Exmark Metro 4500-352 User Manual

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METRO®

ForSerialNos. 790,000&Higher

PartNo.4500-352Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct containschemicalsknowntotheStateof Californiatocausecancer,birthdefects,or otherreproductiveharm.

Important:Whenthemowerisusedoroperated onanyCaliforniaforest,brushorgrasscovered land,aworkingsparkarrestermustbeattached tothemufer.Ifnot,theoperatorisviolating statelaw,Section4442PublicResourceCode.To acquireasparkarresterforyourunit,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.

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

ServicePre-CleanerElementandAir

Cleaner......................................................21

ChangeEngineOil........................................21

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.....................................................24

AdjustingtheCuttingHeight.........................24

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

AdjustingtheNumberofSpacersbelow

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

AdjustingtheCuttingHeightwithBlade

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

TransmissionBeltAdjustment.......................27

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

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

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

BeltGuideAdjustment..................................29

BrakeandWheelDriveLinkage

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

ShifterLeverAdjustment...............................31

ShifterDetentAdjustment.............................32

PTOSafetySwitchAdjustment......................32

HandleHeightAdjustment............................32

WheelDriveSpringTension

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

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

CleanEngineandExhaustSystem

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

RemoveEngineShroudsandCleanCooling

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

CleanDebrisFromMachine..........................34

CleanGrassBuild-UpUnderDeck................34

WasteDisposal..............................................34

Troubleshooting...................................................35

Schematics...........................................................37

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER, WARNING,orCAUTION.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

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

CAUTION

DANGER:Whitelettering/Redbackground. Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.

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

CAUTION:Blacklettering/Y ellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

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

Thismachineproducessoundlevelsin excessof85dBAattheoperator’searand cancausehearinglossthroughextended periodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

Safety

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen area,whentheengineiscold.Wipeup anygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletely full.Addgasolinetothefueltankuntil thelevelis1/4to1/2inch(6–13mm) belowthebottomofthellerneck.This emptyspaceinthetankallowsgasoline toexpand.

•Neversmokewhenhandlinggasoline, andstayawayfromanopenameor wheregasolinefumesmaybeignitedby spark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine. Neverremovethecapofthefueltankor addfuelwhenengineisrunningorwhen theengineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

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.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

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

Safety

Operation

WARNING

Operatingengineparts,especiallythe mufer,becomeextremelyhot.Severeburns canoccuroncontactanddebris,suchas leaves,grass,brush,etc.cancatchre.

•Allowengineparts,especiallythemufer, tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer andenginearea.

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

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcan killyou.

DoNotrunengineindoorsorinasmall connedareawheredangerouscarbon monoxidefumescancollect.

•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 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.

•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.Lossof controland/orlossofoperator’sfooting couldresultinafallwithanarmorleg gettingunderthemowerorenginedeck whichmayresultinseriousinjury,deathor drowning.

•Mowacrossslopes,neverupanddown.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan20 degrees.

•Reducespeedanduseextremecaution onslopes.

•Avoidsuddenturnsorrapidspeed changes.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

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

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

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.

•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.

•Allreplacementpartsmustbethesameas orequivalenttothepartssuppliedasoriginal equipment.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect

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

48inchUnitsOnly

Safety

103-1967

PistolGripUnitsOnly

Specications

ModelNumbers

SerialNos:790,000andHigher

M15KA322P;M15KA362P;M15KA483P;M15KA362;M15KA483;M17KA322PCA;M17KA362CA; M17KA483CA;

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•RPM:FullSpeed:3600(NoLoad)

FuelSystem

•Capacity:5.0gal.(18.9L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher.

•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)

15-20ft-lb(20-27N-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(seeFigure4and Figure5).

1.NeutralLock/ParkBrake Latch

2.Rotatelatchforwardfor parkbrakeposition

3.Rotatelatchbackfor neutrallockposition

Figure4

PistolGripHandle

4.OPCLever

5.DriveLever

Operation

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

ChokeControl

Locatedonthefrontleftcornerofthefueltank support.

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

Figure5

ECSHandle

1.OPCLever3.NeutralLockLatch/Park

2.Rotatelatchforneutral lockandparkbrake positions

BrakeLatch

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 .

NeutralLock/ParkBrakeLatches

•ForPistolGripHandles:Locatedonhandles aheadofthegrips.

•ForECSHandles:Locatedontheupperhandle assemblyontheendsofthehandlegrips.

ThrottleControl

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.

FuelShut-OffValve

Locatedinthefuellinemidwaybetweenthetank andengine.

Operation

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

Rotatevalve1/4turnclockwisetoshutfueloff. Rotatevalve1/4turncounterclockwisetoturnfuel on.

Pre-Start

Fillfueltank.Forbestresultsuseonlyclean,fresh regulargradeunleadedgasolinewithanoctanerating of87orhigher.Regulargradeleadedgasolinemay alsobeused;however,combustionchamberand cylinderheadwillrequiremorefrequentservice.See EngineOwner’sManual.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Neverllthefueltankso

thatthefuellevelrisesabovealevelthatis1/2inch belowthebottomofthellernecktoallowforfuel expansionandpreventfuelspillage.

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

OperatingInstructions

Note:Kawasakienginesgenerallyneedtobe

“choked”evenwhenwarm.

PTOEngagement

DANGER

Therotatingbladesunderthemowerdeck aredangerous.Bladecontactcancause seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower ormowerdeckwhenthebladesareengaged.

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunless thereisagrasscollectionsystemormulch kitinplaceandworkingproperly.

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.

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(seeFigure6)

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.

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

•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.SeeFigure7position4. Releasedrivelevers.

CAUTION

Besurethedriveleversaresecurelyseatedat thebottomofthe“neutral”or“park”areas oftheneutrallocklatches.

Operation

Toplacethedriveleversinthe“drive”position, slightlysqueezethedriveleverswhileplacing thumbsontheouterthumblobeoftheneutral lock/parkbrakelatches(ortheindexngeron thefrontlobe)androtatethemfromunderthe drivelevers.Slowlyandcarefullyreleasethedrive levers.SeeFigure7position1.

Figure7

1.DriveLeverindrive position

2.DriveLeverinneutral position

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.

Loadingthemowerontoatrailerwithout strongenoughorproperlysupportedramps couldbedangerous.Therampscould collapsecausingtheunittofall,whichcould causeinjury.

•Useproperrampsthataresecuredtothe truckortrailer.

•Keepfeetandlegsoutfromunderthe unitwhenloadingandunloading.

•Ifnecessary,useassistancewhenloading .

Besurethefuelshut-offvalveisclosed.

Useaheavydutytrailertotransportthemachine. Engageneutrallocklatchesandparkbrake,then blockwheels.

Securelyfastenthemachinetothetrailerwithstraps, chains,cables,orropes.

DoNotrelysolelyontheparkingbraketoholdthe machineonthetrailer.

Tomoverearward,squeezethedriveleverstoneutral positionandmovetheshiftertothe“R”.

Besurethatthetrailerhasallnecessarylightingand markingasrequiredbylawanduseasafetychain.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Maintenance

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecould seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch, engageparkingbrake,andpullthewire(s) offthesparkplug(s)beforeyoudoany maintenance.Alsopushthewire(s)aside soitdoesnotaccidentallycontactthespark plug(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.Touching ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheengine area.

Every25hours

Every40hours

Every80hours

Every100hours

Every160hours

•Servicetheaircleaner.(Mayneedmoreoftenundersevereconditions.SeetheEngine manualforadditionalinformation.)

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasethebrakearm.

•Greasethetransmissionoutputshaftcoupler

•Greasethemowerdeckidlerpivots

•Removeengineshroudsandcleancoolingns.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Checkthesparkplugs.

•Checkgreaselevel,inputandoutputshaftbearingwearonPeerlessTransmission.

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.

1.Springdiscwasher (conetowardsbolthead)

Figure8

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

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(seeFigure8).

ReplacingtheDischarge Deector

ServiceInterval:Asrequired

DANGER

Anuncovereddischargeopeningcouldallow thelawnmowertothrowobjectsinthe operator’sorbystander’sdirectionandresult inseriousinjury.Also,contactwiththeblade couldoccur.

Neveroperatethelawnmowerunlessyou installamulchplate,dischargedeector,or grasscollectionsystem.

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

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

Figure9

1.Rod4.Mowerdeck

2.Spring5.Dischargedeector

3.Dischargedeector

bracket

6.Assembledview

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

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

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

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

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,

ServicePre-CleanerElement andAirCleaner

ServiceInterval:Every25hours—Service

theaircleaner.(May needmoreoftenunder severeconditions.See theEnginemanualfor additionalinformation.)

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

2.SeetheEngineOwner’ sManualforcleaning instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May needmoreoftenunder severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

Maintenance

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.

Note:Amoreuniformcuttingheightmaybe obtainedwithhighertirepressureonroughterrain. Alowertirepressureprovidesmoreotation.

CheckConditionOfBelts

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

6.Transmission Output Shaft Coupler

7.Mower Deck Idler Pivots

Initial

Pumps

12222

2222

18222

2222

2111

NumberofPlacesService

32inch

Deck

36inch

Deck

48inch

Deck

Interval

Daily

hours

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removethemowerdeckbeltshieldtocheck mowerbladedrivebeltcondition.

3.Lookunderenginedecktocheckthetransmission drivebeltcondition.

4.Inspectwheeldrivebeltconditions.

5.Checkallidlerarmstobesuretheypivotfreely. Disassemble,cleanandgreasepivotbushingsif necessary.

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

Maintenance

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledinthefuellinebetweenthe fueltankandtheengine.Replacewhennecessary.

CheckGreaseLevel, InputandOutputShaft BearingWearonPeerless Transmission

ServiceInterval:Every160hours—Check

greaselevel,inputand outputshaftbearing wearonPeerless Transmission.

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

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwners Manual.

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

9.Reinstalluppercasehalfandfasteninplacewith sixboltspreviouslyremoved.

10.Reinstallallpartsremovedinsteps3and4.Install drivebeltandadjusttensionasstatedinthe TransmissionBeltAdjustmentsection.

Maintenance

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

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.

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.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

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

Maintenance

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

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

Axle

Position

(Figure10)

NumberOfSpacers

BelowCaster

SupportHub

1/2 inch

Numberof1/4inchBladeSpacersBelowSpindle

3/16

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)

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)

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)

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)

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)

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)

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)

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)

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)

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)

Maintenance

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

Cutting

Height

Range

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

3/16

inch

31/8inch

(7.9cm)

31/4inch

(8.3cm)

Numberof1/4inchBladeSpacersBelowSpindle

33/8inch

(8.6cm)

31/2inch

(8.9cm)

35/8inch

(9.2cm)

33/4inch

(9.5cm)

37/8inch

(9.8cm)

4inch

(10.1cm)

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

AdjustingtheAxlePosition

Desiredcuttingheightrangecanbeobtainedby adjustingtherearaxleandplacingcasterspacers aboveorbelowthecasterarm(SeeFigure10and

10.Installmowerdeckbeltshield.

11.Adjustwheeldriveandbrakelinkagesas required(seeBrakeandWheelDriveLinkage Adjustmentsection).

Figure11alongwiththeCuttingHeightAdjustment Chart).Itmaybenecessarytoreadjustwheeldrive andbrakelinkages.

41/8inch

(10.5cm)

41/4inch

(10.8cm)

Toadjustrearaxle:

1.Stopthemachineandmovethedriveleversto theneutrallockposition.

2.DisengagethePTO.

3.Placethedriveleversintheneutrallockposition.

4.Removemowerdeckbeltshieldforaccesstoaxle adjustmentbolts.

5.Loosenbutdonotremovethetwoaxlepivot boltsandthetwoaxleadjustmentbolts(see Figure10).

6.Placeajackundertherearcenteroftheengine deck.

7.Raisethebackendoftheenginedeckupenough toremovethetwoaxleadjustmentbolts.

8.Withthejack,raiseorlowerthebackendofthe enginedecksothattwoaxleadjustmentboltscan bereinstalledindesiredholelocation.Atapered punchcanbeusedtohelpaligntheholes.

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).

9.Retightenallfourbolts,lowerunitandremove jack.

Maintenance

AdjustingtheNumber ofSpacersbelowCaster SupportHub

1.Stopthemachineandmovethedriveleversto theneutrallockposition.

2.DisengagethePTO.

3.Placethedriveleversinthe“parkbrake”position.

4.Pushdownonhandlestoliftfrontcastersoffthe ground.

5.Supportwithjackstands.

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

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 HeightAdjustmentTableandnotesinthe AdjustingtheCuttingHeightsection.

9.Installunusedspacersbetweentopofspindleand spindlenut.

10.T orqueboltto75–80ft-lb(102–109N-m)(see Figure12).

Figure11

1.Four1/2inch(127mm) spacers

2.QuickPin4.Castersupport

7.Adjustthenumberof1/2inchspacersbetween bottomofhubandcasteryoketoobtainthe desiredcuttingheightfromtheCuttingHeight AdjustmentTableintheAdjustingtheCutting Heightsection.

8.Installremainingspacersontopofhub.

9.Install“quickpin”.

10.Repeatforothercaster.

3.3/16inch(4.8mm) spacer

AdjustingtheCuttingHeight withBladeSpacers

1.Stopthemachineandmovethedriveleverstothe neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

Figure12

1.Springdiscwasher (conetowardsbolthead)

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

TransmissionBelt Adjustment

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

Maintenance

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

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

Checkbelttensionafterthersthourofoperation andatleasttwiceduringtherst24hoursof operation.Adjustasnecessary.

Figure13

48inchDeckShownforReferenceOnly

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

2.Checktheadjustmentofthelowerbladedrive linkagelocatedbetweenthebellcrankonthe enginedeckandassistarmonthemowerdeck. Lengthenorshortenthelinkage.Whenproperly adjusted,thereshouldbe1/16inchto1/8inch (2–3mm)ofclearancebetweenbell-crankand transmissionoutputshaftwhenbeltisengaged. Makesuretheassistarmisagainsttherearassist armstoponthedeck(seeFigure13).Pushthe leverdowntothedisengagedposition.Theassist armshouldcontactthefrontassistarmstopon thedeck.Ifitdoesnotcontact,readjustsothat thebellcrankisclosertothetransmissionoutput shaft.

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

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”

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

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

Maintenance

MowerDeckBeltRoutings:

Figure14

32inchand36inchMowerDeck

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

5.Engagethebladecontrolandchecktomakesure thebladebrakepadclearsthesheave.

Figure16

ShownwithBladesDisengaged

1.BladeBrakeRod

2.SpringMountingBolts

3.1/8inchto3/16inch(3–5 mm)

Figure15

48inchMowerDeck

BladeBrakeAdjustment

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

2.Disengageblades.

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

4.Checkthedistancebetweenthespacerandthe nutattheendofthebladebrakerod.The

BeltGuideAdjustment

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

2.Engagethebladedrivebelt.

3.Checkbeltguideundertheenginedeckforproper adjustment(SeeFigure17andFigure18).Adjust asnecessary.

Thedisengagedbeltshouldnotdragorfalloff pulleywhenguidesareproperlyadjusted.

Figure17

32inchand36inchBeltGuideLocation

(Viewedfromunderneaththedeck)

1.11/4inch(3.1cm)

Maintenance

Figure18

48inchBeltGuideLocation

(Viewedfromunderneaththedeck)

1.13/8inch(3.5cm)

BrakeandWheelDrive LinkageAdjustment

1.Checkforcorrectbrakeadjustment:

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.

A.Forwheeldrivelinkageadjustment,

removethehairpinbetweentheneutral locklatchanddrivelever(Figure19).

1.DriveLever

2.ClevisPin

3.DriveLinkage

B.Adjustdrivelinkagelengthbythreading

intooroutoftheswiveluntilthereis a3/16inchto1/4inch(.47-.64cm) clearancebetweenthelinkageassembly andthebottomoftheslotintheneutral lock/parkbrakelatch(seeFigure20).

Figure19

LeftSideShown

4.NeutralLock/ParkBrake Latch

5.Hairpin

SeeFigure6forStandardPistolGriphandlesand Figure7forECShandles.

Note:Theneutrallock/parkbrakelatchesmust beabletobemovedintotheparkbrakeposition, ifnot,thebrakelinkagesmustbeadjustedagain.

3.Checkforcorrectwheeldrivelinkageadjustment.

•ForPistolGripHandles

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

Toadjustthewheeldrivelinkage:

Figure20

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

2.NeutralLock/ParkBrakeLatch

3.DriveLinkage

Note:Neutrallock/parkbrakelatch clearanceshouldbecheckedwhenthereis

aslightupwardforceplacedonthedrive leverstoremoveany"slack"inthelinkage.

C.Re-installhairpinintoholeontheclevis

pinbetweentheneutrallock/parkbrake latchanddrivelever(SeeFigure19). Repeatprocedureonoppositesideofunit.

•ForECSHandles:

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

Maintenance

Figure22

RightSideofUnitShown

Figure21

1.NotchinNeutral Lock/ParkBrakeLatch

2.DriveLever

Toadjustthewheeldrivelinkage:

A.Locateadriveleverlinkageononeside

oftheunitandremovethe5/16-18x1 3/4inchhexcapscrewand5/16-18inch nylocnut(seeFigure22).

B.Threaddriveleverlinkageintooroutof

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

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

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

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.

Figure23

1.Equaldistance

2.ShifterLever

3.ShifterPlate

Maintenance

ShifterDetentAdjustment

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

Figure24

1.ShifterLever

2.Equaldistance

•Toadjusttheshifterlever:

1.Removethe3/8inchnylocnutandspring discwasherfromthestudontopofthe transmission(SeeFigure25).

3.Adjustmentslot

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

Important:Screwingsetscrewintoofarwill preventthetransmissionfromshifting .

PTOSafetySwitch Adjustment

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

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

3.Besurethebellcrankdoesnotcontacttheswitch bodytopreventdamagetotheswitch.

4.Retightenswitchmountinghardware.

Figure25

1.ShifterLever

2.SquareHoledWasher

2.Removetheshifterleverandbenditslightly. DoNotbendtheleverwhileitisattachedto thetransmission.

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

•Toadjustshifterplate:

Note:Thesquare-holewashermustbebetweenthe leverandthetransmission.

Placeshifterleverintheneutralposition.Loosenthe twoboltssecuringtheshifterplatetotheshifterlever legs.Adjustshifterplateandretightenbolts.

3.Transmission

HandleHeightAdjustment

Thehandlecanbepivotedtoallowpositioningin oneofthethreeholesallowingvariousadjustments foroperatorcomfort(seeFigure26).

Toadjustthehandleheight:

1.Removethebottommountinghardwareoneach sideofthehandle.

2.Pivotthehandletooneofthethreepositions.

3.Re-installhardwareandtighten.

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

Figure26

1.UpperHandle3.AdjustmentHoles

2.UpperHole

4.FuelT ankSupport

Note:AdjustmentHolesareactuallyintheside ofthefueltanksupport.

1.Moretractionappliedas boltmovesdown

2.PositionA–Normal Conditions

3.PositionB–MoreSevere

Maintenance

Figure27

4.PositionC–MostSevere

5.FrontofUnit

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(seeFigure27).

Maintenance

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancause engineandexhaustsystemareatooverheat whichcancreatearehazard.

Cleanalldebrisfromengineandexhaust systemarea.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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).

3.Raisedeckandsupportunitusingjackstandsor equivalentsupport.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every80hours

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

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

3.Makesurecoolingshroudsareproperly reinstalled.Operatingtheenginewithout coolingshroudswillcauseenginedamagedueto overheating.

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

4.Cleanoutanygrassbuild-upfromundersideof deckandindischargechute.

WasteDisposal

MotorOilDisposal

Engineoilisapollutanttotheenvironment.Dispose ofusedoilatacertiedrecyclingcenteroraccording toyourstateandlocalregulations.

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.Engineloadisexcessive.1.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.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

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

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 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

G4500-425

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-F RONT RIDING AC CESSORIES A ND 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.4500-352Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark Metro 4500-352 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual