in the Adjustment Section 4 OPERATION INSTRUCTIONS 4 1 Controls 4 1 1 4 1 2 Familiarize yourself with the controls and operation of the unit Carefully read the following information about the controls and their operation Operator Presence Control OPC Levers Located on the upper handle assembly directly above the handle grips See Figure 9 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 9 Drive Levers Located on each side of the upper handle assembly directly below the handle grips See Figure 9 These levers individually control the clutching action of the wheel drive belts and the brakes When the drive levers are all o
17. 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 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 and freight charges E X M A R K PA R aT 5 PLU US where applicable
18. is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday Parts Plus service is available only in the 48 contiguous United States UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday The next day air charge plus the Saturday delivery fee will be the responsibility of the purchaser Exmark Mfg will assume no responsibility for Saturday delivery shipments To qualify all Exmark Parts Plus orders must be received by Exmark by 3 00 p m central time Orders must be six 6 line items or less Exclusions from the Exmark Parts Plus 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 CONGRATULATIONS purchase of your Exmark Mower This product has been carefully designed a
19. of power equipment and teach this regard to all who operate this unit 1 2 2 Read the instructions carefully Familiarize yourself with the controls and the proper use of the equipment If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them 1 2 3 Do not allow operation of this machine by untrained personnel Never allow children teenagers or people unfamiliar with these instructions to use the mower Local regulations may restrict the age of the operator 1 2 4 Avoid mowing while people especially children or pets are nearby Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property PREPARATION 131 Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark 1 3 2 The use of personal protective equipment such as but not limited to protection for the eyes ears feet and head is recommended CAUTION POTENTIAL HAZARD This machine produces sound levels in excess of 85 dBA at the operator s ear when in operation WHAT CAN HAPPEN Exposure to sound levels of 85 dBA or above for extended periods of time can cause hearing loss HOW TO AVOID THE HAZARD Wear hearing protection when operating this machine 1 3 3 While mowing always wear substantial footwea
20. on transmission belt idler pulley Slide bolt inward in slot and retighten nyloc nut c When properly adjusted the belt should have 1 2 12 mm of deflection with three pounds 13 3 Nt of pressure on the belt midway between the transmission and engine pulley 5 2 6 Wheel drive belts and scrapers 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 NOTE Wheel drive springs have three tension settings See Section 5 2 11 5 2 7 Brake Adjustment See 3 11 steps c and d 5 2 8 Wheel drive linkage adjustment See 3 11 steps a and b 5 2 9 Shifter lever adjustment See 3 10 5 2 10 Shifter detent adjustment Transmission shifter detent can be adjusted by adjusting the setscrew on the backside 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 IMPORTANT Screwing setscrew in too far will prevent the transmission from shifting 5 2 11 Wheel drive spring tension adjustment may be necessary to increase wheel drive belt tension under
21. sure the square hole washer remains between the lever and transmission Replace the spring disc washer and nyloc nut see figure 4 Torque the 3 8 nut to 35ft lbs 47N M 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 5 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 Shift to neutral position Lever should not contact the left edged of the upper slot Push lever down Lever should not contact the right edge of the bottom slot See Figure 6 Shifter plate can be adjusted side 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 Equal Distance Shifter Lever Shifter Plate Transmission Square Holed FIGURE 5 FIGURE 4 Washer THIS CLEARANCE SHOULD BE EQUAL SHIFTER LEVER Equal Shifter Lever TO TRANSMISSION ae Equal Distance Adjustment Slots FIGURE 6 THIS CLEARANCE SHOULD BE EQUAL 3 11 Install and adjust wheel drive linkages a Locate the 2 drive lever linkages which have a balljoint and jam nut installed on one end Locate the
22. turning Parking brakes are engaged by locking drive control levers in the brake position TRANSMISSION 2 6 1 Peerless 700 070A five speeds forward and one reverse 2 6 2 Speed Range 1 2 0 mph 3 22 km h 4 4 1 mph 6 60 km h 249 2 7 mph 4 35 km h 5 6 2 mph 9 98 km h 3 3 5 mph 5 63 km h Rev 3 1 mph 4 99 km h WHEEL DRIVE SYSTEM Banded double A Section V Belts single topside idlers and replaceable bolt on drive sheaves and brake drums TIRES Drive Front Caster Pneumatic Air Filled Semi Pneumatic Size 16 x 6 50 8 9 x 3 50 4 Quantity 2 2 Tread Turf Master Smooth Ply Rating 4 Pressure 14 psi 97 kPa DECK 2 9 1 Cutting Width Model 36 in 35 25 in 89 5 cm Model 48 in 47 25 in 120 0 cm 2 9 2 Discharge Right Side 2 9 3 Blade Size Model 36 in 18 00 in 45 7 cm Qty 2 Model 48 in 16 25 in 41 3 cm Qty 3 2 9 4 of Drive Manual engagement of belt with over center lock Belt tension is adjustable via turnbuckle 2 9 5 Deck Mounting Full floating deck is attached to support frame removable for service 2 9 6 Cutting Height Adjusts 1 2 1 3 cm increments from 1 5 3 8 cm to 4 1 2 11 4 9 2 10 DIMENSIONS 2 10 1 Overall Width Discharge chute down Discharge chute up Transport only 36 46 25 117 5 cm 36 1 91 7 cm 48 58 25
23. 5 2 ADJUSTMENTS 5 2 1 Cutting height and anti scalp roller adjustment A WARNING POTENTIAL HAZARD When the two front support rod hairpins are removed from the mower deck the weight of the tractor section may cause the front frame to rise suddenly WHAT CAN HAPPEN If the unit rises suddenly injury may occur HOW TO AVOID THE HAZARD Securely hold down the front of the unit when the front support rod hairpins are removed a Stop engine wait for all moving parts to stop and remove key or spark plug wire s b Install hairpin clips in the holes shown on sketch below for the desired cutting height See Figure 13 IMPORTANT To maintain correct cutting height and rake check the following for proper adjustment 1 The front and rear hairpins are in the same holes with the proper spacers under the hair pins See Figure 12 2 The tire pressures are set as directed in Section 5 1 11 3 The length of the rear deck support link assemblies should average 6 89 approximately 6 7 8 17 5 cm from the center of the balljoint to the center of the furthest hole See Figure 12 NOTE All 4 pins must equally support the weight of the deck Adjustment in the length of the rear deck support assemblies may be necessary If one side of the frame is longer than 6 89 17 5 cm than the opposite side must be shorter by the same amount LEFT HAND SIDE SHOWN 375 FIGURE 12 CUTTING HEIGHT ADJUSTMENT 25
24. E LINE 34 1997 2005 EXMARK MFG CO INC INDUSTRIAL PARK BOX 808 BEATRICE NE 68310 ALL RIGHTS RESERVED SEE EXMARK S COMPLETE LINE OF ACCESSORIES RIDING ACCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SUN SHADE TRASH CONTAINER TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WALK BEHIND ACCESSORIES GRASS CATCHER MICRO MULCH SYSTEM STEERABLE SULKY SULKY HITCH KIT TURF STRIPER Check us out on the Web www exmark com WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm PART NO 103 9184 402 223 6300 FAX 402 223 5489 PRINTED IN U S A ark MFG CO INC
25. GUS UNG MG rake a E 25 28 6 WASTE DISPOSAL 6 1 Motor Olli beds 28 7 TROUBLE SHOOTING 7 1 Mower Pulling Left or RIQWt ses 28 7 2 Mower Cuts ita ect eee dues oa adn 28 1 3 Engine Will acces Airco en Ss eae asian A tees aie eens 28 29 8 WIRING 30 31 1 SAFETY 1 1 1 2 1 3 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL A 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 to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER White lettering Red background Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury TRAINING 1 2 1 Regard the Exmark mower as piece
26. HOWN FOR 3 4 19 mm DISENGAGE BLADE CLUTCH SHUT OFF GROUND CLEARANCE ENGINE AND REMOVE KEY BEFORE MAKING ADJUSTMENTS SERVICING OR CLEANING DECK CUTTING HEIGHT INCHES mm 1 5 38 CUTTING CUTTING HEIGHT ADJUSTMENT 1 2 0 51 HEIGHT 2 5 64 3 0 76 INCHES mm FOR MAXIMUM FLOTATION ROLLERS MAY DECK 3 5 90 POSITIONED LOWER BUT MUST MAINTAIN A MINIMUM SUPPORT PIN 14 OF 1 4 6 4 mm GROUND CLEARANCE NEVER POSITION THE ROLLERS SUPPORT MOWER DECK T H R T T L E 1 553049 2 1 553049 103 1798 LOCATION Front of Mower Deck Top Surface PART NO 103 1798 LOCATION Side of Console Torque Blade Bolts to 55 60 ft lbs 75 81 N m 103 7491 103 7491 LOCATION LH Side of Mower Deck A 103 1623 ENHANCED CONTROL SYSTEM PART NO 103 2244 LOCATION LH Side of Console 4 WARNING e Read operator s manual before operating Do NOT operate unless trained to safely operate this machine Do NOT operate without shields guards and Safety devices in place and working Do NOT carry passengers Clear area of debris before mowing e Before leaving operator s position Thrown objects blade contact can Disengage PTO Cause serious injury or death Keep all people and pets out of Shut off engine and remove key before area when mowing
27. UEEZE DRIVE LEVERS BEFORE SHIFTING RN1234 STOP ENGINE BEFORE REACHING UNDERNEATH 1 303517 OPEN BELT DRIVE PART 1 303517 LOCATION LH Side of Rear Surface of Mower Deck KEEP HANDS and FEET AWAY 5 1 303518 PART NO 1 303518 LOCATION Transmission Shifter Plate WARNING Use Only Exmark Riding Attachments Use of Other Riding Attachments May Create a Hazardous Condition Resulting in Injury 403143 PART NO 1 403005 LOCATION RH amp LH Corners of Mower Deck Q PART NO 1 403143 LOCATION RH Side of Rear Surface of Engine Deck ay MOWER 413093 48 413308 52 STATIONARY IDLERS 1 413327 FRONT OF MOWER 1 413094 l 1 413206 9 PART NO 1 413206 LOCATION Top of Cutter Deck Under Center Belt Shield 36 N TENSION INDICATOR CHECK HOURLY FOR THE PART NO 1 413327 LOCATION Top of Cutter Deck Under Belt Shield 48 amp 52 Decks MUFFLER AND SHIELDS MAY EXCEED 150 1 513746 PART 1 513746 LOCATION On Engine Blower Housing next to Muffler amp on Center Belt Cover FIRST 4 HRS CHECK DAILY THEREAFTER ALIGN BOLT WITH TENSION INDICATOR 1 16 1 413421 PART NO 1 413421 LOCATION Left Rear on Top of Engine Deck ANTI SCALP ROLLER WARNING ADJUSTMENT FOR NORMAL OPERATING CONDITIONS PLACE ROLLERS IN POSITIONS S
28. ar is reverse assist only the operator must pull the unit backwards 4 4 TRANSPORTING WARNING POTENTIAL HAZARD Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous WHAT CAN HAPPEN The ramps could collapse causing the unit to fall which could cause injury HOW TO AVOID THE HAZARD Use proper ramps that are secured to the truck or trailer Keep feet and legs out from under the unit when loading and unloading If necessary use assistance when loading 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 18 5 MAINTENANCE amp ADJUSTMENTS A WARNING POTENTIAL HAZARD While maintenance or adjustments are being made someone could start the engine WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or other bystanders HOW TO AVOID THE HAZARD Remove the key from the
29. as directed below SPRAY LUBRICANT CHART NO OF SERVICE 23 d Lubricate drive wheel hubs once year First remove wheel then remove hub cap Lubricate the grease fitting on each wheel hub with an NGLI grade no 2 multipurpose gun grease until grease appears through outer bearing Reinstall hub caps and wheels e Replace 5 speed gearbox grease yearly Use 18 oz of Peerless grease Part No 788067 See Section 5 1 10 5 1 15 Check spark plugs Service Interval 160 hrs a Remove spark plugs check condition and adjust plug gap or replace with new plugs See Engine Owner s Manual 5 1 16 Remove engine shrouds and clean cooling fins Service Interval See Engine Owner s Manual a Stop engine wait for all moving parts to stop and remove key or spark plug wire s b Remove cooling shrouds from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling c Make sure cooling shrouds are properly reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating 5 1 17 Change fuel filter Service Interval As Required a A fuel filter is installed in the fuel line between the fuel tank and the engine Replace when necessary 5 1 18 Refer to Engine Operators Manual for detailed maintenance regarding the engine 5 1 19 Thread locking adhesives such as Loctite 242 or Fel Pro Pro Lock Nut Type are used on the following fa
30. certain conditions such as wet grass hilly terrain or while pulling a sulky a Stop engine wait for all moving parts to stop and remove key or 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 15 27 More Traction Aplied as Bolt is Moved Down FRONT OF UNIT FIGURE 15 DRIVE BELT TENSION ADJUSTMENT POSITIONS 6 WASTE DISPOSAL 6 1 MOTOR OIL DISPOSAL 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 7 TROUBLE SHOOTING 7 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 6 b Check to be sure idler arms pivot freely if not lubricate idler pivots 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 11 steps a and b Check for proper tire pressure in drive tires Recommended tire pressu
31. d DO NOT attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do not operate without entire exhaust system in place and in proper working condition DANGER POTENTIAL HAZARD In certain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN A static charge can ignite gasoline vapors A fire explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD Purchase and store gasoline only in an approved container Always place gasoline containers on the ground away from your vehicle before filling Do fill gasoline containers inside a vehicle or ona truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment a truck or trailer from a portable container rather than from a gasoline dispenser nozzle Ifa 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 WARNING POTENTIAL HAZARD Gasoline vapor can collect inside enclosed trailers and may be ignite
32. d by electrical sparks or hot engine exhaust components WHAT CAN HAPPEN Explosion and fire may occur resulting in property damage personal injury and or death HOW TO AVOID THE HAZARD Provide adequate ventilation of any enclosed trailer to prevent build up of gasoline vapors especially at floor level Refuel only outdoors never inside an enclosed trailer sure all fuel tanks and gasoline storage containers have proper caps installed to prevent spillage and minimize vapor escaping into the trailer Do not place any equipment that is leaking gasoline in an enclosed trailer 1 4 OPERATION Although hazard control and accident prevention are partially 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 38 WARNING POTENTIAL HAZARD Operating engine parts especially the muffler become extremely hot WHAT CAN HAPPEN Severe burns can occur on contact Debris such as leaves grass brush etc can catch fire HOW TO AVOID THE HAZARD Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine
33. e The choke control is located on the front left corner of the fuel tank support and is activated by pulling the control outward Once the engine has started move the choke control to the OFF position DO NOT run warm engine with the choke in the ON position Throttle Control Located on the control console s right side 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 Off Run Switch Located on the console Turn key to the Run position to allow the engine to be started Turn key to the Off position to shut engine off Fuel Shut Off Valve Installed in the fuel line midway between the tank and the engine 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 Rotate valve 1 4 turn clockwise to shut fuel off Rotate valve 1 4 turn counter clockwise to turn fuel on 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
34. e handles the mower engine MUST stop b Check OPC circuits Clear the area Run engine at one third throttle then with drive levers and neutral lock park brake latches in park brake position Shift the transmission into gear and release OPC levers engine MUST stop Again run engine at one third throttle move the transmission shifter lever to neutral engage PTO and release OPC levers engine MUST stop machine does not pass any of these tests DO NOT operate Contact your authorized EXMARK SERVICE DEALER IMPORTANT It is essential that all Operator Safety Mechanisms be in place and in proper operating condition prior to mowing Check for loose hardware Service Interval Daily a Stop engine and wait for all moving parts to stop Remove ignition key or spark plug wire s b Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Check Brake and Wheel Drive Linkage Adjustment Service Interval Daily Refer to Section 3 11 Note any bent linkage or hardware which may need servicing or replacing Service pre cleaner element and air cleaner Service Interval See Engine Owner s Manual a Stop engine and wait for all moving parts to stop Remove key or spark plug wire s b See engine owners manual for cleaning instructions Change engine oil Service Interval See Engine Owner s Manual NOTE Change oil after first five
35. f the way out the brakes disengage and the wheel drive belts engage 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 Neutral Lock Parking Brake Latch Located at the end of the handles 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 See Figure 9 Apply parking brakes whenever leaving the operators position 14 4 2 4 1 5 4 1 10 ROTATE LATCH FOR NEUTRAL LOCK amp PARK BRAKE POSITIONS oT OPC LEVER NEUTRAL LOCK PARK BRAKE LATCH DRIVE LEVER FIGURE 9 NEUTRAL LOCK PARK BRAKE LATCH PTO Engagement Located on the left side of the upper handle To engage the blades push the lever forward or away from the operator until the linkage locks over center To disengage the blades pull the lever to the rear or towards the operator Choke Control Choke is used to aid in starting a cold engin
36. he two leads from the neutral start switch Release the tension on the transmission belt Check for side play caused by bearing wear on the input and out put shafts of the transmission Replace bearings if necessary Remove the six bolts that fasten the upper case to the lower case and carefully remove the upper case half Check the grease level in the lower case The grease level should be approximately 1 1 2 to 1 3 4 3 8 to 4 4 cm from the gearbox bottom If necessary fill to proper level with Peerless grease Part No 788067 Reinstall upper case half and fasten in place with six bolts previously removed Reinstall all parts removed in Steps c and d Install drive belt and adjust tension as stated in Section 5 2 5 Check tire pressures Service Interval Pneumatic air filled Drive Tires 40 hrs a b Semi pneumatic Caster Tires No Maintenance Stop engine and wait for all moving parts to stop Remove key or spark plug wire s Check air pressure in drive tires recommended tire pressure is 12 to 16 psi 83 110 kPa 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 Inspect Belt wear Service Interval 40 hrs a Stop engine and wait for all moving parts to stop Remove key or spark plug wire s 22 b Remove deck support shield to check mowe
37. ignition switch and or pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s WARNING POTENTIAL HAZARD The engine can become very hot WHAT CAN HAPPEN Touching a engine can cause severe burns HOW TO AVOID THE HAZARD Allow the engine cool completely before service making repairs around the engine area 51 PERIODIC MAINTENANCE 5 1 1 5 1 2 Check engine oil level Service Interval See Engine Owner s Manual a Stop engine and wait for all moving parts to stop Make sure machine is ona level surface b Check with engine cool c Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick DO NOT screw into place Remove dipstick and check oil level d If the oil level is low add oil as specified in the Engine Owner s Manual to bring the oil level up to the FULL mark on the dipstick DO NOT OVERFILL IMPORTANT DO NOT operate the engine with oil level below the LOW or ADD mark or over the FULL mark Clean engine air cooling system Service Interval See Engine Owner s Manual a Stop engine and wait for all moving parts to stop Remove key or spark plug wire s b Clean all debris from engine air intake screen and from around engine shrouding Clean grass build up under deck Service Interval Daily a S
38. iring connections Even minor corrosion may cause a faulty connection Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect IMPORTANT It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use NOTE After carefully checking the above steps attempt to start the engine If it does not start contact your authorized Exmark service dealer ENGINE TROUBLESHOOTING When a problem 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 or adjustment procedures such as valves governor etc Have this work done by your Engine Service Dealer ENGINE TROUBLESHOOTING TABLE PROBLEM NO IMPROPER DIRT IN FAULTY ENGINE eye wee FUEL FUEL FUEL LINE FILTER OVERLOADED TUF erratically Knocks orpings x T Tx RETE E E E J x x Overheats _ 4 a fuel consumption 29 8 WIRING DIAGRAM 15 KAWASAKI K HO NIdO GNNOYD 5 099019 2 HOLIMS A SHOLOZNNOD
39. lds and all safety devices place and in safe working condition 1 5 9 Frequently check for worn or deteriorating components that could create a hazard 1 5 10 All replacement parts must be the same as or equivalent to the parts supplied as original equipment RIDING ATTACHMENTS 1 6 1 Use only Exmark riding attachments The use of other than Exmark riding attachments may create a hazardous condition resulting in injury SAFETY SIGNS 1 7 1 Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels 1 7 2 Safety signs must be replaced if they are missing or illegible 1 7 3 When new components are installed be sure that current 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 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 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 WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH KIT IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL 1 303508 BLADES HAVE STOPPED PART NO 1 303508 LOCATION Front of Mower Deck Top Surface SQ
40. lease the drive levers Shift transmission to neutral PTO Engagement DANGER POTENTIAL HAZARD The rotating blades under the mower deck are dangerous WHAT CAN HAPPEN Blade contact can cause serious injury or kill you HOW TO AVOID THE HAZARD DO NOT put hands or feet under the mower or mower deck when the blades are engaged 17 DANGER POTENTIAL HAZARD uncovered discharge opening will allow objects to be thrown operator s or bystander s direction Also contact with the blade could occur WHAT CAN HAPPEN Thrown objects or blade contact can cause serious injury or death HOW TO AVOID THE HAZARD Never operate the mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Be sure that all persons are clear of mower deck and discharge area before engaging the PTO Set throttle to midway position Push the PTO engagement arm forward and down to engage blades Accelerate to full throttle to begin mowing See Section 4 1 4 4 3 8 PTO Disengagement Pull upward and back completely on the PTO engagement arm to disengage the blades See Section 4 1 4 4 3 9 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 ge
41. m in place and in proper working condition Stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before adjusting servicing or performing maintenance If mower deck becomes clogged stop engine and wait for all moving parts to stop Remove spark plug wire s or remove key before cleaning blockage Keep hands feet and clothing away from power driven parts Keep off mower unless seat platform is provided Keep others off mower WARNING POTENTIAL HAZARD Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals WHAT CAN HAPPEN Failure to use caution may cause serious injury or illness HOW TO AVOID THE HAZARD Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth IMPORTANT When the mower is used or 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 syst me d allumage par tincelle de est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for
42. nd 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 TABLE OF CONTENTS Di PAGE 1 1 Safety Alert Symbol a RE 1 EE 1 15
43. not authorized to handle warranty adjustments on engines This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following e Pickup and delivery charges to and from any authorized Exmark Service Dealer e Any damage or deterioration due to normal use wear and tear or exposure e Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service 1 Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S Customers may also call 402 223 6375 2 Bring the product and your proof of purchase sales receipt to the Exmark Service Dealer If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exma
44. ollers are placed in these positions reduced deck flotation will result PTO engagement Linkage Located between the PTO engagement lever on the left handle and the left rear corner of the engine deck a Stop engine and wait for all moving parts to stop b With PTO engaged adjust the linkage length by loosening the lock nut on the turnbuckle and adjusting the turnbuckle so that the bolt on the bellcrank and the indicator arm align with each other within 1 16 1 6 mm See Figure 14 Tighten locknut against turnbuckle L ar INDICATOR ALIGN BOLT TO INDICATOR WITHIN 1 16 are DECK FIGURE 14 PTO ENGAGEMENT LINKAGE PTO Safety Switch Mounted to a tab on the inside left side of the fuel tank support a Stop engine and wait for all moving parts to stop Remove key or spark plug wire s b With PTO disengaged and the bellcrank touching the rear of the slot in the engine deck adjust the PTO safety switch if needed until the bellcrank arm is 5 16 8 mm from the switch body sure bellcrank DOES NOT touch the switch body or damage to the switch could occur d Retighten PTO switch mounting hardware miy 26 5 2 4 Engine to Cutter Deck No adjustment necessary 5 2 5 Transmission Belt Adjustment a Stop engine and wait for all moving parts to stop Remove key or spark plug wire s b To tighten transmission belt loosen the 3 8 nyloc nut
45. on the cable on the left side of the engine Attach throttle cable to engine a Position the throttle control lever located on console 14 6mm from the upper end of the slot b Attach inner wire of the throttle cable to the top hole in the throttle control lever as shown in Figure 2 c Loosen the clamp place the cable behind it and pull on the cable to move the throttle linkage to the full throttle position Tighten the cable clamp screw CHOKE CABLE lt gt eam Je _ 5 C CLAMP Xy J THROTTLE CABLE THROTTLE CONTROL LEVER FIGURE 2 SPEED CONTROL THROTTLE CABLE HOOK UP 3 9 Connect the PTO engagement linkages Loosen jam nut and remove turnbuckle from lower linkage Screw turnbuckle onto both upper and lower linkages simultaneously See figure 3 Note that the threads on upper linkage are left hand See 5 2 2 for linkage adjustment Note ECS handles have the PTO linkage on the inside of the PTO engagement lever tab and the hairpin on the outside UPPER PTO IN ENGAGEMENT Sak LINKAGE TURNBUCKLE 1 JAMNUT LOWERPTO ENGAGEMENT LINKAGE FIGURE 3 PTO ENGAGEMENT LINKAGE 5 3 10 Install and adjust shifter lever a Shifte Lever 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
46. operator only Keep all others away from mower during operation 5 1 5 1 6 1 7 1 4 17 Do Not mow with grass deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly 1 4 18 Be aware of the mower discharge and direct discharge away from others 1 4 19 Do NOT operate the mower under the influence of alcohol or drugs 1 4 20 Use care when approaching blind corners shrubs trees or other objects that may obscure vision MAINTENANCE AND STORAGE 1 5 1 For engine maintenance follow the engine manufacture s recommendations precisely as stated in the engine manual 1 5 2 Keep engine and engine area free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire 1 5 3 Store fuel in a container specifically designed for this purpose in a cool dry place 1 5 4 Keep the mower and fuel container in locked storage to prevent children from playing or tampering with them 1 5 5 Gasoline powered equipment fuel containers should not be stored a basement or any enclosed area where open pilot lights or heat appliances are present 1 5 6 Maximum mowing results and safety can only be achieved if the mower is properly maintained and operated correctly 1 5 7 Check all bolts frequently to maintain proper tightness 1 5 8 Keep all guards shie
47. r and long trousers Do not operate equipment when barefoot or when wearing open sandals sos 1 3 4 Thoroughly inspect the area where the equipment is to be used and remove all stones sticks wires bones and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders A WARNING POTENTIAL HAZARD Engine exhaust contains carbon monoxide which is an odorless deadly poison WHAT CAN HAPPEN e Carbon monoxide can kill you HOW TO AVOID THE HAZARD Do not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect DANGER POTENTIAL HAZARD In certain conditions gasoline is extremely flammable and highly explosive WHAT CAN HAPPEN A fire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only outdoors Store gasoline an approved container and keep it out of the reach of children 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 gasoline level rises above a level that is 1 2 below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage If fuel is spille
48. r deck drive condition c Look under engine deck to check the transmission drive and clutching belt condition d Inspect wheel drive belt conditions e Check the wheel drive idler arms to be sure they pivot freely Disassemble clean and grease pivot bushings if necessary 5 1 13 Inspect PTO Clutching Belt Tension Service Interval Check every 2 hrs for first 8 hrs operation then check every 40 hrs thereafter a Stop engine and wait for all moving parts to stop b Engage PTO lever c Look through the round hole in the left rear corner of the engine deck to inspect PTO clutching belt tension Bolt on PTO engagement linkage bellcrank and indicator arm should align within 1 16 See figure 14 Refer to section 5 2 2 for adjustment 5 1 14 Lubrication Service Interval Refer to Chart a Stop engine wait for all moving parts to stop and remove key or spark plug wire s b Lubricate fittings with one to two pumps of NGLI grade no 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule GREASE LUBRICATION CHART QUANTITY SERVICE 36 48 INTERVAL No 5 Clutch Arm Pivot Located Under Engine Deck No 7 Trans Coupler Located Below Fuel Tank Support 7 No 3 Idler Arm Pivots Disassemble and grease once a Month under a No Load condition G0020 c Lubricate pivot points with a spray penetrating lubricant
49. re for the drive tires is 12 to 16 psi 82 110 kPa Higher pressures may be used in the tire on the side that it pulls to up to 28 psi 193 kPa Note Different pressures may make mower cut unevenly 7 2 MOWER CUTS UNEVENLY a Check the drive tire pressure and tire circumference See 5 1 11 A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation b Check deck support pins Hairpin clips must be in the same hole position on each support pin Check deck support alignment and check mounting brackets to be sure all bolts are tight d Check blades tip to tip for straightness They should be within 3 16 4 8 mm or one blade width from being in line 7 3 ENGINE WILL NOT START a Check that choke is the ON position for a cold engine NOTE Kawasaki engines may need to be choked even when warm sure the key switch is the ON position sure transmission is in true neutral position See section 3 10c d Check that the PTO is disengaged and the PTO switch is depressed Check that there is fuel the tank and that the fuel valve is open 28 f Check that the spark plug wire s are properly connected g Check for loose faulty wiring connections If it is necessary to disconnect wire connectors Do Not pull on the wires while disconnecting h lt Check for corrosion at all w
50. reverse the operator has to pull the unit backward to assist with the movement of the unit PRE START 4 2 1 4 2 2 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary inspection and maintenance steps 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 15 4 2 3 Do not add oil to gasoline Do not overfill fuel tank Never fill the fuel tank so that the fuel level rises above a level that is 1 2 1 3 cm below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage Make sure you understand the controls their locations their functions and their safety requirements 4 3 OPERATING INSTRUCTIONS 4 3 1 4 3 2 4 3 3 4 3 4 Refer to Engine Owner s Manual for detailed operating instructions regarding the engine Starting Engine Operator must have PTO disengaged and 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 Figure 10 d Pull out the choke control Place the throttle control midway between the Slow and Fast positions Turn the key to position Pull recoil rope to sta
51. rk Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com 191 Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense As acondition to this warranty customer shall have read the operator s manual and shall have completed and submitted to Exmark Warranty Company within the prescribed time the Exmark warranty registration General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein Neither Exmark nor Exmark Warranty Company shall have any liability for any other cost loss or damage including but not limited to any incidental or consequential loss or damage In particular we shall have no liability or responsibility for Expenses related to gasoline oil or lubricants e 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
52. rt engine After the engine warms up gradually push in choke control DO NOT run warm engine with the choke in the ON position NOTE Kawasaki engines generally need to be choked even when warm Stopping Engine Lock the drive levers in the park brake position disengage PTO and position transmission in neutral Place the throttle control midway between the slow and fast positions Allow the engine to run a minimum of 15 seconds then turn the key to the OFF position 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 Drive Lever Neutral Lock Park Brake Latch Operation To lock the drive levers in neutral lock squeeze the drive levers to the neutral position See Figure 10 b Place thumbs on the inner thumb lobe of the neutral lock park brake latches and rotate them to the neutral position See Figure 10 c Release the drive levers 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 10 d Release the drive levers CAUTION POTENTIAL HAZARD If the neutral lock park brake latches not completely engaged the drive levers could unexpectedly slip into the forward drive position WHAT CAN HAPPEN lf
53. s Always have safety shields guards switches and other devices in place and in proper working condition Do Not change the engine governor settings or over speed the engine Operating an engine at excessive speed may increase the hazard of personal injury Place transmission in neutral disengage PTO and engage park brake before starting engine Start the engine carefully with feet well away from blades Keep hands feet and clothing away from rotating parts while the mower is being operated Stop the engine wait for all moving parts to stop and remove spark plug wire s or ignition key Before checking cleaning or working on the mower After striking a foreign object inspect mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop the engine and wait for all moving parts to stop Before removing the grass catcher Before refueling Before making height adjustments Before stopping the engine place the throttle control midway between the slow and fast positions Allow the engine to run a minimum of 15 seconds then stop the engine The fuel system is provided with a shut off valve The fuel shut off valve is used to shut off the fuel when e The machine will not be used for a few days e During transport to and from the job e When parking inside a building This mower was designed for one
54. steners a Transmission drive sheave setscrews b Wheel drive sheave setscrews on transmission output shafts c OPC lever setscrews d Sheave retaining bolt in end of engine crankshaft e Lower Sheave retaining bolt on clutch arm Fuel tank bulkhead fitting threads S N 370 000 amp higher g Cutter housing spindle nut Adhesives such as Loctite RC 609 RC 680 or Fel Pro Pro Lock Retaining or Retaining l are used on the following a OPC lever hubs and cross shaft NOTE Care must be used not to bond the bearing next to each OPC hub to the cross shaft which could cause binding of the OPC levers and erratic operation b Fuel tank studs where studs are inserted into tank 5 1 20 An anti seize compound is used on the following locations a Between engine crankshaft and transmission and blade drive sheaves b On clutch arm assembly between bearings and shaft and between lower sheave and shaft c Between transmission input shaft and sheaves d Between transmission output shafts and sheaves e Between transmission output shafts and bearings 24 5 1 21 HTS grease food grade antisieze is used the following locations a Between the cutter housing spindle and bearings b Between the cutter housing spindle and sheave c Under top cutter housing bearing guard 5 1 22 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact
55. the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage HOW TO AVOID THE HAZARD sure the drive levers are securely seated at the bottom of the neutral or park areas of the neutral lock latches 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 10 a 16 4 3 5 4 3 6 4 3 7 DRIVE LEVER DRIVE LEVER IN DRIVE IN NEUTRAL d DRIVE LEVER DRIVE LEVER LOCKED IN NEUTRAL LOCKED IN PARK FIGURE 10 DRIVE LEVER NEUTRAL LOCK PARK BRAKE LATCH OPERATION Drive Wheel Engagement and Turning With drive levers in neutral or park brake position shift transmission into desired gear Squeeze both drive levers and move both neutral lock park brake latches from the neutral or park brake position to the drive position For straight ahead motion Smoothly release both drive levers to engage drive wheels For turning Squeeze the right hand drive lever to turn right and the left hand drive lever to turn left See Section 4 1 2 To Stop Squeeze drive levers back to engage brakes Move neutral lock park brake latches into the park brake position and re
56. top engine wait for all moving parts to stop and remove key 19 b Raise deck to the highest position Lift the front of unit and support unit using jack stands or equivalent support CAUTION POTENTIAL HAZARD Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous WHAT CAN HAPPEN The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Clean out any grass build up from underside of deck and in discharge chute 5 1 4 Check mower blades Service Interval Daily a Stop engine wait for all moving parts to stop and remove key b Lift deck and secure in raised position as stated in Section 5 1 3 Inspect blades and sharpen or replace as required d Re install the blades if they were removed in the following order See Figure 11 1 Install bushing through blade with bushing flange on bottom grass side of blade 2 Install bushing blade combo into spindle 3 Install blade bolt and spring disc washer Be sure the spring disc washer cone is installed towards the bolt head Place a block of wood between front or rear baffles and the blade then torque the blade bolts to 55 60 ft lbs 75 81 N m 1 2 3
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