Exmark Metro 00 Higher, Metro 850 User Manual

Download

METRO®

ForSerialNos. 850,000&Higher

PartNo.4500-534Rev.B

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:IMPORTANTTheengineinthis productisnotequippedwithasparkarrester mufer.ItisaviolationofCaliforniaPublic ResourceCode(CPRC)Section4442touse oroperatethisengineonanyforest-covered, brush-covered,orgrass-coveredlandasdened inCPRC4126.Otherstatesorfederalareasmay havesimilarlaws.

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

ThissparkignitionsystemcomplieswithCanadian ICES-002Cesystèmed’allumageparètincellede vèhiculeestconformeàlanormeNMB-002du Canada

TheenclosedEngineOwner’sManualis suppliedforinformationregardingTheU.S. EnvironmentalProtectionAgency(EPA)and theCaliforniaEmissionControlRegulationof emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit. ShouldthisengineOwner’sManualbecome damagedorillegible,replaceimmediately. Replacementsmaybeorderedthroughthe enginemanufacturer.

Exmarkreservestherighttomakechangesor addimprovementstoitsproductsatanytime withoutincurringanyobligationtomakesuch changestoproductsmanufacturedpreviously. Exmark,oritsdistributorsanddealers,accept noresponsibilityforvariationswhichmaybe evidentintheactualspecicationsofitsproducts andthestatementsanddescriptionscontained inthispublication.

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety instructions,youwillprolongthelifeofyourmower, maintainitsmaximumefciency ,andpromotesafe operation.

Ifadditionalinformationisneeded,orshouldyou requiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor. Exmarkpartsmanualsareavailableonlineat http://www.exmark.com/manuals.htm

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

AllExmarkequipmentdealersanddistributorsare keptinformedofthelatestmethodsofservicing andareequippedtoprovidepromptandefcient serviceintheeldorattheirservicestations.They carryamplestockofservicepartsorcansecurethem promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready .

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.......................9

Specications.......................................................12

ModelNumbers............................................12

Systems.........................................................12

Dimensions...................................................13

TorqueRequirements....................................13

ProductOverview................................................14

Operation.............................................................14

Controls........................................................14

Pre-Start........................................................16

OperatingInstructions..................................16

Transporting.................................................18

Maintenance.........................................................19

RecommendedMaintenanceSchedule(s)...........19

PeriodicMaintenance.......................................20

CheckEngineOilLevel.................................20

CheckMowerBlades.....................................20

CheckSafetyInterlockSystem.......................21

CheckforLooseHardware............................21

ServiceAirCleaner........................................21

ChangeEngineOil........................................22

CheckTirePressures.....................................22

CheckConditionOfBelts..............................22

LubricateGreaseFittings...............................22

CheckSparkPlugs.........................................23

CheckGreaseLevel,InputandOutput

ShaftBearingWearonPeerless

Transmission.............................................23

ThreadLockingAdhesives.............................24

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................24

Copper-BasedAnti-seize..............................24

DielectricGrease...........................................24

Adjustments.....................................................25

AdjustingtheCuttingHeight.........................25

AdjustingtheAxlePosition............................26

AdjustingtheNumberofSpacersbelow

CasterSupportHub...................................27

AdjustingtheCuttingHeightwithBlade

Spacers......................................................27

TransmissionBeltAdjustment.......................28

WheelDriveBeltPulleyScrapers...................28

EnginetoMowerDeckBelt...........................28

BladeBrakeAdjustment................................29

BeltGuideAdjustment..................................30

BrakeandWheelDriveLinkage

Adjustment...............................................30

ShifterLeverAdjustment...............................32

ShifterDetentAdjustment.............................33

PTOSafetySwitchAdjustment......................33

HandleHeightAdjustment............................33

WheelDriveSpringTension

Adjustment...............................................33

Cleaning...........................................................34

CleanEngineandExhaustSystem

Area..........................................................34

RemoveEngineShroudsandCleanCooling

Fins...........................................................34

CleanDebrisFromMachine..........................35

CleanGrassBuild-UpUnderDeck................35

WasteDisposal..............................................35

Troubleshooting...................................................36

Schematics...........................................................38

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Yellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator’s

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses, substantialfootwear,longtrousers,andhearing protection.DoNotoperatewhenbarefootor whenwearingopensandals.Longhair,loose clothingorjewelrymaygettangledinmoving parts.

CAUTION

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)can notreadEnglishitistheowner’sresponsibilityto explainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

•Inspecttheareawheretheequipmentistobe usedandremoveallrocks,toys,sticks,wires, bones,andotherforeignobjectswhichcanbe thrownbythemachineandmaycausepersonal injurytotheoperatororbystanders.

Safety

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Fillthefueltanktothebottomoftheller neck.Theemptyspaceinthetankallows gasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineor emissionsystem(ifequipped).

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitegasolinevapors.Areor explosionfromgasolinecanburnyouand othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperator’spresencecontrols, safetyswitches,andshieldsareattachedand functioningproperly.DoNotoperateunlessthey arefunctioningproperly.

Safety

Operation

WARNING

Operatingengineparts,especiallythemufer, becomeextremelyhot.Severeburnscanoccur oncontactanddebris,suchasleaves,grass, brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to coolbeforetouching.

•Removeaccumulateddebrisfrommufer andenginearea.

•Installandmaintaininworkingordera sparkarresterbeforeusingequipment onforest-covered,grass-covered,or brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

–Beforemakingheightadjustments.

WARNING

Hands,feet,hair,clothing,oraccessoriescan becomeentangledinrotatingparts.Contact withtherotatingpartscancausetraumatic amputationorseverelacerations.

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.

•Keephands,feet,hair,jewelry,orclothing awayfromrotatingparts.

•DONOToperatethemowerwhenpeople, especiallychildren,orpetsareinthearea.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

•Neveroperatethemowerwithdamagedguards, shields,orcovers.Alwayshavesafetyshields, guards,switchesandotherdevicesinplaceandin properworkingcondition.

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly.

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Stopengine,waitforallmovingpartstostop, removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning onslopesaslossoftractionand/ortip-overcould occur.Theoperatorisresponsibleforsafeoperation onslopes.

Safety

DANGER

Operatingonwetgrassorsteepslopescan causeslidingandlossofcontrol.Lossofcontrol and/orlossofoperator’sfootingcouldresultina fallwithanarmorleggettingunderthemower orenginedeckwhichmayresultinserious injury,deathordrowning.

•Mowacrossslopes,neverupanddown.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan20degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

•Removeormarkobstaclessuchasrocks,tree limbs,etc.fromthemowingarea.Tallgrasscan hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Keepengineandengineareafreefrom accumulationofgrass,leaves,excessivegrease oroil,andotherdebriswhichcanaccumulate intheseareas.Thesematerialscanbecome combustibleandmayresultinare.

•LetenginecoolbeforestoringandDoNotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•Usecarewhencheckingblades.Wraptheblade(s) orweargloves,andusecautionwhenservicing them.Onlyreplacedamagedblades.Never straightenorweldthem.

•Keephandsandfeetawayfrommovingparts. Ifpossible,DoNotmakeadjustmentswiththe enginerunning.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.

WARNING

Removingstandardoriginalequipmentparts, orusingnon-Exmarkreplacementpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.

Replaceallpartsincluding,butnotlimitedto tires,belts,andbladeswithoriginalExmark parts.

SafetyandInstructionalDecals

Safety

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

1-303508

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe backingtoexposetheadhesivesurface.Apply onlytoaclean,drysurface.Smoothtoremove anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

1-323427

32inchand36inchUnitsOnly

1-303517

1-323550

1-303518

PistolGripHandleUnitsOnly

1-403005

Safety

1-403143

98-5954

103–2076

103-2244

ECSUnitsOnly

103-1623

ECSUnitsOnly

103-1798

103-2245

ECSUnitsOnly

103-5626

48inchDeckUnitsOnly

Safety

117–2718

103-1967

PistolGripUnitsOnly

Specications

ModelNumbers

SerialNos:850,000andHigher

M16KA322PM16KA362PM16KA362M16KA483PM16KA483M16KA322PCAM16KA362CAM16KA483CA

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•RPM:FullSpeed:3600(NoLoad)

FuelSystem

•Capacity:5.0gal.(18.9L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher;containingnomorethan10% methanolorethanol.

•FuelFilter:ReplaceableIn-line

•FuelShut-OffValve:1/4turnincrements

SafetyInterlockSystem

Operatormusthavethetransmissioninneutraland PTOdisengagedtostartengine.ReleaseofOperator PresenceControl(OPC)leverswillcauseengineto stopiftransmissionisnotinneutraland/orPTO isengaged.

Steering/BrakeControls

Fingertipdrivecontrolleversprovideindependent controloftraction,braking,andneutraltoeachdrive wheelformoving,stopping,andpowerturning. Parkingbrakesareengagedbylockingdrivecontrol leversinthe“brake”position.

Transmission

•Peerless700-070A,vespeedsforwardandone reverse.

•Speedrange:

–1st:2.0mph(3.22km/hr)

–2nd:2.7mph(4.35km/hr)

–3rd:3.5mph(5.63km/hr)

–4th:4.1mph(6.60km/hr)

–5th:6.2mph(9.98km/hr)

–Reverse:3.1mph(4.99km/hr)

WheelDriveSystem

BandeddoubleA-SectionV-belts,singletop-side idlersandreplaceablebolt-ondrivesheavesandbrake drums.(SingleB-SectionV -beltsforthe32inch Model)

Tires&Wheels

Drive

Pneumatic(Air-Filled)

3236&48

Quantity

Tread

Size13x5.00-613x6.50-69x3.50-4

PlyRating

Pressure

Bearings

222

TurfSaverTurfMasterSmooth

14psi (97kPa)

Replaceable Ball

14psi (97kPa)

Replaceable Ball

Front Caster

SemiPneumatic

AllDecks

Replaceable Roller

Specications

CuttingDeck

•CuttingWidth:

–32inchDeck:31.75inches(80.7cm)

–36inchDeck:35.38inches(89.9cm)

–48inchDeck:47.25inches(120.0cm)

•Discharge:Side

•BladeSize:

–32inchDeck:16.25inches(41.3cm)—

Quantity:2

–36inchDeck:18.00inches(45.7cm)—

Quantity:2

–48inchDeck:16.25inches(41.3cm)—

Quantity:3

•DeckDrive:Manualengagementofbeltwith over-centerlock.Bladebelttensionisadjustable viaturnbuckle.

•BladeBrake:Whenthebladeengagementcontrol ismovedtothedisengagedpositionafriction brakepadstopstherotationoftheblades.

•DeckMounting:Bolteddirectlytoenginedeck.

•DeckDepth:

OverallLength:

32inch Deck

Standard PistolGrip Handles

ECS Handles

78.0inches (198.1cm)

77.3inches (196.3cm)

36inch Deck

78.0inches (198.1cm)

77.3inches (196.3cm)

48inch Deck

73.0inches (185.4cm)

72.3inches (183.6cm)

OverallHeight:

StandardPistolGrip Handles

ECSHandles

40.0inches(101.6cm)

42.1inches(106.9cm)

TreadWidth:(OutsidetoOutsideof Tires,Widthwise)

32inch Deck

Standard PistolGrip &ECS Handles

32.1inches (81.4cm)

36inch Deck

35.6inches (90.4cm)

48inch Deck

35.6inches (90.4cm)

–32inchDeck:5.0inches(12.7cm)

–36inchDeck:5.0inches(12.7cm)

–48inchDeck:5.0inches(12.7cm)

•CuttingHeightAdjustment:

Adjustsfrom1inch(2.5cm)to41/4inches(10.8 cm)in1/4inch(6.4mm)orsmallerincrements byvariousadjustmentsofcasterspacers,blade spacers,andaxleheight.

Dimensions

OverallWidth:

32inch Deck

Deector Up

Deector Down

32.7inches (83.1cm)

43.3inches (110.0cm)

36inch Deck

36.4inches (92.5cm)

47.0inches (119.4cm)

48inch Deck

48.1inches (122.2cm)

57.9inches (147.1cm)

CurbWeight:

32inch Deck

Standard PistolGrip Handles

ECS Handles

420lb (191kg)

435lb (197kg)

TorqueRequirements

BoltLocation

Blade/CutterHousing SpindleBolt

CasterBracketMounts

MowerDeck/Engine DeckMount

EngineMountingBolts

TransmissionShifterLever Nut

36inch Deck

430lb (195kg)

446lb (202kg)

Torque

75-80ft-lb(102-109N-m)

30-35ft-lb(41-48N-m)

17-23ft-lb(23-31N-m)

30-35ft-lb(41-48N-m)

48inch Deck

475lb (215kg)

490lb (222kg)

Operation

ProductOverview

Figure3

1.Controls4.ECSHandles

2.FuelCap5.BladeSpacers

3.PistolGripHandles

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

OperatorPresenceControl(OPC) Levers

Locatedontheupperhandleassemblydirectlyabove thehandlegrips.

Whentheseleversaredepressed,theOPCsystem sensesthattheoperatorisinthenormaloperator’s position.Whentheleversarereleased,theOPC systemsensesthattheoperatorhasmovedfromthe normaloperatingpositionandwillkilltheengineif eitherthetransmissionshiftleverisnotintheneutral positionorthePTOisengaged(see Figure5).

Figure4and

PistolGripHandle

1.NeutralLock/ParkBrakeLatch

2.Rotatelatchforwardforparkbrakeposition

3.Rotatelatchbackforneutrallockposition

4.OPCLever

5.DriveLever

Figure4

Operation

ChokeControl

Locatedonthefrontleftcornerofthefueltank support.

Chokeisusedtoaidinstartingacoldengine.The chokecontrolispulledouttobeinthe“ON”position andpushedintobeinthe“OFF”position.DoNot runawarmenginewithchokeinthe“ON”position.

ThrottleControl

Figure5

ECSHandle

1.OPCLever

2.Rotatelatchforneutrallockandparkbrakepositions

3.NeutralLockLatch/ParkBrakeLatch

4.DriveLever

DriveLevers

Locatedoneachsideoftheupperhandleassembly aheadofandbelowthehandlegrips(seeFigure4 andFigure5).

Theseleversindividuallycontrolclutchingactionof thewheeldrivebeltsandbrakes.Whenthedrive leversareallthewaydown,thebrakesdisengageand thewheeldrivebeltsengage

Graduallysqueezingtheleftorrighthanddrivelever disengagesthewheeldrivebelts,causingthelefthand orrighthandwheeltoslowdownuntiltheyreach neutralorstop.Thismakesthemachineturntothe leftorrightrespectively.Squeezingfurtherengages theparkbrakes.Thesharpnessoftheturnvariesby howmuchtheleverissqueezed.Forstraightahead motion,smoothlyreleasebothdriveleverstoengage bothdrivewheelssimultaneously.

Locatedontheonthecontrolconsolerightside.

Thethrottleisusedtocontrolenginespeed.Moving thethrottlecontrolforwardwillincreaseengine speedandmovingittotherearwilldecreaseengine speed.Movingthethrottleforwardintothedetent isfullposition.

TransmissionShiftLever

Locatedunderthecontrolconsoleandbehindthe fueltank.

Itshiftsthe5-speedtransmissionintoveforward gears,neutralandreverse.Shifttransmissiononly whendriveleversareintheneutralposition.Shifting withoutdriveleversinneutralmaycausedamageto thetransmission.

Note:Reverseis“reverseassist”only,meaningwhen thetransmissionisinreverse,theoperatorhastopull theunitbackwardto“assist”withthemovementof theunit.

“Off-Run”Switch

Locatedonthecontrolconsole.

Turnthekeytothe“Run”positiontoallowthe enginetobestarted.Turnthekeytothe“Off” positiontoshutengineoff.

NeutralLock/ParkBrakeLatches

•ForPistolGripHandles:Locatedonhandles aheadofthegrips.

•ForECSHandles:Locatedontheupperhandle assemblyontheendsofthehandlegrips.

Thelatchesallowtheoperatortolockthedrivelevers ina“neutral”positionwhereneitherthewheeldrive beltsnorthebrakesengageorina“parkbrake” positionwherethewheeldrivebeltsarenotengaged andtheparkbrakeisengaged(seeFigure4and Figure5).

FuelShut-OffValve

Locatedinthefuellinemidwaybetweenthetank andengine.

Thefuelshut-offvalveisusedtoshutoffthe owoffuelwhenparkinginsideabuilding,during transportationtoandfromthejobsites,andwhen themachinewillnotbeusedforafewdays.

Rotatevalve1/4turnclockwisetoshutfueloff. Rotatevalve1/4turncounterclockwisetoturnfuel on.

Operation

Pre-Start

Fillfueltankonlevelground.Forbestresultsuse onlyclean,freshregulargradeunleadedgasolinewith anoctaneratingof87orhigher.

Important:Neverusemethanol,gasoline containingmethanol,gasoholcontainingmore than10%ethanol,premiumgasoline,orwhite gasbecausethefuelsystemcouldbedamaged.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe tankallowsgasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineoremission system(ifequipped).

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

OperatingInstructions

PTOEngagement

DANGER

Therotatingbladesunderthemowerdeckare dangerous.Bladecontactcancauseserious injuryorkillyou.

DoNotputhandsorfeetunderthemoweror mowerdeckwhenthebladesareengaged.

DANGER

Anuncovereddischargeopeningwillallow objectstobethrowninanoperator’sor bystander’sdirection.Also,contactwiththe bladecouldoccur.Thrownobjectsorblade contactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunlessthere isagrasscollectionsystemormulchkitinplace andworkingproperly.

ThePTOswitchengagesthecuttingblades.Besure thatallpersonsareclearofmowerdeckanddischarge areabeforeengagingthePTO.

OpentheFuelShut-OffValve

Rotatethevalve1/4turncounterclockwisetoturn fuelon.

StartingtheEngine

Note:Alwaysengagetheleftandrightneutral

lock/parkbrakelatchesinthe“parkbrake”position whenstartingtheengine

1.Onacoldengine,placethethrottlemidway betweenthe“Slow”and“Fast”positionsand placethechokeinthe“On”position.Onawarm engine,placethethrottlelevermidwaybetween “Slow”and“Fast”positionsandleavethechoke inthe“Off”position.

2.Turnignitionswitchto“Run”position.Pullthe recoilropetostartengine.

3.Onacoldengine,graduallyreturnchoketothe “Off”positionafterenginestartsandwarmsup.

Note:Kawasakienginesgenerallyneedtobe “choked”evenwhenwarm.

1.Setthrottleto“MIDW AY”position.

2.PushthePTOleverforwardtoengageblades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

1.Setthrottleto“MIDW AY”position.

2.Pullthebladeengagementlevertothefull rearwardpositiontodisengagetheblades

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Lockdriveleversin“parkbrake”position.

3.DisengagethePTO.

4.Movetransmissionshiftleverto“neutral”.

5.Placethethrottlemidwaybetweenthe“SLOW” and“FAST”positions.

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalvewhenthemachine willnotbeinuseforafewdays,when transporting,orwhentheunitisparkedinside abuilding.

DrivingtheMachine

DriveLever/NeutralLock/ParkBrakeLatch Operation

•ForPistolGripHandles

Tolockthedriveleversin“neutral”,squeezethe driveleversbacktotheneutralposition.Place thumbsontheupperportionoftheneutral lock/parkbrakelatchesandmovethemtothe rear.Releasethedrivelevers.

Tolocktheleversin“parkbrake”,squeezethe driveleversbacktothebrakeposition.Place thumbsontheupperportionoftheneutral lock/parkbrakelatchesandmovethemtothe front.Releasethedrivelevers(see

Figure6)

Operation

Figure6

1.Latchisinthedrive position

2.Rotateforwardforpark brakeposition

3.Rotatebackforneutral lockposition

4.Parkbrake9.Reverse—squeezedrive

5.Fullspeedforward

6.Neutrallock

7.Forward—releasedrive lever

8.Neutral—holdinthis position

lever

CAUTION

Iftheneutrallock/parkbrakelatchesarenot completelyengagedthedriveleverscould unexpectedlyslipintotheforwarddrive position.Ifthedriveleversslipintothedrive position,theunitcouldlurchforwardand causeinjuryorpropertydamage.

Besurethepinsprotrudingthroughtheslots ofeachneutrallocklatcharecompletely engagedintherearslotofeachlatch.

Toplacethedriveleversinthedriveposition, rmlyholdthedrivelevers,placethumbsonthe upperportionoftheneutrallock/parkbrake latchesandmovethemoutofthe“neutral”or the“parkbrake”position.Slowlyandsmoothly releasethedrivelevers.

•ForECSHandles

Tolockthedriveleversin“neutrallock”,squeeze thedriveleverstothe“neutral”position.See Figure7position2.Placethumbsontheinner thumblobeoftheneutrallock/parkbrakelatches androtatethemtothe“neutral”position.See Figure7position3.Releasethedrivelevers.

Tolockthedriveleversin“parkbrake”,squeeze thedriveleversfarthertothe“brake”position. Placethumbsontheinnerthumblobeofthe neutrallock/parkbrakelatchesandrotatethem tothe“park”position.See

Figure7position4.

Releasedrivelevers.

CAUTION

Besurethedriveleversaresecurelyseatedat thebottomofthe“neutral”or“park”areasof theneutrallocklatches.

Operation

Toplacethedriveleversinthe“drive”position, slightlysqueezethedriveleverswhileplacing thumbsontheouterthumblobeoftheneutral lock/parkbrakelatches(ortheindexngeron thefrontlobe)androtatethemfromunderthe drivelevers.Slowlyandcarefullyreleasethedrive levers.See

1.DriveLeverindrive position

2.DriveLeverinneutral position

Figure7position1.

Figure7

3.DriveLeverlockedin neutralposition

4.DriveLeverlockedin parkposition

Smoothlyreleasebothdriveleverstoengagedrive wheels.

Pulltheunitbackwardto“assist”withthemovement oftheunit.

Tostop,squeezedriveleversallthewaybackto engagethebrakes.Movetheneutrallocklatchesinto the“parkbrake”positionandreleasedrivelevers. Movethespeedcontrollevertotheneutralposition.

ChangingGears

Whenchanginggears,alwayssqueezedriveleversto theneutralposition.Theshiftlevermaybemoved withakneeorbyhand(engagetheneutrallock latchesifshiftingbyhand).

Note:Reversegearis“reverseassist”only,the operatormustpulltheunitbackwards.

Transporting

TransportingaUnit

WARNING

DrivingForward

1.Withdriveleversinthe“neutral”or“parkbrake” position,shifttransmissionintodesiredgear.

2.Squeezebothdriveleversandmovebothneutral lock/parkbrakelatchesfromthe“neutral”or “parkbrake”positiontothe“drive”position.

3.Tomoveforwardinastraightline,smoothly releasebothdriveleverstoengagedrivewheels.

Toturnleftorright,squeezetherighthanddrive levertoturnrightandthelefthanddrivelever toturnleft.

Squeezedriveleversallthewaybacktoengage brakes.Moveneutrallock/parkbrakelatchesinto the“parkbrake”positionandreleasedrivelevers. Shifttransmissionintoneutral.

DrivinginReverse

Note:Reversegearisreverseassistonly,theoperator mustpulltheunitbackwards.

Tomoverearward,squeezethedriveleverstoneutral positionandmovetheshiftertothe“R”.

Loadingthemowerontoatrailerwithoutstrong enoughorproperlysupportedrampscouldbe dangerous.Therampscouldcollapsecausing theunittofall,whichcouldcauseinjury.

•Useproperrampsthataresecuredtothe truckortrailer.

•Keepfeetandlegsoutfromundertheunit whenloadingandunloading.

•Ifnecessary,useassistancewhenloading.

Besurethefuelshut-offvalveisclosed.

Useaheavydutytrailertotransportthemachine. Engageneutrallocklatchesandparkbrake,then blockwheels.

Securelyfastenthemachinetothetrailerwithstraps, chains,cables,orropes.

DoNotrelysolelyontheparkingbraketoholdthe machineonthetrailer.

Besurethatthetrailerhasallnecessarylightingand markingasrequiredbylawanduseasafetychain.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Maintenance

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

Removethekeyfromtheignitionswitch,engage parkingbrake,andpullthewire(s)offthespark plug(s)beforeyoudoanymaintenance.Also pushthewire(s)asidesoitdoesnotaccidentally contactthesparkplug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Beforeeachuseordaily

MaintenanceProcedure

•Changetheengineoil.

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Greasethefrontcasterwheelbearings.

•Greasefrontcasterpivots.

•Greasethedrivewheels.

•Greasethedrivewheelidlerarm.

•Cleantheengineandexhaustsystemarea.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthedeck.

WARNING

Theenginecanbecomeveryhot.T ouchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

Every25hours

Every40hours

Every100hours

Every160hours

Every200hours

•Servicethefoamelement.(Mayneedmoreoftenundersevereconditions.SeetheEngine Owner’smanualforadditionalinformation.)

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethebrakearm.

•Greasethetransmissionoutputshaftcoupler

•Greasethemowerdeckidlerpivots

•Servicethepaperelement.(Mayneedmoreoftenundersevereconditions.SeetheEngine Owner’smanualforadditionalinformation.)

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Removeengineshroudsandcleancoolingns.

•Checkthesparkplugs.

•Checkgreaselevel,inputandoutputshaftbearingwearonPeerlessTransmission.

•Replacethepaperelement.

Yearly

•Replacegearboxgrease.

Maintenance

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstickand wipeoiloff.Reinsertthedipstickandpushitall thewaydownintothetube.DoNotscrewinto place.Removethedipstickandreadtheoillevel.

4.Iftheoillevelislow ,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Useoilasspeciedin EngineOwner’sManual.DoNotoverll.

Important:DoNotoperatetheenginewiththe oillevelbelowthe“LOW”(or“ADD”)markon thedipstick,oroverthe“FULL”mark.

Figure8

1.Springdiscwasher(conetowardsbolthead)

2.Bladebolttorqueto75-80ft-lb(102-109N-m).

ReplacingtheDischarge

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstated intheCleanGrassBuild-UpUnderDeck procedure.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Re-installtheblades(iftheywereremoved)and torquebladeboltsto75-80ft-lb(102-109N-m). Besurethespringdiscwasherconeisinstalled towardthebolthead(see

Figure8).

Deector

ServiceInterval:Asrequired

DANGER

Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator’sor bystander’sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.

Neveroperatethelawnmowerunlessyouinstall amulchplate,dischargedeector,orgrass collectionsystem.

1.Toremoveadamagedorworndischarge deector,liftthelegofthespringwiththeloop outofthenotchinthedischargedeectorand slidetherodoutofthedischargedeector brackets,anddischargedeector.

2.Toinstallnewdischargedeector,orientthe springontherodasshowninFigure9.Slidethe rodthroughthefrontdischargedeectorbracket, dischargedeector,andreardeectorbracket.

Maintenance

shiftthetransmissionintogearandreleasethe OPClevers–theenginemuststop.

3.Again,runtheengineaton-thirdthrottle,move thetransmissionshifterlevertoneutral,engage thePTOandreleasetheOPClevers–theengine muststop.

Note:Ifmachinedoesnotpassanyofthesetests, donotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing .

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

Figure9

1.Rod4.Mowerdeck

2.Spring5.Dischargedeector

3.Dischargedeector

3.Hookthebentendoftherodaroundthefront dischargedeectorbrackettoretainitfrom slidingout.Placethelegofthespringwiththe loopinthenotchinthedischargedeectorto holdthedischargedeectorinthedownposition (seeFigure9).

Important:Thedischargedeectormustbe springloadedinthedownposition.Liftthe deectoruptotestthatitsnapstothefull downposition.

bracket

6.Assembledview

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

1.Foryoursafety,yourExmarkmowerisequipped withOperatorPresenceControls,referredtoas (OPC).WheneitherthePTOisengaged,orthe transmissionshifterleverisnotinneutralandthe operatorremovesbothhandsfromthehandles, themowerenginemuststop.

2.TodetermineiftheOPCisinoperatingcondition, clearareaofbystanders.Runtheengineat one-thirdthrottle,thenwiththedriveleversand neutrallocklatchesinthe“parkbrake”position,

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every25hours—Service

thefoamelement.(May needmoreoftenunder severeconditions.See theEngineOwner’s manualforadditional information.)

Every100hours—Service thepaperelement.(May needmoreoftenunder severeconditions.Seethe EngineOwner’smanual foradditionalinformation.)

Every200hours/Yearly (whichevercomes rst)—Replacethepaper element.

1.Stopengine,waitforallmovingpartstostop,and removekeyorsparkplugwire(s).Engageparking brake.

2.SeetheEngineOwner’sManualformaintenance instructions.

Maintenance

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May needmoreoftenunder severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Removetheoildrainplugfromtherighthand sideoftheengine.Allowoiltodrain,replace drainplug.

4.Replacetheoillterpertheengineowner’ s manual.Cleanaroundoillterandunscrewlter toremove.Beforethenewlterisinstalled, applyathincoatingofoilonthesurfaceofthe rubberseal.Turnlterclockwiseuntilrubberseal contactsthelteradapter,thentightenlteran additional2/3to3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

6.Useoilrecommendedinengineowner’smanual. DoNotoverll.Starttheengineandcheckfor leaks.Stopengineandrecheckoillevel.

7.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto12–16psi(83–110kPa).

4.Inatetirestopressuresstatedabove.Measure thecircumferenceofeachdrivetire.Adjusttire pressureswithintheaboverangetotrytomake tirecircumferencesmatchascloselyaspossible.

5.Semi-pneumaticcastertiresDoNotneedtobe inated.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removethemowerdeckbeltshieldtocheck mowerbladedrivebeltcondition.

3.Lookunderenginedecktocheckthetransmission drivebeltcondition.

4.Inspectwheeldrivebeltconditions.

5.Checkallidlerarmstobesuretheypivotfreely . Disassemble,cleanandgreasepivotbushingsif necessary.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.LubricatettingswithNGLIgrade#2 multi-purposegungrease.

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

1.Front Caster Wheel Bearings

2.Front Caster Pivots

3.Drive Wheels

4.Drive Wheel IdlerArm

5.Brake Arm

Initial

Pumps

12222

2222

18222

2222

NumberofPlacesService

32inch

Deck

36inch

Deck

Interval

48inch

Deck

Daily

hours

Note:Amoreuniformcuttingheightmaybe obtainedwithhighertirepressureonroughterrain. Alowertirepressureprovidesmoreotation.

CheckConditionOfBelts

ServiceInterval:Every40hours

Maintenance

LubricationChart(cont'd.)

Fitting

Locations

6.Transmission Output Shaft Coupler

7.Mower Deck Idler Pivots

Initial

Pumps

2222

2111

NumberofPlacesService

Interval

hours

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner’ s Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledinthefuellinebetweenthe fueltankandtheengine.Replacewhennecessary.

CheckGreaseLevel, InputandOutputShaft BearingWearonPeerless Transmission

ServiceInterval:Every160hours—Check

greaselevel,inputand outputshaftbearing wearonPeerless Transmission.

48inchDeckShownforReferenceOnly

Number4and7(IdlerArmPivots)Disassembleand

greaseonceamonthundera“NoLoad”condition

Number6(TransmissionCoupler)Located

belowfueltanksupport

3.Replace5-speedgearboxgreaseyearly.Use18oz. ofPeerlessgrease(PartNo.788067).SeeCheck

GreaseLevel,InputandOutputShaftBearing WearonPeerlessTransmissionsectionfor

speciallubricationinstructions.

4.Lubricatepivotpointswithaspraypenetrating lubricantasshownintheSprayLubricantChart.

SprayLubricantChart

NumberofPlaces

PivotPoints

1.Blade Engagement Bellcrank

32inch

Deck

111

36inch

Deck

48inch

Deck

Service

Interval

40hours

Yearly—Replacegearbox grease.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.Removekey orsparkplugwire(s).

2.Placedriveleversandneutrallock/parkbrake latchesinneutrallockposition

3.Removeshifterleverfromtopoftransmission.

4.Removeshifterplatefromtopoftransmission andthetwoleadsfromtheneutralstartswitch.

5.Releasethetensiononthetransmissionbelt.

6.Checkforsideplaycausedbybearingwearon theinputandoutputshaftsofthetransmission. Replacebearingsifnecessary.

7.Removethesixboltsthatfastentheuppercase tothelowercaseandcarefullyremovetheupper casehalf

8.Checkthegreaselevelinthelowercase.The greaselevelshouldbeapproximately11/2inch to13/4inch(3.8to4.4cm)fromthegearbox bottom.Ifnecessary,lltoproperlevelwith Peerlessgrease(PartNo.788067).

Maintenance

9.Reinstalluppercasehalfandfasteninplacewith sixboltspreviouslyremoved.

10.Reinstallallpartsremovedinsteps3and4.Install drivebeltandadjusttensionasstatedinthe TransmissionBeltAdjustmentsection.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242” or“Fel-Pro,Pro-LockNutType”areusedonthe followingfasteners:

•Allbeltdrivepulleysetscrews.

•OPCleversetscrews.

•Pulleyretainingboltinendofenginecrankshaft.

•Fueltankbulkheadttingthreads

Adhesivessuchas“LoctiteRC/609orRC/680”or “Fel-ProPro-LockRetainingIorRetainingII”are usedonthefollowing:

•OPCleverhubsandcross-shaft

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

Note:Caremustbeusednottobondthe bearing,nexttoeachOPChub,tothecross-shaft whichcouldcausebindingoftheOPCleversand erraticoperation.

•Fueltankstuds,wherestudsareinsertedintotank.

MobilHTSGrease(Or Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocations:

•Betweenthecutterhousingspindleandbearings.

•Betweenthecutterhousingspindleandsheave.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing locations:

•Betweenthebladedriveandtransmissiondrive pulleysandenginecrankshaft.

•Betweenthetransmissiondrivepulleyand transmissiondriveshaft.

•Betweenthebearingsandsheavesand transmissionoutputshafts.

Maintenance

Adjustments

Note:DisengagePTO,shutoffengine,waitfor allmovingpartstostop,engageparkingbrake,and removekeybeforeservicing,cleaning,ormakingany adjustmentstotheunit.

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted from1inchto41/4inches(2.54cmto11.4cm)in 1/4inch(.64cm)incrementsbyadjustingtheaxle position,numberofspacersbelowthecasterhub, andnumberofspacersbetweenbladeandspindle.

RefertotheCuttingHeightAdjustmenttableand selectacuttingheightrangeinthelefthandcolumn whichcorrespondstotherangeofcuttingheights youwillmostoftenbeusing.Adjustmentswithinthis rangecanthenbemadebyadjustingthenumberof bladespacersbetweenthebladeandthebottomof thespindle(thisisamucheasieradjustmenttomake

thanadjustingaxlepositionandnumberofspacers belowcastersupporthub).

Notethat:

•Forthebestcutanddischarge,placeaminimum oftwospacersbetweenthebladeandthespindle.

•Forhighestqualitycut,placeallfourspacers betweenthebladeandthespindle.

•Ifmulchingkitisinstalled,thehighestqualitycut canbeobtainedwith3spacersbetweentheblade andthespindle(minimumis1foragoodcut).

•Whenmulchingleavesitisbesttohavefewer spacersbetweenbladeandspindle.

Refertothetableandselectdesiredcuttingheight range.RefertoAdjustingtheAxlePosition,

AdjustingtheNumberofSpacersbelowCaster SupportHub,andAdjustingtheCutting HeightwithBladeSpacersandsectionstomake

adjustmentsmakeadjustmenttoobtainspecic cuttingheight.

CuttingHeightAdjustmentT able(1inchto41/4inches(2.5cm-10.8cm))

Cutting Height

Range

1–2inches

(2.5–5.0cm)A00

11/8–

21/8inches

(2.9–5.4cm)A01

13/8–

23/8inches

(3.5–6.0cm)A10

13/8–

23/8inches

(3.5–6.0cm)B01

15/8–

25/8inches

(4.1–6.7cm)B10

13/4–

23/4inches

(4.4–7.0cm)B11

2–3inches

(5.0–7.6cm)B20

17/8–

27/8inches

(4.8–7.3cm)C11

Axle

Position

(Figure10)

NumberOfSpacers

BelowCaster

SupportHub

1/2 inch

(1.2cm)

3/16

(.48cm)

Numberof1/4inch(.64cm)BladeSpacersBelowSpindle

inch

1inch

(2.5cm)

11/8inch

(2.9cm)

13/8inch

(3.5cm)

13/8inch

(3.5cm)

15/8inch

(4.1cm)

13/4inch

(4.4cm)

2inch

(5.0cm)

17/8inch

(4.8cm)

11/4inch

(3.2cm)

13/8inch

(3.5cm)

15/8inch

(4.1cm)

15/8inch

(4.1cm)

17/8inch

(4.8cm)

2inch

(5.0cm)

21/4inch

(5.7cm)

21/8inch

(5.4cm)

11/2inch

(3.5cm)

15/8inch

(4.1cm)

17/8inch

(4.8cm)

17/8inch

(4.8cm)

21/8inch

(5.4cm)

21/4inch

(5.7cm)

21/2inch

(6.4cm)

23/8inch

(6.0cm)

13/4inch

(4.4cm)

17/8inch

(4.8cm)

21/8inch

(5.4cm)

21/8inch

(5.4cm)

23/8inch

(6.0cm)

21/2inch

(6.4cm)

23/4inch

(7.0cm)

25/8inch

(6.7cm)

2inch

(5.0cm)

21/8inch

(5.4cm)

23/8inch

(6.0cm)

23/8inch

(6.0cm)

25/8inch

(6.7cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

27/8inch

(7.3cm)

Maintenance

CuttingHeightAdjustmentTable(1inchto41/4inches(2.5cm-10.8cm))(cont'd.)

Cutting

Height

Range

21/8–

31/8inches

(5.4–7.9cm)C20

21/4–

31/4inches

(5.7–8.3cm)C21

21/2–

31/2inches

(6.4–8.9cm)C30

23/8–

33/8inches

(6.0–8.6cm)D21

21/2– 31/2inches (6.4–8.9cm)D30

23/4–

33/4inches

(7.0–9.5cm)D31

3–4inches

(7.6–10.1cm)D40

27/8–

37/8inches

(7.3–9.8cm)E31

31/8–

41/8inches (7.9–10.5cm)E40

31/4–

41/4inches (8.3–10.8cm)E41

Axle

Position

(Figure10)

NumberOfSpacers

BelowCaster

SupportHub

1/2 inch

(1.2cm)

(.48cm)

Numberof1/4inch(.64cm)BladeSpacersBelowSpindle

3/16

inch

21/8inch

(5.4cm)

21/4inch

(5.7cm)

21/2inch

(6.4cm)

23/8inch

(6.0cm)

21/2inch

(6.4cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

27/8inch

(7.3cm)

31/8inch

(7.9cm)

31/4inch

(8.3cm)

23/8inch

(6.0cm)

21/2inch

(6.4cm)

23/4inch

(7.0cm)

25/8inch

(6.7cm)

23/4inch

(7.0cm)

3inch (7.6cm)

31/4inch

(8.3cm)

31/8inch

(7.9cm)

33/8inch

(8.6cm)

31/2inch

(8.9cm)

25/8inch

(6.7cm)

23/4inch

(7.0cm)

3inch

(7.6cm)

27/8inch

(7.3cm)

3inch

(7.6cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

33/8inch

(8.6cm)

35/8inch

(9.2cm)

33/4inch

(9.5cm)

27/8inch

(7.3cm)

3inch

(7.6cm)

31/4inch

(8.3cm)

31/8inch

(7.9cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

33/4inch

(9.5cm)

35/8inch

(9.2cm)

37/8inch

(9.8cm)

4inch

(10.1cm)

31/8inch

(7.9cm)

31/4inch

(8.3cm)

31/2inch

(8.9cm)

33/8inch

(8.6cm)

31/2inch

(8.9cm)

33/4inch

(9.5cm)

4inch

(10.1cm)

37/8inch

(9.8cm)

41/8inch

(10.5cm)

41/4inch

(10.8cm)

Important:AlwaysadjusttheNumberofSpacersbelowCasterHubtocorrespondtotheAxle Positionasshownintabletoobtainproper“rake”(bladesshouldalwaysbeleveltotheground ortippedslightlydownatthefront).

AdjustingtheAxlePosition

Desiredcuttingheightrangecanbeobtainedby adjustingtherearaxleandplacingcasterspacers aboveorbelowthecasterarm(SeeFigure10and Figure11alongwiththeCuttingHeightAdjustment Chart).Itmaybenecessarytoreadjustwheeldrive andbrakelinkages.

Toadjustrearaxle:

3.Placethedriveleversintheneutrallockposition.

4.Removemowerdeckbeltshieldforaccesstoaxle adjustmentbolts.

5.Loosenbutdonotremovethetwoaxlepivot boltsandthetwoaxleadjustmentbolts(see Figure10).

6.Placeajackundertherearcenteroftheengine deck.

1.Stopthemachineandmovethedriveleversto theneutrallockposition.

7.Raisethebackendoftheenginedeckupenough toremovethetwoaxleadjustmentbolts.

2.DisengagethePTO.

8.Withthejack,raiseorlowerthebackendofthe enginedecksothattwoaxleadjustmentboltscan bereinstalledindesiredholelocation.Atapered punchcanbeusedtohelpaligntheholes.

9.Retightenallfourbolts,lowerunitandremove jack.

10.Installmowerdeckbeltshield.

11.Adjustwheeldriveandbrakelinkagesas required(seeBrakeandWheelDriveLinkage Adjustmentsection).

Maintenance

Figure11

1.Four1/2inch(127mm) spacers

2.QuickPin4.Castersupport

7.Adjustthenumberof1/2inchspacersbetween bottomofhubandcasteryoketoobtainthe desiredcuttingheightfromtheCuttingHeight AdjustmentTableintheAdjustingtheCutting Heightsection.

3.3/16inch(4.8mm) spacer

Figure10

1.AxlePivotBolt

2.AxleAdjustmentHoles (Locatedinthesideof thereardeck.)

3.PositionA7.PositionE

4.PositionB8.Placejackhere

5.PositionC

6.PositionD

Note:Theaxlepositionsarein1/2inch(1.3cm) incrementsandthelargecasterspacersare1/2 inch(1.3cm)thick.Therefore,byadjustingthe samenumberof1/2inch(1.3cm)casterspacersas axleholepositionsthebladeswillretainthesame front-to-backtip(rake).

AdjustingtheNumber ofSpacersbelowCaster SupportHub

1.Stopthemachineandmovethedriveleversto theneutrallockposition.

2.DisengagethePTO.

3.Placethedriveleversinthe“parkbrake”position.

4.Pushdownonhandlestoliftfrontcastersoffthe ground.

5.Supportwithjackstands.

6.Remove“quickpin”fromonecasterandremove casterfromhub(seeFigure11).

8.Installremainingspacersontopofhub.

9.Install“quickpin”.

10.Repeatforothercaster.

AdjustingtheCuttingHeight withBladeSpacers

1.Stopthemachineandmovethedriveleverstothe neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Bladesmaybeadjustedforcuttingheightbyusing thefour1/4inch(.64cm)spacersfoundonthe bladespindlebolts(factorysettingistwoabove andtwobelow).Thisallowsa1inch(2.5cm) rangein1/4inch(.64cm)incrementsofcutting heightinanyaxleposition.Thesamenumber ofbladespacersmustbeusedonallbladesto achievealevelcut(twoaboveandtwobelow,one aboveandthreebelow,etc.).

6.Raisefrontofdeckandsupportwithjackstands.

7.Holdbladeboltonbottomandloosenspindle nutontop.

8.Adjustnumberofspacersbetweenbottomof spindleandbladeasindicatedintheCutting

Maintenance

HeightAdjustmentTableandnotesinthe AdjustingtheCuttingHeightsection.

9.Installunusedspacersbetweentopofspindleand spindlenut.

10.Torqueboltto75–80ft-lb(102–109N-m)(see Figure12).

Figure12

1.Springdiscwasher (conetowardsbolthead)

2.Bladebolttorqueto 75–80ft-lb(102–109 N-m)

TransmissionBelt Adjustment

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.Totightentransmissionbelt,loosenthe3/8inch nylocnutontransmissionbeltidlerpulley.Slide boltinwardinslotandretightennylocnut.

3.Whenproperlyadjusted,thebeltshouldhave1/2 inch(1.3cm)ofdeectionwiththreepounds ofpressureonthebeltmidwaybetweenthe transmissionandenginepulley .

WheelDriveBeltPulley Scrapers

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.Besuremudandgrassscraper,oneachside, isadjustedproperlyandcenteredinthepulley grooves.Thepointedpartofthescrapershould becenteredandasdeepinthepulleygrooveas possiblewithoutrubbingatanypoint.

EnginetoMowerDeckBelt

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.Checktheadjustmentofthelowerbladedrive linkagelocatedbetweenthebellcrankonthe enginedeckandassistarmonthemowerdeck. Lengthenorshortenthelinkage.Whenproperly adjusted,thereshouldbe1/16inchto1/8inch (2–3mm)ofclearancebetweenbell-crankand transmissionoutputshaftwhenbeltisengaged. Makesuretheassistarmisagainsttherearassist armstoponthedeck(see leverdowntothedisengagedposition.Theassist armshouldcontactthefrontassistarmstopon thedeck.Ifitdoesnotcontact,readjustsothat thebellcrankisclosertothetransmissionoutput shaft.

3.Beltmustbetightenoughtonotslipduringheavy loadswhilecuttinggrass.Over-tensioningwill reducebeltandspindlebearinglife.Toadjust belttension,loosenthe5/16inchwhizlocknut onturnbuckleandrotatetheturnbuckle;rotate turnbuckletowardrearofmowertotighten,and towardfrontofmowertoloosenbelttension(see Figure13).Leaveaminimumof5/16inch(.79 cm)oftheeyeboltthreadsengagedonbothends oftheturnbuckle.

For48”Decks:Ifthereisnoadjustmentleftin theturnbuckleandthebeltisstillloose,therear idlerpulleycanberepositionedinthefronthole (SeeFigure12).Thebeltguidelocatednextto thepulleymustalsoberepositionedinthefront holewhenthepulleyismoved.Theturnbuckle willneedtobereadjusted.

Figure13).Pushthe

Maintenance

Checkbelttensionafterthersthourofoperation andatleasttwiceduringtherst24hoursof operation.Adjustasnecessary.

Figure13

48inchDeckShownforReferenceOnly

1.PulleylocationforMetro

2.Pulleycanbemovedtothefrontpositiontotightenthe beltwhenthereisnoadjustmentleftintheturnbuckle (48inchdeckonly)

3.Beltguidemustbemovedtothefrontpositionifthe pulleyismoved.(48inchdeckonly)

4.Turnbuckle

5.5/16inch(.79cm)minimumengagement

6.5/16inchwhizlocknut

7.RearAssistArmStop

8.AssistArm

9.FrontAssistArmStop

10.Point“A”

MowerDeckBeltRoutings:

Figure14

32inchand36inchMowerDeck

4.Properbelttensionwillrequireabout10lb(4.5 kg)sidepullonbelt,halfwaybetweenpulleys(see Figure13,item10–PointA)todeectbelt1/2 inch(12mm).

5.Checkbeltguideundertheenginedecktoseethat itisproperlyset(seeBeltGuideAdjustment section).Alsocheckthebladebrakeadjustment (seeBladeBrakeAdjustmentsection).

Figure15

48inchMowerDeck

BladeBrakeAdjustment

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.Disengageblades.

3.Makesurethebladebrakepadrestsagainst thesheave.Adjustthespringmountingbolts toproperlyalignthepadonthesheave(see Figure16).

4.Checkthedistancebetweenthespacerandthe nutattheendofthebladebrakerod.The

Maintenance

distanceshouldbebetween1/8inchand3/16 inch(3–5mm)(seeFigure16).

5.Engagethebladecontrolandchecktomakesure thebladebrakepadclearsthesheave.

Figure16

ShownwithBladesDisengaged

1.BladeBrakeRod

2.SpringMountingBolts

3.1/8inchto3/16inch(3–5 mm)

Figure18

48inchBeltGuideLocation

(Viewedfromunderneaththedeck)

1.13/8inch(3.5cm)

BrakeandWheelDrive LinkageAdjustment

1.Checkforcorrectbrakeadjustment:

BeltGuideAdjustment

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.Engagethebladedrivebelt.

3.Checkbeltguideundertheenginedeckforproper adjustment(See asnecessary.

Thedisengagedbeltshouldnotdragorfalloff pulleywhenguidesareproperlyadjusted.

Figure17andFigure18).Adjust

Placethedriveleversinthe“parkbrake” position.Themowershouldnotmoveforward orbackward.Ifitdoes,tightenthewingnuts.

Placethedriveleversinthe“neutrallock” position.Themowershouldmoveforwardand backwardfreely .Ifitdoesnot,brakeadjustment isnecessary

2.Adjustbrakesbyadjustingwingnutontheupper endofeachbrakerod.Tightenthewingnut untilthebrakesengagewhenthedriveleversare squeezedenoughtoallowtheneutrallock/park brakelatchestobeplacedintothe“parkbrake” position.

Figure6forStandardPistolGriphandlesand

See Figure7forECShandles.

Note:Theneutrallock/parkbrakelatchesmust beabletobemovedintotheparkbrakeposition, ifnot,thebrakelinkagesmustbeadjustedagain.

3.Checkforcorrectwheeldrivelinkageadjustment.

•ForPistolGripHandles

32inchand36inchBeltGuideLocation

(Viewedfromunderneaththedeck)

1.11/4inch(3.1cm)

Figure17

Allowdriveleverstodropintothefullforward position:Theclevispinshouldrestinthe neutrallocklatchwithapproximately3/16 inchto1/4inch(4.7–6.4mm)clearancefrom thebottomoftheslot(seeFigure19).Adjust ifnecessary.

Toadjustthewheeldrivelinkage:

Maintenance

A.Forwheeldrivelinkageadjustment,

1.DriveLever

2.ClevisPin

3.DriveLinkage

removethehairpinbetweentheneutral locklatchanddrivelever(Figure19).

Figure19

LeftSideShown

4.NeutralLock/ParkBrake Latch

5.Hairpin

aslightupwardforceplacedonthedrive leverstoremoveany"slack"inthelinkage.

C.Re-installhairpinintoholeontheclevis

pinbetweentheneutrallock/parkbrake latchanddrivelever(See

Figure19).

Repeatprocedureonoppositesideofunit.

•ForECSHandles:

Allowdriveleverstodropintothefullforward position:theatedgeofthedrivelever shouldalignwiththebottomrollernotch(See Figure21).Adjustifnecessary

B.Adjustdrivelinkagelengthbythreading

intooroutoftheswiveluntilthereis a3/16inchto1/4inch(.47-.64cm) clearancebetweenthelinkageassembly andthebottomoftheslotintheneutral lock/parkbrakelatch(see

Figure20

1.3/16inchto1/4inch(.47cm-.64cm)

2.NeutralLock/ParkBrakeLatch

3.DriveLinkage

Figure20).

Figure21

1.NotchinNeutral Lock/ParkBrakeLatch

2.DriveLever

Toadjustthewheeldrivelinkage:

A.Locateadriveleverlinkageononeside

oftheunitandremovethe5/16-18x1 3/4inchhexcapscrewand5/16-18inch nylocnut(see

Figure22).

B.Threaddriveleverlinkageintooroutof

theswivellocatedonthewheeldriveidler armuntiltheatedgeofthedrivelever alignswithbottomoftherollernotch intheneutrallock/parkbrakelatch(see Figure22).

C.Re-installthe5/16-18x13/4inchhex

capscrewandsecurewiththe5/16-18 inchnylocnut.Repeatfortheotherside (seeFigure22).

Note:Neutrallock/parkbrakelatch clearanceshouldbecheckedwhenthereis

Maintenance

Figure24

1.ShifterLever

2.Equaldistance

•Toadjusttheshifterlever:

3.Adjustmentslot

Figure22

RightSideofUnitShown

1.Wingnut

2.TransmissionLeverin neutral

3.5/16–18inchnylocnut7.Swivel

4.DriveLeversinneutral8.BrakeRod

5.5/16–18x13/4inchhex capscrew

6.DriveLeverLinkage

ShifterLeverAdjustment

Theshifterleverinneutralshouldnotcontactthe upperorloweredgeoftheslotortheleftedgeof theupperslotortherightedgeofthebottomslot (SeeFigure23andFigure24).Theclearanceshould beequal.Adjusttheshifterleverandshifterplate ifnecessary.

1.Removethe3/8inchnylocnutandspring discwasherfromthestudontopofthe transmission(See

1.ShifterLever

2.SquareHoledWasher

Figure25).

Figure25

3.Transmission

2.Removetheshifterleverandbenditslightly. DoNotbendtheleverwhileitisattachedto thetransmission.

1.Equaldistance

2.ShifterLever

Figure23

3.ShifterPlate

3.Re-installleverandtorquethe3/8inchnyloc nutto35ft-lb(47N-m).

•Toadjustshifterplate:

Note:Thesquare-holewashermustbebetweenthe leverandthetransmission.

Placeshifterleverintheneutralposition.Loosenthe twoboltssecuringtheshifterplatetotheshifterlever legs.Adjustshifterplateandretightenbolts.

ShifterDetentAdjustment

Transmissionshifterdetentcanbeadjusted byadjustingthesetscrewonthebacksideof transmissionlocatedjustbehindtheneutralstart switch.Turnsetscrewin(clockwise)toholdthe transmissionshiftermorepositivelyineachgearand toincreasetheforceontheleverrequiredtoshift gears.

Turnsetscrewout(counterclockwise)todecrease forceonleverrequiredtoshiftgears.Factorysetting istoturnsetscrewallthewayinthenbackout11/2 turns.

Important:Screwingsetscrewintoofarwill preventthetransmissionfromshifting.

Maintenance

Figure26

1.UpperHandle3.AdjustmentHoles

2.UpperHole

4.FuelTankSupport

PTOSafetySwitch Adjustment

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.Withthebladesdisengagedandthebellcrank touchingtheenginedeck,adjustthebladesafety switch(ifneeded)untilthebellcrankdepresses theplungerby1/4inch(.64cm).

3.Besurethebellcrankdoesnotcontacttheswitch bodytopreventdamagetotheswitch.

4.Retightenswitchmountinghardware.

HandleHeightAdjustment

Thehandlecanbepivotedtoallowpositioningin oneofthethreeholesallowingvariousadjustments foroperatorcomfort(see

Toadjustthehandleheight:

1.Removethebottommountinghardwareoneach sideofthehandle.

2.Pivotthehandletooneofthethreepositions.

3.Re-installhardwareandtighten.

Figure26).

Note:AdjustmentHolesareactuallyintheside ofthefueltanksupport.

WheelDriveSpringTension Adjustment

Itmaybenecessarytoincreasewheeldrivebelt tensionundercertainoperatingconditionssuchas, wetgrass,hillyterrain,orwhilepullingasulky.

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

2.Disengageneutrallock/parkbrakelatchesand releasedriveleverstolowerspringforce.

3.Removethe5/16-18inchwhizlocknutsecuring theadjustmentbolttothedrivewheelshield. Locateboltassemblyinthedesiredpositionas follows:

•PositionA-NormalConditions

•PositionB-MoreSevere

•PositionC-MostSevere

Note:Leverforceislowestwithboltassembly inPositionAandwillincreaseinPositionsBand C(see

Figure27).

Important:Ifthehandleheightpositionis changed,itwillbenecessarytoreadjustthe driveandbrakelinkage(seeCheckBrakeand WheelDriveLinkageAdjustmentsectionin Operation.)

Maintenance

1.Moretractionappliedas boltmovesdown

2.PositionA–Normal Conditions

3.PositionB–MoreSevere

Figure27

4.PositionC–MostSevere

5.FrontofUnit

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancauseengine andexhaustsystemareatooverheatwhichcan createarehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every100hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removecoolingshroudsfromengineandclean coolingns.Alsocleandust,dirt,andoilfrom externalsurfacesofenginewhichcancause impropercooling.

3.Makesurecoolingshroudsareproperly reinstalled.Operatingtheenginewithout coolingshroudswillcauseenginedamagedueto overheating.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanoffanyoil,debris,orgrassbuild-uponthe machineandcuttingdeck,especiallyunderdeck beltshields,aroundthefueltank,aroundengine andexhaustarea.

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.DisengagePTO.

2.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.Removekeyorsparkplug wire(s).

Maintenance

3.Raisedeckandsupportunitusingjackstandsor equivalentsupport.

CAUTION

Raisingthemowerforserviceormaintenance relyingsolelyonmechanicalorhydraulic jackscouldbedangerous.Themechanicalor hydraulicjacksmaynotbeenoughsupport ormaymalfunctionallowingtheunittofall, whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

4.Cleanoutanygrassbuild-upfromundersideof deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Enginewillnotstart,startshard,orfailsto keeprunning.

Enginelosespower

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Thethrottleandchokearenotinthe correctposition.

4.Dirtinfuellter.4.Replacethefuellter.

5.Dirt,water,orstalefuelisinthefuel system.

6.Aircleanerisdirty.

7.Electricalconnectionsarecorroded,loose orfaulty.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Faultysparkplug.

10.Sparkplugwireisnotconnected.

11.PTOisengaged.

12.Transmissionisnotintrueneutral position.

13.OPCleversarereleased.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

5.Ventholeinthefuelcapisplugged.

6.Dirtinfuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel system.

2.Openthefuelshutoffvalve.

3.Besurethethrottlecontrolismidway betweenthe“SLOW”and“F AST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.

5.ContactanAuthorizedServiceDealer.

6.Cleanorreplacetheaircleanerelement.

7.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

9.Clean,adjustorreplacesparkplug.

10.Checkthesparkplugwireconnection.

11.DisengagethePTO.

12.Ensuretheshifterleverisintheneutral position.

13.DepressOPClevers.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

Engineoverheats

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Coolingnsandairpassagesforthe engineareplugged.

2.Addoiltothecrankcase.

3.Removetheobstructionsfromthecooling nsandairpassages.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Mowerpullsleftorright(withleversfully forward).

Machinedoesnotdrive.

Unevencuttingheight.

1.Idlerarmpulleysanddrivesheavesare dirty.

2.Wheeldrivebeltpulleyscrapers adjustmentisnotcorrect

3.Idlerpivotarmscannotpivotfreely3.Lubricateilderpivots.

4.Drivebeltsareworn.4.Replacedrivebeltsasaset.(DoNotmix

5.Drivelinkageadjustmentisnotcorrect.5.Correctadjustment.

6.Tirepressureindrivetiresnotcorrect.6.Adjusttirepressureinthedrivetires.

1.Transmissiondrivebeltisworn,looseor broken.

2.Transmissiondrivebeltisoffapulley.2.Changethebelt.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

7.Tipsofadjacentbladesareatanuneven cuttingheight.Bladestipsshouldbeeven within3/16inchwhichisapproximately onebladethickness.

8.Castermountingbracketsareloose.8.Tightenhardware.

1.Removemudand/orgrassbuildup.

2.Correctadjustment.

anewbeltwithaworndrivebelt.)

1.Changethebelt.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

Abnormalvibration

Bladesdonotrotate.

Bladesdonotstopwhendisengaged.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley ,idlerpulley,orblade pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

7.Beltisdamaged.7.Installnewbelt.

1.Deckbeltisworn,looseorbroken.1.Installnewdeckbelt.

2.Deckbeltisoffpulley.2.Installdeckpulleyandchecktheidler

1.Bladebrakeisnotadjustedproperly.1.Adjustbladebrake.

2.Beltguideisnotproperlyset2.Adjustbeltguidetoproperposition.

3.PTOengagementisnotproperlyset.3.CheckthePTOengagementposition.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

pulley,idlerarmandspringforcorrect positionandfunction.

Schematics

KEY

SWITCH

PTO

SWITCH

N.O.

TRANSMISSION

N.C.

TO SAFETY

INTERLOCK

MODULE

OPC

SWITCH

N.O.

RED

BLACK

BROWN

DK BLUE

ORANGE

YELLOW

GREEN

BLACK

ENGINE GROUND

ENGINE KILL

TERMINAL

RED

CONNECTORS ARE VIEWED FROM WIRE END N.C. = NORMALLY CLOSED N.O. = NORMALLY OPEN

G006816

A B C D E F

Schematics

Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part on these products and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of two years.

This warranty applies to Exmark commercial turf equipment sold in the U.S. or Canada. This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer. The warranty period commences upon the date of the original retail purchase.

 Warranty Exceptions 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 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.

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

If your product requires warranty service it must be returned to an authorized Exmark service dealer within the warranty period. This warranty extends only to turf equipment operated under normal conditions. You must read the operator’s manual. You must also properly service and maintain your Exmark product as described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein. Neither Exmark

nor Exmark Warranty Company shall be liable for any incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other    extraordinary repair charges or charges relating to repairs or  replacements outside of normal business hours at the place   of business of the authorized Exmark Service Dealer.

• Rental of like or similar replacement equipment during the   period of any warranty, repair or replacement work.

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that   covered by the terms of this warranty.

• Any claims for lost revenue, lost profit or additional cost as   a result of a claim of breach of warranty.

• Attorney's fees.

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.

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-589_B

Notes:

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

G011841

Figure28

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopeindicatortodeterminethe degreeofslopeofhillsbeforeoperating.DoNotoperatethismachineonaslopegreaterthan20degrees.Fold alongtheappropriatelinetomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT R IDING ACCE SSORIES AND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-534Rev .B (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark Metro 00 Higher, Metro 850 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual