Exmark 4500-352 Lawn Mower User Manual
Contents
1. For the best cut and discharge place a minimum of two spacers between the blade and the spindle For highest quality cut place all four spacers between the blade and the spindle If mulching kit is installed the highest quality cut can be obtained with 3 spacers between the blade and the spindle minimum is 1 for a good cut When mulching leaves it is best to have fewer spacers between blade and spindle Refer to the table and select desired cutting height range Refer to Adjusting the Axle Position Adjusting the Number of Spacers below Caster Support Hub and Adjusting the Cutting Height with Blade Spacers and sections to make adjustments make adjustment to obtain specific cutting height 24 Maintenance Cutting Height Adjustment Table 1 inch to 4 1 4 inches 2 5 cm 10 8 cm Cutting Axle Number Of Spacers Number of 1 4 inch Blade Spacers Below Spindle Height Position Below Caster Figure 10 Support Hub 1 2 inches 2 5 5 0 cm 2 1 8 inches 1 8 inch 5 4 cm 2 3 8 inches 3 8 inc 5 8 inc 7 8 inc 3 8 inch 3 5 6 0 cm 3 5 cm 4 1 cm 4 8 cm 6 0 cm 1 3 8 2 3 8 inches 3 8 inc 5 8 inc 7 8 inc 3 8 inch 3 5 6 0 cm 3 5 cm 4 1 cm 4 8 cm 6 0 cm 2 5 8 inches 5 8 inc 7 8 inc 1 8 inc 3 8 inc 5 8 inch 4 1 6 7 cm 4 1 cm 4 8 cm 5 4 cm 6 0 cm 6 7 cm 1 3 4 2 3 4 inches 3 4 inc 3 4 inch 4 4 7 0 cm 4 4 cm 7 0 cm 2 3 inches 5 0 7 6 cm 1 7 8 2 7 8 inch2. C see Figure 27 G006813 Figure 27 1 traction applied as 4 Position C Most Severe bolt moves down 2 Position A Normal 5 Conditions 3 Position B More Severe Front of Unit 33 Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval Before each use or daily May be required more often in dry or dirty conditions A CAUTION Excessive debris around engine cooling air intake and exhaust system area can cause engine and exhaust system area to overheat which can create a fire hazard Clean all debris from engine and exhaust system area 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debtis from rotating engine air intake screen around engine shrouding and exhaust system area 3 Wipe up any excessive grease or oil around the engine and exhaust system Remove Engine Shrouds and Clean Cooling Fins Service Interval Every 80 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Remove key ot spark plug wire s 2 Remove cooling shrouds from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling 3 Make sure cooling shrouds are properly reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating Clean Debris From Machine
3. Avoid blades unless blades and engine are stopped CAUTION 103 1623 ECS Units Only L E 103 1798 103 1798 CAUTION SURFACE 103 2076 103 2076 ENHANCED CONTROL SYSTEM 103 2244 ECS Units Only ENHANCED CONTROL SYSTEM 103 2245 ECS Units Only 10 Safety ENGINE SHEAVE FRONT OF MOWER 103 5626 103 5626 48 inch Units Only Thrown objects or blade contact can cause serious injury or death Keep all people and pets out of area when mowing Avoid blades unless blades and engine are stopped CAUTION Hearing protection recommended 103 1967 A WARNING 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 Before leaving operator s position Disengage Shift speed control lever to neutral Engage park brakes Shut off engine and remove key before adjusting servicing or cleaning Use extreme caution when operating on slopes Mow across slope NOT and down Do NOT operate on slopes greater than 20 NOT mow wet slopes 103 1967 Pistol Grip Units Only 11 Specifications Specifications Model Numbers S
4. Tighten the blade mounting bolt Tighten the engine mounting bolts Tighten the appropriate pulley Contact an Authorized Service Dealer Contact an Authorized Service Dealer Install new belt Install new deck belt Install deck pulley and check the idler pulley idler arm and spring for correct position and function Adjust blade brake Adjust belt guide to proper position Check the PTO engagement position Schematics Schematics KEY SWITCH SWITCH N O TRANSMISSION N C PTO Q SWITCH N O 5 SAFETY J INTERLOCK nn MODULE i tc gt 5 o d fc a 20 5 a lt 5 ENGINE GROUND ye Qx BLACK aD RED e ENGINE KILL TERMINAL CONNECTORS ARE VIEWED FROM WIRE END NORMALLY CLOSED NORMALLY OPEN 37 Exmark Commercial Turf Equipment 2 Year Limited Warranty Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part on these products and found by us in the exercise of our reasonable discretion to be defective in factory materials or workmanship for a period of two years This warranty applies to Exmark commercial turf equipment sold in th
5. Semi Pneumatic 13 5 00 6 13 6 50 6 9 x 3 50 4 Pressure 14 psi 14 psi 97 kPa 97 kPa Bearings Replaceable Replaceable Replaceable Ball Ball Roller 12 Specifications Cutting Deck Overall Length 32 inch Deck 31 75 inches 80 7 cm Ds Dee Eee Standard 78 0 inches 78 0 inches 73 0 inches 36 inch Deck 35 38 inches 89 9 cm Pistol Grip 198 1 cm 198 1 185 4 cm 48 inch Deck 47 25 inches 120 0 cm Handles Mess ECS 77 3 inches 77 3 inches 72 3 inches 196 3 cm 196 3 183 6 cm e Blade Size 32 inch Deck 16 25 inches 41 3 cm Overall Height Quantity 2 i i 0 inches 101 66 indi Dede 1800 taches 5 2 Quantity 2 ECS Handles 42 1 inches 106 9 cm 48 inch Deck 16 25 inches 41 3 Quantity 3 Deck Drive Manual engagement of belt with Tread Width Outside to Outside of over center lock Blade belt tension is adjustable Tires Widthwise via turnbuckle NE G X F Blade Brake When the blade engagement control Deck Deck Deck is moved to the disengaged position a friction Standard 32 1 inches 35 6 inches 35 6 inches brake pad stops the rotation of the blades Pistol Grip 81 4 cm 90 4 cm 90 4 cm Deck Mounting Bolted directly to engine deck ur Deck Depth 32inch Deck 5 0 inches 12 7 cm Curb Weight 48 inch Deck 5 0 inches 12 7 cm Deck Deck
6. Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Clean off any oil debris or grass build up on the machine and cutting deck especially under deck belt shields around the fuel tank around engine and exhaust area Clean Grass Build Up Under Deck Service Interval Before each use or daily 1 Disengage PTO 2 Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wire s 3 Raise deck and support unit using jack stands equivalent support CAUTION Raising the mower deck for service maintenance relying solely on mechanical hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support 4 Clean out any grass build up from underside of deck and in discharge chute Waste Disposal 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 34 Troubleshooting Troubleshooting Important It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use When a problem occurs do not
7. 1 4 inch 3 1 cm Maintenance 1 G006808 Figure 18 48 inch Belt Guide Location Viewed from underneath the deck 1 3 8 inch 3 5 cm Brake and Wheel Drive Linkage Adjustment 1 Check for correct brake adjustment Place the drive levers in the park brake position The mower should not move forward ot 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 brake adjustment is necessary Adjust brakes by adjusting wingnut on the upper end of each brake rod Tighten the wingnut until the brakes engage when the drive levers are squeezed enough to allow the neutral lock park brake latches to be placed into the park brake position See Figure 6 for Standard Pistol Grip handles and Figure 7 for ECS handles Note The neutral lock park brake latches must be able to be moved into the park brake position if not the brake linkages must be adjusted again Check for correct wheel drive linkage adjustment For Pistol Grip Handles Allow drive levers to drop into the full forward position The clevis pin should rest in the neutral lock latch with approximately 3 16 inch to 1 4 inch 4 7 6 4 mm clearance from the bottom of the slot see Figure 19 Adjust if necessary To adjust the wheel drive linkage For wheel drive linkage adjustment
8. Adjustment 32 Wheel Drive Spring Tension TACITUS 33 OR ORTI ANE UTE 34 Clean Engine and Exhaust System iera 34 Remove Engine Shrouds Clean Cooling 34 Clean Debris From Machine ie 34 Clean Grass Build Up Under Deck 34 Waste e eu t 34 Tro bleshootng 35 Schemat s rue no eimi te 37 Safety Safety Safety Alert Symbol This Safety Alert Symbol Figure 2 is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 1 Safety alert symbol The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION 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
9. Deck Standard 420 Ib 430 Ib 475 b Cuing Adusien Pistol Grip 191kg 195 kg 215 Adjusts from 1 inch 2 5 cm to 4 1 4 inches 10 8 Handles cm in 1 4 inch 6 4 mm or smaller increments ECS 435 Ib 446 Ib 490 Ib by vatious adjustments of caster spacers blade Handles 197 kg 202 kg 222 kg spacers and axle height Torque Requirements Blade Cutter Housing 75 80 ft Ib 102 109 N m Spindle Bolt Caster Bracket Mounts 30 35 ft lb 41 48 N m Dimensions Overall Width 32 inch 36 inch 48 inch Deck Deck Deck Deflector 32 7 inches 36 4 inches 48 1 inches Up 83 1 cm 92 5 cm 122 2 cm Engine Mounting Bolts 15 20 ft lb 20 27 N m Mower Deck Engine 30 35 ft lb 41 48 N m Deck Mount Transmission Shifter Lever 30 35 ft lb 41 48 N m Nut Deflector 43 3 inches 47 0 inches 57 9 inches Down 110 0 cm 119 4 147 1 cm 13 Operation Product Overview Controls Fuel Cap Pistol Grip Handles Figure 3 4 ECS Handles 5 Blade Spacers 9010116 Operation Note Determine the left and right sides of the machine from the normal operating position Controls Operator Presence Control OPC Levers Located on the upper handle assembly directly above the handle grips When these levers are depressed the OPC system senses that the operator is in the normal operator s position When the levers are released the OPC system se
10. entire exhaust system in place and in proper working condition A DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge 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 on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete A WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth Check that the operator s presence controls safety switches and shields are attache
11. is worn loose or broken Transmission drive belt is off a pulley Blade s not sharp Cutting blade s is are bent Mower deck is not level Underside of mower is dirty Tire pressure in drive tires not correct Blade spindle bent Tips of adjacent blades are at an uneven cutting height Blades tips should be even within 3 16 inch which is approximately one blade thickness Caster mounting brackets are loose Cutting blade s is are bent or unbalanced Blade mounting bolt is loose Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Blade spindle is bent Belt is damaged Deck belt is worn loose or broken Deck belt is off pulley Blade brake is not adjusted properly Belt guide is not properly set PTO engagement is not properly set 36 Remove mud and or grass buildup Correct adjustment Lubricate ilder pivots Replace drive belts as a set Do Not mix a new belt with a worn drive belt Correct adjustment Adjust pressure in the drive tires Change the belt Change the belt Sharpen the blade s Install new cutting blade s Level mower deck from side to side and front to rear Clean the underside of the mower Adjust tite pressure in the drive tires Contact an Authorized Service Dealer Replace blades spindles and or check for damage to mower deck Tighten hardware Install new cutting blade s
12. key and engage parking brake Before checking cleaning or working on the mower After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage patking brake Before refueling Before dumping the grass catcher Before making height adjustments A WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Contact with the rotating parts can cause traumatic amputation or severe lacerations Do Not operate the machine without guards shields and safety devices in place and working properly Keep hands feet hair jewelry or clothing away from rotating parts DO NOT operate the mower when people especially children or pets are in the area Be alert slow down and use caution when making turns Look behind and to the side before changing directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed Be aware of the mower discharge path and direct discharge away from others Do Not operate the mower under the influence of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck U
13. periods of exposure Weat hearing protection when operating this machine e Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders Safety A DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire explosion from gasoline can burn you others and cause property damage Fill the fuel tank outdoors in an open area when the engine is cold Wipe up any gasoline that spills Never refill the fuel tank or drain the machine indoors inside an enclosed trailer Do Not fill the fuel tank completely full Add gasoline to the fuel tank until the level is 1 4 to 1 2 inch 6 13 mm below the bottom of the filler neck This empty space in the tank allows gasoline to expand Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark Store gasoline in an approved container and keep it out of the reach of children 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 If fuel is spilled Do Not attempt to start the engine Move away from the area of the spill and avoid creating any of ignition until fuel vapors have dissipated Do Not operate without
14. remove the hairpin between the neutral lock latch and drive lever Figure 19 2 G006801 Figure 19 i Left Side Shown Drive Lever 4 Neutral Lock Park Brake Latch Clevis Pin 5 Hairpin Drive Linkage Adjust drive linkage length threading into or out of the swivel until there is a 3 16 inch to 1 4 inch 47 64 cm clearance between the linkage assembly and the bottom of the slot in the neutral lock park brake latch see Figure 20 6006802 Figure 20 3 16 inch to 1 4 inch 47 cm 64 cm Neutral Lock Park Brake Latch Drive Linkage 30 Note Neutral lock patk brake latch clearance should be checked when there is Maintenance a slight upward force placed on the drive levers to remove any slack in the linkage C Re install hairpin into hole on the clevis pin between the neutral lock park brake latch and drive lever See Figure 19 Repeat procedure on opposite side of unit For ECS Handles Allow drive levers to drop into the full forward position the flat edge of the drive lever should align with the bottom roller notch See Figure 21 Adjust if necessary 6006803 Figure 21 2 Drive Lever Lock Park Brake Latch To adjust the wheel drive linkage A Locate a drive lever linkage on one side of the unit and remove the 5 16 18 x 1 3 4 inch hex cap screw and 5 16 18 inch nyloc nut see
15. safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower SQUEEZE DRIVE LEVERS BEFORE SHIFTING RpN123 4 1 303518 5 1 303518 ENGINE SHEAVE BLADE DRIVE BELT FRONT OF MOWER 1 323427 32 inch 36 inch Units Only PARK BRAKE DRIVE LOCK 1 323550 Pistol Grip Handle Units Only KEEP HANDS and FEET AWAY 1 403005 Use Only Exmark Riding Attachments Use of Other Riding Attachments May Create a Hazardous Condition Resulting in Injury 1 403143 A DANGER THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 103 1623 4 WARNING 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 Before leaving operator s position Disengage PTO Shift transmission to neutral Engage park brakes Shut off engine and remove key before adjusting servicing or cleaning Use extreme caution when operating on slopes Do NOT operate on slopes greater than 207 Mow across slope NOT up and down Do NOT mow wet slopes Thrown objects or blade contact can cause serious injury or death gt Keep all people and pets out of area mK when mowing
16. supported ramps could be dangerous The ramps could collapse causing the unit to fall which could cause injury 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 the fuel shut off valve is closed Use a heavy duty trailer to transport the machine Engage neutral lock latches and park brake then block wheels Securely fasten the machine to the trailer with straps chains cables or ropes Do Not tely solely on the parking brake to hold the machine on the trailer Be sure that the trailer has all necessary lighting and marking as required by law and use a safety chain 18 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position A WARNING A WARNING While maintenance or adjustments are being The engine can become very hot Touching made someone could start the engine a hot engine can cause severe burns Accidental starting of the engine could seriously injure you other bystanders Allow the engine to cool completely before service or making repairs around the engine Remove the key from the ignition switch area engage parking brake and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s Recommen
17. the neutral or park brake position to the drive position 3 To move forward in a straight line smoothly release both drive levers to engage drive wheels To turn left or right squeeze the right hand drive lever to turn right and the left hand drive lever to turn left Squeeze drive levers all the way back to engage brakes Move neutral lock park brake latches into the park brake position and release drive levers Shift transmission into neutral Driving in Reverse Note Reverse gear is reverse assist only the operator must pull the unit backwards move rearward squeeze the drive levers to neutral Sq position and move the shifter to the Smoothly release both drive levers to engage drive wheels Pull the unit backward to assist with the movement of the unit To stop squeeze drive levers all the way back to engage the brakes Move the neutral lock latches into the park brake position and release drive levers Move the speed control lever to the neutral position Changing Gears When changing gears always squeeze drive levers to the neutral position The shift lever may be moved with a knee or by hand engage the neutral lock latches if shifting by hand Note Reverse gear is reverse assist only the operator must pull the unit backwards Transporting Transporting a Unit A WARNING Loading the mower onto a trailer without strong enough or properly
18. 9 co 7 UT 10 slope This is a5 slope No Slope Example Compare slope with folded edge Align this edge with a vertical surface 4 a tree building fence post pole etc y E i d ou Ya In i QU J A d 1 vf Iv 1 n Y li yep bla Whi whys pad uS d Pda 1 1 TUA mmn Ayu duh hy gay are hair P 39 G006944 SEE EXMARK S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM ROPS DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB GRASS CATCHER TURF STRIPER MICRO MULCH SYSTEM STANDON Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchased Engine Model No an
19. Adjustment section Maintenance Mower Deck Belt Routings 0006814 Figure 14 32 inch and 36 inch Mower Deck G006815 o Figure 15 48 inch Mower Deck distance should be between 1 8 inch and 3 16 inch 3 5 mm see Figure 16 Engage the blade control and check to make sure the blade brake pad clears the sheave 1006806 Figure 16 Shown with Blades Disengaged Blade Brake Rod 3 1 8 inch to 3 16 inch 3 5 mm 2 Spring Mounting Bolts Blade Brake Adjustment 1 Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wite s Disengage blades 3 Make sure the blade brake pad rests against the sheave Adjust the spring mounting bolts to properly align the pad on the sheave see Figure 16 Check the distance between the spacer and the nut at the end of the blade brake rod Belt Guide Adjustment Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wire s Engage the blade drive belt Check belt guide under the engine deck for proper adjustment See Figure 17 and Figure 18 Adjust as necessaty The disengaged belt should not drag or fall off pulley when guides are properly adjusted 6006807 Figure 17 32 inch 36 inch Belt Guide Location Viewed from underneath the deck 1
20. Figure 22 B Thread drive lever linkage into or out of the swivel located on the wheel drive idler arm until the flat edge of the drive lever aligns with bottom of the roller notch in the neutral lock park brake latch see Figure 22 C Re install the 5 16 18 x 1 3 4 inch hex cap screw and secure with the 5 16 18 inch nyloc nut Repeat for the other side see Figure 22 4 3 6006804 Figure 22 Right Side of Unit Shown 1 Wingnut 5 5 16 18 x 1 3 4 inch hex capscrew 2 Transmission Lever in 6 Drive Lever Linkage neutral 3 5 16 18 inch nyloc nut 7 Swivel 4 Drive Levers in neutral 8 Brake Rod Shifter Lever Adjustment The shifter lever in neutral should not contact the upper or lower edge of the slot or the left edge of the upper slot the right edge of the bottom slot See Figure 23 and Figure 24 The clearance should be equal Adjust the shifter lever and shifter plate if necessaty 1 R 1 2 3 4 5 2 3 Figure 23 1 Equal distance 3 Shifter Plate 2 Shifter Lever 31 Maintenance CZ 2 3 Figure 24 1 Shifter Lever 2 Equal distance 3 Adjustment slot To adjust the shifter lever 1 Remove the 3 8 inch nyloc nut and spring disc washer from the stud on top of the transmission See Figure 25 Figure 25 1 Shifter Lever 2 Square Holed Washer 3 Transmission 2 Remove the shifter lever and bend it slightly Do Not bend the lever
21. IpnUBW lt gt N LO e e O 2 5 a For Serial Nos 790 000 amp Higher AWARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancet birth defects or other reproductive harm Important When the mower is used or operated on any California forest brush or grass covered land a working spark arrester must be attached to the muffler If not the operator is violating state law Section 4442 Public Resource Code To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with Canadian ICES 002 Ce syst me d allumage par tincelle de v hicule est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no responsibility for varia
22. This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training Read the Operator s Manual and other training material If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate service the equipment Local regulations may restrict the age of the operator e The owner uset can prevent and is responsible for accidents or injuries occurring to himself or herself other people or property Preparation Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark Wear appropriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals Long hair loose clothing or jewelry may get tangled in moving parts CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause heating loss through extended
23. Valve Rotate the valve 1 4 turn counterclockwise to turn fuel on Starting the Engine Note Always engage the left and right neutral lock park brake latches in the park brake position when starting the engine 1 cold engine place the throttle midway between the Slow and Fast positions and place the choke in the On position On a warm engine place the throttle lever midway between Slow and Fast positions and leave the choke in the Off position 2 Turn ignition switch to Run position Pull the recoil rope to start engine 3 Ona cold engine gradually return choke to the position after engine starts warms up Note Kawasaki engines generally need to be choked even when warm PTO Engagement A DANGER The rotating blades under the mower deck are dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged A DANGER An uncovered discharge opening will allow objects to be thrown in an operatot s or bystander s direction Also contact with the blade could occur Thrown objects or blade contact can cause serious injury or death 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 The PTO switch engages the cutting blades Be sure that
24. all persons are clear of mower deck and discharge area before engaging the PTO 1 Set throttle to MIDWAY position 2 2 Push the PTO lever forward to engage blades Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set throttle to MIDWAY position 2 Pull the blade engagement lever to the full rearward position to disengage the blades Stopping the Engine 1 Bring the unit to a full stop Lock drive levers in park brake position Disengage the PTO Move transmission shift lever to neutral Place the throttle midway between the SLOW and FAST positions 2 2 4 5 16 6 Allow the engine to run for minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 7 Remove the key to prevent children or other unauthorized persons from starting engine 8 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine Drive Lever Neutral Lock Park Brake Latch Operation e For Pistol Grip Handles 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 reat Release the drive levers To lock the levers in park brake squeeze the dri
25. authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S or Canada customers may also call 402 223 6375 38 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must read the operator s manual You must also properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein Neither Exmark nor Exmark Warranty Company shall be liable for any incid
26. ays avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturet s recommendations for wheel weights or counter weights to improve stability Use extreme care with grass catchers or attachments These can change the stability of the machine and cause loss of control spark plug wire Wait fot all movement to stop before adjusting cleaning or repairing Keep engine and engine area free from accumulation of grass leaves excessive grease ot oil and other debris which can accumulate in these areas These matetials can become combustible and may result in a fire Let engine cool before storing and Do Not store neat flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors Park machine on level ground Never allow untrained personnel to service machine Use jack stands to support components when required Carefully release pressure from components with stored energy Use care when checking blades Wrap the blade s or wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible Do Not make adjustments with the engine running Keep all guards shields and all safety devices in place and in safe working conditio
27. blades should always be level to the ground ot tipped slightly down at the front Adjusting the Axle Position 10 Install mower deck belt shield Desired cutting height range can be obtained by 11 Adjust wheel drive and brake linkages as adjusting the rear axle and placing caster spacers required see Brake and Wheel Drive Linkage above or below the caster arm See Figure 10 and Adjustment section Figure 11 along with the Cutting Height Adjustment Chart It may be necessary to readjust wheel drive and brake linkages To adjust rear axle 1 Stop the machine and move the drive levers to the neutral lock position 2 Disengage the PTO Place the drive levers in the neutral lock position 4 Remove mower deck belt shield for access to axle Figure 10 adjustment bolts 1 Axle Pivot Bolt 5 Position C 5 Loosen but do not remove the two axle pivot 2 Axle Adjustment Holes 6 Position D bolts and the two axle adjustment bolts see Located in the side of Fioure 1 0 the rear deck gu 3 Position A 7 Position E 6 Place a jack under the rear center of the engine a gt OSION B E deck 7 Raise the back end of the engine deck up enough Note The axle positions are in 1 2 inch 1 3 cm to remove the two axle adjustment bolts increments and the large spacers are 1 2 inch 1 3 cm thick Therefore by adjusting the same number of 1 2 inch 1 3 cm caster spacers as axle hole positi
28. ckward to assist with the movement of the unit Switch Located on the control console Turn the key to the position to allow the engine to be started Turn the key to the Off position to shut engine off Fuel Shut Off Valve Located in the fuel line midway between the tank and engine 15 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 counterclockwise to turn fuel on Pre Start Fill fuel tank For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 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 1 2 inch 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 Refer to the Maintenance section and perform all the necessary inspection and maintenance steps Operating Instructions Open the Fuel Shut Off
29. cutting height may be obtained with higher tire pressure on rough terrain A lower tite pressure provides more flotation Check Condition Of Belts Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Remove the mower deck belt shield to check mowet blade drive belt condition Look under engine deck to check the transmission drive belt condition Inspect wheel drive belt conditions Check all idler arms to be sure they pivot freely Disassemble clean and grease pivot bushings if necessary Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate fittings with NGLI grade 2 multi purpose gun grease Refer to the following chart for fitting locations and lubrication schedule Lubrication Chart Fitting Initial Number of Places Service Locations Pumps Interval 32 inch 36 inch 48 inch Deck Deck Deck 2 Front Caster Pivots 3 Drive Wheels 4 Drive Wheel Idler Arm 5 Brake Arm 22 Maintenance G006800 48 inch Deck Shown for Reference Only Number 4 and 7 Idler Arm Pivots Disassemble and grease once month under a No Load condition Number 6 Transmission Coupler Located below fuel tank support Replace 5 speed gearbox grease yearly Use 18 oz of Peerless grease Part No 788067 Se
30. d Spec No Model No Engine Serial No E No Serial No 2009 Exmark Mfg Inc Part No 4500 352 Rev A Industrial Park Box 808 402 223 6300 Cle Beatrice NE 68310 Fax 402 223 5489 Rights Reserved Printed in the USA www exmark com
31. d and functioning properly Do Not operate unless they are functioning properly Safety Operation A WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land A WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect Operate only in daylight or good artificial light keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake is engaged before starting engine Never raise deck with blades running Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting or overspeed the engine Stop engine wait for all moving parts to stop remove
32. ded Maintenance Schedule s Maintenance Service Maintenance Procedure Interval After the first 5 hours Change the engine oil Check the engine oil level Check the mower blades Check the safety interlock system Check for loose hardware Grease the front caster wheel bearings Before each use or daily Grease front caster pivots Grease the drive wheels Grease the drive wheel idler arm Clean the engine and exhaust system area Clean the grass and debris build up from the machine and cutting deck Clean the grass build up from under the deck Service the air cleaner May need more often under severe conditions See the Engine Every 25 hours 9 manual for additional information Check the tire pressures Check the condition of the belts Every 40 hours Grease the brake arm Grease the transmission output shaft coupler Grease the mower deck idler pivots Every 80 hours Remove engine shrouds and clean cooling fins Every 100 hours Change the engine oil May need more often under severe conditions E 160 h Check the spark plugs Yer Check grease level input and output shaft bearing wear on Peerless Transmission Yearly Replace gearbox grease 19 Maintenance Periodic Maintenance Check Engine Oil Level Service Interval Before each use or daily 1 Stop engine and wait for all moving parts to stop Make sure unit is on a level surface Check with engine cold C
33. e Check Grease Level Input and Output Shaft Bearing Wear on Peerless Transmission section for special lubrication instructions Lubricate pivot points with a spray penetrating lubricant as shown in the Spray Lubricant Chart Spray Lubricant Chart Number of Places 32 inch 36 inch 48 inch Deck Deck Deck Service Interval 40 houts Pivot Points 1 Blade Engagement Bellcrank Check Spark Plugs Service Interval Every 160 hours Remove spark plugs check condition and reset gaps ot teplace with new plugs See Engine Owners Manual Change Fuel Filter Service Interval As required fuel filter is installed in the fuel line between the fuel tank and the engine Replace when necessary Check Grease Level Input and Output Shaft Bearing Wear on Peerless Transmission Service Interval Every 160 hours Check grease level input and output shaft bearing wear on Peerless Transmission Yearly Replace gearbox grease 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Remove key or spark plug wire s Place drive levers and neutral lock park brake latches in neutral lock position Remove shifter lever from top of transmission Remove shifter plate from top of transmission and the two leads from the neutral statt switch Release the tension on the transmission belt Check for side play caused by bearing wear on the input and output shafts of the transmission Rep
34. e U S or Canada This warranty may only be assigned or transferred to a second or third owner by an authorized Exmark dealer The warranty period commences upon the date of the original retail purchase Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery 1 Year Prorated Engine 2 years The Engine warranty is covered by the engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the literature packet This warranty only includes the cost of parts and labor Items and Conditions Not Covered This warranty does not cover the following Pickup and delivery charges to and from any authorized Exmark Service Dealer Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage All warranty work must be performed by an
35. e lawn mower unless you install a mulch plate discharge deflector or grass collection system 1 remove a damaged or worn discharge deflector lift the leg of the spring with the loop out of the notch in the discharge deflector and slide the rod out of the discharge deflector brackets and discharge deflector To install new discharge deflector orient the spring on the rod as shown in Figure 9 Slide the rod through the front discharge deflector bracket discharge deflector and rear deflector bracket 20 Maintenance 6010195 9 1 4 2 Spring 5 Discharge deflector bracket 3 Discharge deflector 6 Assembled view 3 Hook the bent end of the rod around the front discharge deflector bracket to retain it from sliding out Place the leg of the spring with the loop in the notch in the discharge deflector to hold the discharge deflector in the down position see Figure 9 Important The discharge deflector must be spring loaded in the down position Lift the deflector up to test that it snaps to the full down position Check Safety Interlock System Service Interval Before each use or daily 1 For your safety your Exmark mower is equipped with Operator Presence Controls referred to as OPC When either the PTO is engaged or the transmission shifter lever is not in neutral and the operator removes both hands from the handles the mower engine must sto
36. een the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Contact an Authorized Service Dealer Clean adjust or replace spark plug Check the spark plug wire connection Disengage the PTO Ensure the shifter lever is in the neutral position Depress OPC levers Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Clean or replace the fuel cap Replace the fuel filter Contact an Authorized Service Dealer Reduce the ground speed Add oil to the crankcase Troubleshooting Mower pulls left or right with levers fully forward Machine does not drive Uneven cutting height Abnormal vibration Blades do not rotate Blades do not stop when disengaged Idler arm pulleys and drive sheaves are dirty Wheel drive belt pulley scrapers adjustment is not correct Idler pivot arms cannot pivot freely Drive belts are worn Drive linkage adjustment is not correct Tire pressure in drive tires not correct Transmission drive belt
37. ental or consequential loss or damage Such damages include but are not limited to Expenses related to gasoline oil or lubricants Travel time overtime after hours time or other extraordinary repair charges or charges relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark Service Dealer Rental of like or similar replacement equipment during the period of any warranty repair or replacement work Any telephone or telegram charges or travel charges Loss or damage to person or property other than that covered by the terms of this warranty Any claims for lost revenue lost profit or additional cost as result of a claim of breach of warranty Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower All implied warranties of merchantability that the product is fit for ordinary use and fitness for use that the product is fit for a particular purpose are limited to the duration of the express warranty Some states do not allow exclusions of incidental or consequential damages or limitations on how long an implied warranty lasts so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state G4500 425 9 queo f 345 99
38. erial Nos 790 000 and Higher M15KA322P M15KA362P M15KA483P M15K 362 M15KA483 17 22 M17KA362CA M17KA483CA Systems Engine Engine Specifications See your Engine Ownet s Manual RPM Full Speed 3600 No Load Fuel System e Capacity 5 0 gal 18 9 Type of Fuel Regular unleaded gasoline 87 octane higher e Fuel Filter Replaceable In line Fuel Shut Off Valve 1 4 turn increments Safety Interlock System Operator must have the transmission in neutral and PTO disengaged to start engine Release of Operator Presence Control OPC levers will cause engine to stop if transmission is not in neutral and or PTO 15 engaged Steering Brake Controls Fingertip drive control levers provide independent control of traction braking and neutral to each drive wheel for moving stopping and power turning Parking brakes are engaged by locking drive control levers in the brake position Transmission e Peerless 700 070A five speeds forward and one reverse Speed range 1st 2 0 mph 3 22 km hr 2nd 2 7 mph 4 35 km hr 3rd 3 5 mph 5 63 km hr 4th 4 1 mph 6 60 km hr 5th 6 2 mph 9 98 km hr Reverse 3 1 mph 4 99 km hr 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 inch Model Tires amp Wheels me Caster Pneumatic Air Filled
39. es 2 7 8 inch 4 8 7 3 cm 7 3 3 8 inc 7 8 inc 3 1 8 inch 6 0 cm 7 3 cm 7 9 cm 1 2 inc 3 4 inc 3 1 4 inch 6 4 cm 7 0 cm 8 5 cm 3 4 inc 3 1 2 inch 6 4 8 9 d 7 0 cm 8 9 cm 2 3 8 3 3 8 inches 3 8 inc 7 8 inch 2 3 3 8 inch 6 0 8 6 6 0 7 3 8 6 21 2 3 1 2 inches 1 2 inc 3 4 inc 2 3 1 2 inch 6 48 9 cm 5 6 4 7 0 8 9 2 3 4 3 3 4 3 4 inc 3 1 4 inch 3 3 4 inch 7 0 9 5 3 7 0 cm 8 5 cm 9 5 cm 3 4 inches 3 1 4 inch 3 1 2 inch 3 4 inch 7 6 10 1 cm 8 3 cm 8 9 cm 10 1 cm 2 7 8 3 7 8 inches 7 8 inch 3 1 8 inch 3 3 8 inch 3 5 8 inc 3 7 8 inch 7 3 9 8 cm 5 7 3 7 9 8 6 9 2 9 8 cm 25 Maintenance Cutting Height Adjustment Table 1 inch to 4 1 4 inches 2 5 cm 10 8 cm cont d Cutting Axle Number Of Spacers Number of 1 4 inch Blade Spacers Below Spindle Height Position Below Caster Range Figure 10 Support Hub 3 1 8 4 1 8 inches 3 1 8 inch 3 3 8 inch 3 5 8 inch 3 7 8 inch 4 1 8 inch 7 9 10 5 cm 3 7 9 cm 8 6 cm 9 2 cm 9 8 cm 10 5 3 1 4 3 1 4 inch 3 1 2 inch 3 3 4 inch 4 inch 4 1 4 inch 3 8 3 cm 8 9 cm 9 5 cm 10 1 cm 10 8 cm 4 1 4 inches 8 3 10 8 cm Important Always adjust the Number of Spacers below Caster Hub to correspond to the Axle Position as shown in table to obtain proper rake
40. handle can be pivoted to allow positioning in one of the three holes allowing various adjustments for operator comfort see Figure 26 To adjust the handle height 1 Remove the bottom mounting hardware on each side of the handle Pivot the handle to one of the three positions Re install hardware and tighten Important If the handle height position is changed it will be necessary to readjust the drive and brake linkage see Check Brake and Wheel Drive Linkage Adjustment section in Operation 32 Maintenance 6006812 Figure 26 1 Upper Handle 2 Upper Hole 3 Adjustment Holes 4 Fuel Tank Support Note Adjustment Holes are actually in the side of the fuel tank support Wheel Drive Spring Tension Adjustment It may be necessary to increase wheel drive belt tension under certain operating conditions such as wet grass hilly terrain or while pulling a sulky 1 Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wite s 2 Disengage neutral lock park brake latches and release drive levers to lower spring force 3 Remove the 5 16 18 inch whizlock nut securing the adjustment bolt to the drive wheel shield Locate bolt assembly in the desired position as follows e Position A Normal Conditions e Position B More Severe Position C Most Severe Note Lever force is lowest with bolt assembly in Position and will increase in Positions B and
41. ition 3 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 7 position 4 Release drive levers A CAUTION If the neutral lock park brake latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position If the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage Be sure the drive levers are securely seated at the bottom of the neutral or park areas of the neutral lock latches Operation To place the drive levers in the drive position slightly squeeze the drive levers while placing thumbs on the outer thumb lobe of the neutral lock park brake latches or the index finger on the front lobe and rotate them from under the drive levers Slowly and carefully release the drive levers See Figure 7 position 1 6006796 Figure 7 1 Drive Lever in drive 3 Drive Lever locked in position neutral position 2 Drive Lever in neutral 4 Drive Lever locked in position park position Driving Forward 1 With drive levers in the neutral or park brake position shift transmission into desired gear 2 Squeeze both drive levers and move both neutral lock park brake latches from
42. lace 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 the lower case The grease level should be approximately 1 1 2 inch to 1 3 4 inch 3 8 to 4 4 cm from the gearbox bottom If necessary fill to proper level with Peerless grease Part No 788067 Reinstall upper case half and fasten in place with six bolts previously removed 10 Reinstall all parts removed in steps 3 and 4 Install drive belt and adjust tension as stated in the Transmission Belt Adjustment section 23 Maintenance Thread Locking Adhesives Thread locking adhesives such as Loctite 242 ot Fel Pro Pro Lock Nut Type are used on the following fasteners All belt drive pulley setscrews e OPC lever setscrews Pulley retaining bolt in end of engine crankshaft Fuel tank bulkhead fitting threads Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining I or Retaining are used on the following 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 Fuel tank studs where studs are inserted into tank Mobil HTS Grease Or Food Grade Anti seize Mobil HTS grease or food grade anti seize is used in the following locations Between the cut
43. lean area around dipstick Remove dipstick wipe oil off Reinsert the dipstick and push it all the way down into the tube Do Not screw into place Remove the dipstick and read the oil level If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Use oil as specified in Engine Owner s Manual Do Not overfill Important Do Not operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check Mower Blades Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Lift deck and secure in raised position as stated in the Clean Grass Build Up Under Deck procedure 3 Inspect blades and sharpen or replace as required Re install the blades if they were removed and torque blade bolts to 75 80 ft lb 102 109 N m Be sure the spring disc washer cone is installed toward the bolt head see Figure 8 G006799 Figure 8 2 Blade bolt torque to 75 80 ft Ib 102 109 N m 1 Spring disc washer cone towards bolt head Replacing the Discharge Deflector Service Interval As required DANGER An uncovered discharge opening could allow the lawn mower to throw objects in the operator s or bystander s direction and result in serious injury Also contact with the blade could occur Never operate th
44. lt Pulley Scrapers 1 Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wite s 2 Be sure mud and grass scrapet on each side is adjusted properly and centered 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 Engine to Mower Deck Belt 1 Stop engine and wait for all moving patts to stop Engage parking brake Remove key or spark plug wite s 2 Check the adjustment of the lower blade drive linkage located between the bellcrank on the engine deck and assist arm on the mower deck Lengthen or shorten the linkage When properly adjusted there should be 1 16 inch to 1 8 inch 2 3 mm of clearance between bell crank and transmission output shaft when belt is engaged Make sure the assist arm is against the rear assist arm stop on the deck see Figure 13 Push the lever down to the disengaged position The assist arm should contact the front assist arm stop on the deck If it does not contact readjust so that the bellcrank is closer to the transmission output shaft 3 Belt must be tight enough to not slip during heavy loads while cutting grass Over tensioning will reduce belt and spindle bearing life To adjust belt tension loosen the 5 16 inch whizlock nut on turnbuckle and rotate the turnbuckle rotate turnbuckle toward rear of mower to tighten and toward front of mower to loo
45. may be adjusted for cutting height by using the four 1 4 inch 64 cm spacers found on the blade spindle bolts factory setting is two above and two below This allows 1 inch 2 5 cm range in 1 4 inch 64 cm increments of cutting height in any axle position The same number of blade spacers must be used on all blades to achieve a level cut two above and two below one above and three below etc Raise front of deck and support with jack stands Hold blade bolt on bottom and loosen spindle nut on top Adjust number of spacers between bottom of spindle and blade as indicated the Cutting Height Adjustment Table and notes in the Adjusting the Cutting Height section Install unused spacers between top of spindle and spindle nut Torque bolt to 75 80 ft lb 102 109 N m see Figure 12 G006799 Figure 12 Spring disc washer cone towards bolt head 2 Blade bolt torque to 75 80 ft lb 102 109 N m 1 Transmission Adjustment Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wire s Maintenance 2 tighten transmission belt loosen the 3 8 inch nyloc nut on transmission belt idler pulley Slide bolt inward in slot and retighten nyloc nut 3 When properly adjusted the belt should have 1 2 inch 1 3 cm of deflection with three pounds of pressure on the belt midway between the transmission and engine pulley Wheel Drive Be
46. n Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard All replacement parts must be the same as or equivalent to the parts supplied as original equipment Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Replace all worn damaged or missing safety signs When replacement components are installed be sure that current safety signs are affixed to the replaced components If an attachment or accessory has been installed make sure current safety signs are visible 4 WARNING DO NOT OPERATE WITHOUT DISCHARGE DEFLECTOR ENTIRE GRASS COLLECTION SYSTEM OR MULCH IN PLACE DO NOT REMOVE GRASS CATCHER UNTIL BLADES HAVE STOPPED 1 303508 WARNING OPEN BELT DRIVE STOP ENGINE BEFORE REACHING UNDERNEATH 1 17 J 3035 P 1 303517 New safety signs may be obtained from your authorized Exmark equipment dealer or distributor from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following
47. nance mes Check Engine Oil Check Mower Blades Check Safety Interlock System n s Check for Loose Hardware 5 Service Pre Cleaner Element and Air T Change Hite Check Tire Check Condition Lubricate Grease Check Spark P Ies ia Check Grease Level Input and Output Shaft Bearing Wear on Peerless Thread Locking etin Mobil HTS Grease Or Food Grade Jti Copper Based Anti seize Dielectric madame d pe voe Deut ute Adj stments denda e ee ERU ete NR e GE Adjusting the Cutting Height eie Adjusting the Axle Position Adjusting the Number of Spacers below Caster Support ae Adjusting the Cutting Height with Blade SPACETS io cies cont annie Transmission Belt Adjustment Wheel Drive Belt Pulley Scrapers Engine to Mower Deck oie Blade Brake Adjustment eret Belt Guide Adjustment 29 Brake and Wheel Drive Linkage Adjustment o ouod 30 Shifter Lever Adjustment 31 Shifter Detent Adjustment coerente 32 PTO Safety Switch Adjustment 32 Handle Height
48. ndles Located on handles ahead of the grips For ECS Handles Located on the upper handle assembly on the ends of the handle grips The latches allow the operator to lock the drive levers in a neutral position where neither the wheel drive belts nor the brakes engage or in a park brake position where the wheel drive belts are not engaged and the park brake is engaged see Figure 4 and Figure 5 Choke Control Located on the front left corner of the fuel tank support Choke is used to aid in starting a cold engine The choke control is pulled out to be in the position and pushed in to be in the OFF position Do Not run a warm engine with choke in the position Throttle Control Located on the on the control console 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 Moving the throttle forward into the detent is full position 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 ba
49. nses 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 15 engaged see Figure 4 and Figure 5 6006794 5 Figure 4 Pistol Grip Handle 1 Neutral Lock Park Brake 4 OPC Lever Latch 2 Rotate latch forward for 5 Drive Lever park brake position 3 Rotate latch back for neutral lock position 14 Operation 6006793 5 ECS Handle 1 OPC Lever 3 Neutral Lock Latch Park Brake Latch 2 Rotate latch for neutral 4 Drive Lever lock and park brake positions Drive Levers Located on each side of the upper handle assembly ahead of and below the handle grips see Figure 4 and Figure 5 These levers individually control clutching action of the wheel drive belts and brakes When the drive levers are all the way down the brakes disengage and the wheel drive belts engage 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 Park Brake Latches For Pistol Grip Ha
50. ons the blades will retain the same front to back tip rake 8 With the jack raise or lower the back end of the engine deck so that two axle adjustment bolts can be reinstalled in desired hole location A tapered punch can be used to help align the holes 9 Retighten all four bolts lower unit and remove jack 26 Maintenance Adjusting the Number of Spacers below Caster Support Hub 1 Stop the machine and move the drive levers to the neutral lock position 2 Disengage the PTO 3 Place the drive levers in the park brake position 4 Push down on handles to lift front casters off the ground 5 Support with jackstands 6 Remove quick from one caster and remove caster from hub see Figure 11 1 2 3 4 Figure 11 1 Four 1 2 inch 127 3 3 16 inch 4 8 mm spacers spacer 2 Quick Pin 4 Caster support 7 Adjust the number of 1 2 inch spacers between bottom of hub and caster yoke to obtain the desired cutting height from the Cutting Height Adjustment Table in the Adjusting the Cutting Height section 8 Install remaining spacers on top of hub 9 Install quick 10 Repeat for other caster Adjusting the Cutting Height with Blade Spacers 1 Stop the machine and move the drive levers to the neutral locked position 2 Disengage the PTO Engage the park brake Stop the engine remove the key and wait for all moving parts to stop 10 1 Blades
51. overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do Not attempt to service or replace major items or any items that call for special timing of adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors Do Not pull on the wires to separate the connectors Engine will not start starts hard or fails to keep running Engine loses power Engine overheats Fuel tank is empty Fuel shutoff valve is closed The throttle and choke ate not in the correct position Dirt in fuel filter Dirt watet or stale fuel is in the fuel system Ait cleaner is dirty Electrical connections are corroded loose ot faulty Relay or switch is defective Faulty spark plug Spark plug wire is not connected PTO is engaged Transmission is not in true neutral position OPC levets ate released Engine load is excessive Ait cleaner is dirty Oil level in the crankcase is low Cooling fins and air passages for the engine are plugged Vent hole in the fuel cap is plugged Dirt in fuel filter Dirt watet or stale fuel is in the fuel system Engine load is excessive Oil level in the crankcase is low 35 Fill the fuel tank Open the fuel shutoff valve Be sure the throttle control is midway betw
52. p 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 gt shift the transmission into gear and release the OPC levers the engine must stop 3 Again run the engine at on third throttle move the transmission shifter lever to neutral engage the PTO and release the OPC levers the engine must stop Note If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Check for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Visually inspect machine for any loose hardware or any other possible problem Tighten hardware or correct the problem before operating Service Pre Cleaner Element and Air Cleaner Service Interval Every 25 hours Service the air cleaner May need more often under severe conditions See the Engine manual for additional information 1 Stop engine wait for all moving parts to stop and remove key or spark plug wire s Engage parking brake See the Engine Owner s Manual for cleaning instructions Change Engine Oil Service Interval After the first 5 hours Ever
53. se care when approaching blind corners shrubs trees or other objects that may obscure vision Slope Operation 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 Safety A DANGER Operating on wet grass or steep slopes can cause sliding and loss of control Loss of control and or loss of operator s footing could result in a fall with an arm or leg getting under the mower or engine deck which may result in serious injury death or drowning Mow across slopes never up and down Do Not mow slopes when grass is wet 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 rapid speed changes See inside the back cover to determine the approximate slope angle of the area to be mowed Remove ot mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden starts when mowing uphill because the mower may tip backwards Be aware that operating on wet grass across steep slopes ot downhill may cause the mowet to lose traction Loss of traction to the drive wheels may result in sliding and a loss of braking and steering Alw
54. sen belt tension see Figure 13 Leave a minimum of 5 16 inch 79 cm of the eyebolt threads engaged on both ends of the turnbuckle 48 Decks If there is no adjustment left in the turnbuckle and the belt is still loose the rear idler pulley can be repositioned in the front hole See Figure 12 The belt guide located next to the pulley must also be repositioned in the front hole when the pulley is moved The turnbuckle will need to be readjusted Check belt tension after the first hour of operation and at least twice during the first 24 hours of operation Adjust as necessary 4 5 6 6006805 10 o Figure 13 48 inch Deck Shown for Reference Only Pulley location for Metro Pulley can be moved to the front position to tighten the belt when there is no adjustment left in the turnbuckle 48 inch deck only Belt guide must be moved to the front position if the pulley is moved 48 inch deck only Turnbuckle 5 16 inch 79 cm minimum engagement 5 16 inch whizlock nut Rear Assist Arm Stop Assist Arm Front Assist Arm Stop Point A 4 Propet belt tension will require about 10 Ib 4 5 kg side pull on belt halfway between pulleys see Figure 13 item 10 Point A to deflect belt 1 2 inch 12 mm Check belt guide under the engine deck to see that it is properly set see Belt Guide Adjustment section Also check the blade brake adjustment see Blade Brake
55. ter housing spindle and bearings Between the cutter housing spindle and sheave Copper Based Anti seize Copper based anti seize is used in the following locations Between the blade drive and transmission drive pulleys and engine crankshaft Between the transmission drive pulley and transmission drive shaft Between the bearings and sheaves and transmission output shafts Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact Adjustments Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit Adjusting the Cutting Height The cutting height of the mower deck is adjusted from 1 inch to 4 1 4 inches 2 54 cm to 11 4 cm in 1 4 inch 64 cm increments by adjusting the axle position number of spacers below the caster hub and number of spacers between blade and spindle Refer to the Cutting Height Adjustment table and select a cutting height range in the left hand column which corresponds to the range of cutting heights you will most often be using Adjustments within this range can then be made by adjusting the number of blade spacers between the blade and the bottom of the spindle this is a much easier adjustment to make than adjusting axle position and number of spacers below caster support hub Note that
56. their service stations They carry ample stock of service parts or can secure them promptly for you from the factory Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers the space provided UR WY lt 499 Figure 1 1 Model serial number location G006943 Model No Serial No Introduction Safety Safety Alert Safe Operating Safety and Instructional Decals Contents Specifica Model dd oss Torque Requirements edited atten Product Overview Operat gol qe Fo Operating Instr retloris s scu MAUS POMS ta uius ee Recommended Maintenance Schedule s Periodic Mainte
57. tions which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2009 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PS 0 OVERNIGHT FREE If your Exmark dealer does not have the Exmatk part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA Rights Reserved Introduction CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation This manual contains operating maintenance adjustment and safety instructions for your Exmark mowet 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 yout authorized Exmark equipment dealer or distributor 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
58. ve levers back to the brake position Place thumbs on the upper portion of the neutral lock park brake latches and move them to the front Release the drive levers see Figure 6 A CAUTION If the neutral lock park brake latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position If the drive levers slip into the drive position the unit could lurch forward and cause injury or property damage Be sure the pins protruding through the slots of each neutral lock latch are completely engaged in the rear slot of each latch 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 17 G006795 N C EE 9 8 7 Figure 6 Latch is in the drive 6 Neutral lock position Rotate forward for park 7 Forward release drive brake position lever Rotate back for neutral 8 Neutral hold in this lock position position Park brake 9 Reverse squeeze drive lever Full speed forward For ECS Handles To lock the drive levers in neutral lock squeeze the drive levers to the neutral position See Figure 7 position 2 Place thumbs on the inner thumb lobe of the neutral lock park brake latches and rotate them to the neutral position See Figure 7 pos
59. while it is attached to the transmission Re install lever and torque the 3 8 inch nyloc nut to 35 ft lb 47 N m To adjust shifter plate Note The square hole washer must be between the levet and the transmission Place shifter lever in the neutral position Loosen the two bolts securing the shifter plate to the shifter lever legs Adjust shifter plate and retighten bolts Shifter Detent Adjustment Transmission shifter detent can be adjusted by adjusting the setscrew on the back side of transmission located just behind the neutral start switch Turn setscrew in clockwise to hold the transmission shifter more positively in each gear and to increase the force on the lever required to shift gears Turn setscrew out counterclockwise to decrease force on lever required to shift gears Factory setting is to turn setscrew all the way in then back out 1 1 2 turns Important Screwing setscrew in too far will prevent the transmission from shifting PTO Safety Switch Adjustment 1 Stop engine and wait for all moving parts to stop Engage parking brake Remove key or spark plug wire s With the blades disengaged and the bellcrank touching the engine deck adjust the blade safety switch if needed until the bellcrank depresses the plunger by 1 4 inch 64 cm Be sure the bellcrank does not contact the switch body to prevent damage to the switch Retighten switch mounting hardware Handle Height Adjustment The
60. y 100 hours May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Drain oil while engine is warm from operation 21 Maintenance Remove the oil drain plug from the right hand side of the engine Allow oil to drain replace drain plug Replace the oil filter per the engine ownet s manual Clean around oil filter and unscrew filter to remove Before the new filter is installed apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 2 3 to 3 4 turn Clean around oil fill cap and remove cap Fill to specified capacity and replace cap Use oil recommended in engine owner s manual Do Not overfill Start the engine and check for leaks Stop engine and recheck oil level Wipe up any spilled oil from engine deck mounting surfaces Check Tire Pressures Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Check tire pressure in drive tires Inflate drive tires to 12 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 Semi pneumatic caster tires Do Not need to be inflated Note A mote uniform
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