Page 1
For Exmark Mower Parts Call 606-678-9623 or 606-561-4983
®
M FG. CO. INC.
For Serial Nos. 150,000 thru 189,999
and 190,000 & Higher
on the purchase of your new Exmark mower.
C O N G RATULATIONS
This product has been carefully designed and manufactured to give
you a maximum amount of dependability and years of trouble-free
operation.
If additional information is needed, or should you require trained
mechanic service, contact your authorized Exmark equipment
dealer or distributor.
If you need to order replacement parts from your dealer, always
give the model number and serial number of your mower as well
as the part number, description and quantity of the part needed.
The Serial No. plate is located on the top front engine frame on the
right hand side of the machine.
For ease of ordering and reference, we suggest that you record
the information requested in the following identification table.
www.mymowerparts.com
TM
Model N o .
Se rial N o .
Eng ine M od el No.
Eng in e S e rial No.
Date Purchased
Pa ste Label Fro m
Lite ra ture Packet Here
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For Exmark Mower Parts Call 606-678-9623 or 606-561-4983
W ARNING
!
FAILURE TO FOLLOW CAUTIOUS
OPERATING PRACTICES CAN RESULT IN
SERIOUS OPERATOR INJURY.
CAUTION
!
1. Keep all shields, guards and safety devices (especially grass
discharge system) in place and in proper working condition.
2. Stop engine and remove spark plug wire(s) or remove
key before adjusting, servicing, or performing maintenance.
3. When mower deck becomes clogged, stop engine and remove
spark plug wire(s) or remove key before cleaning blockage.
4. Keep hands, feet, and clothing away from power driven parts.
5. Keep off mower unless seat platform is provided.
6. Keep others off mower.
WARNING
!
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
HEALTH WARNING
!
GASOLINE
Harmful or fatal if swallowed. Long-term exposure to
vapors has caused cancer in laboratory animals.
.
Avoid prolonged breathing of vapors.
.
Keep face away from nozzle and gas tank/container opening.
Keep away from eyes and skin.
.
.
Never siphon by mouth.
Failure to use caution may cause serious injury or illness.
When mower is used or operated on any California forest, brush or grass covered
land, a working order spark arrester must be attached to muffler. If not, the operator
is violating state law, Section 442 Public Resource Code. To acquire a spark arrester
for your unit, see your Engine Service Dealer.
IMPORTANT
Exmark reserves the right to make changes or add improvements to
its products at any time without incurring any obligation to make
such changes to products manufactured previously. Exmark, or its
distributors and dealers, accept no responsibility for variations
which may be evident in the actual specifications of its products
and the statements and descri
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tions contained in this publication.
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For Exmark Mower Parts Call 606-678-9623 or 606-561-4983
EXMARK PARTS PLUS
EFFECTIVE DATE: September 1, 1995
Program
If your Exmark dealer does not have the Exmark part in stock,
Exmark will get the parts to the dealer the next business day or
the part will be FREE* Guaranteed!!
How the Program Works
1. If dealer does not have part in stock for a "down" unit at
the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus
2. Distributor ships part(s) to dealer or customer, as
requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus
central time, with an Exmark Parts Plus
shipment of six (6) line items or less.
order of six (6) line items or less.
PROGRAM
order, he contacts Exmark by 3:00 p.m.,
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by
distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.
5. The customer pays for the part and freight
if it is shipped under the Exmark Parts Plus
and if it arrives in
accordance to the program.
6. Who pays for the part and freight
if it fails to arrive overnight in accordance to the program?
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
1. The dealer not submitting the Exmark Parts Plus
order to his Exmark distributor by 1:00 p.m., the dealer
pays for the part and freight.
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus
order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
Exmark pays for the part and freight.
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
pays for the part.
The following restrictions apply
-- The Exmark Parts Plus
Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. UPS has initiated a Saturday
delivery program to many areas of the continental United States and can be requested for an overnight shipment on
Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the
purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts
Plus
orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less.
Exclusions from the Exmark Parts Plus
Program are: Any wholegood or accessory in its entirety, engines and engine
replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter
decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day
or Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be
ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
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CONGRATULATIONS
carefully designed and manufactured to give you a maximum amount of
dependability and years of trouble-free operation.
on the purchase of your Exmark Mower. This product has been
OPERATOR'S MANUAL
This manual contains assembly, operating, maintenance, adjustment and
safety instructions for your Exmark mower.
BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
By following the operating, maintenance and safety instructions, you
will prolong the life of your mower, maintain its maximum efficiency and
promote safe operation.
If additional information is needed, or should you require trained
mechanic service, contact your authorized Exmark equipment dealer or
distributor.
All Exmark equipment dealers and distributors are kept informed of
the latest methods of servicing and are equipped to provide prompt and
efficient service in the field or at their service stations. They carry
ample stock of service parts or can secure them promptly for you from the
factory.
All Exmark parts are thoroughly tested and inspected before leaving
the factory, however, attention is required on your part if you are to
obtain the fullest measure of satisfaction and performance.
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For Exmark Mower Parts Call 606-678-9623 or 606-561-4983
TABLE OF CONTENTS
1. SAFETY.......................................... PAGE
1.1 Safety Alert Symbol ..................................1
1.2 Training .............................................1
1.3 Preparation ........................................1-2
1.4 Operation ..........................................2-3
1.5 Maintenance & Storage ................................4
1.6 Riding Attachments ...................................4
1.7 Safety Signs .......................................4-7
2. SPECIFICATIONS
2.1 Model Number .........................................7
2.2 Engine ...............................................7
2.3 Fuel System ..........................................7
2.4 Safety Interlock System ..............................7
2.5 Steering/Brake Control ...............................7
2.6 Transmission .........................................7
2.7 Wheel Drive System ...................................8
2.8 Tires ................................................8
2.9 Deck .................................................8
2.10 Dimensions .........................................8-9
2.11 Torque Requirements ..................................9
3. ASSEMBLY INSTRUCTIONS
3.1 to 3.18 Assembly ..................................9-14
4. OPERATION INSTRUCTIONS
4.1 Controls .........................................14-16
4.2 Pre-Start ...........................................16
4.3 Operation Instructions ...........................17-18
4.4 Transporting ........................................18
5. MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance .............................19-24
5.2 Adjustments ......................................24-27
6. TROUBLE SHOOTING
6.1 Mower Pulling Left or Right .........................27
6.2 Mower Cuts Unevenly .................................27
6.3 Engine Will Not Start ............................28-29
7. WIRING DIAGRAM
8
WARRANTY
.
............................................32-33
.....................................30-31
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1. SAFETY
1.1 SAFETY ALERT SYMBOL
THIS SAFETY ALERT SYMBOL
THE MACHINE TO IDENTIFY IMPORTANT SAFETY MESSAGES WHICH MUST BE
FOLLOWED TO AVOID ACCIDENTS. THIS SYMBOL MEANS:
IS USED BOTH IN THIS MANUAL AND ON
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
The safety alert symbol appears above information which alerts
you of unsafe actions or situations and will be followed by the
word
When used with the word DANGER: IT DENOTES THAT AN EXTREME HAZARD
EXISTS WHICH WOULD RESULT IN HIGH PROBABILITY OF DEATH OR
IRREPARABLE INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.
When used with the word WARNING: IT DENOTES THAT A HAZARD EXISTS
WHICH CAN RESULT IN INJURY OR DEATH IF PROPER PRECAUTIONS ARE NOT
TAKEN.
When used with the word CAUTION: IT DENOTES A REMINDER OF SAFETY
PRACTICES OR DIRECTS ATTENTION TO UNSAFE PRACTICES WHICH COULD
RESULT IN PERSONAL INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.
DANGER, WARNING
, or
1.2 TRAINING
CAUTION.
1.2.1 Regard the Exmark mower as a piece of power equipment and
teach this regard to all who operate this unit.
1.2.2 Read the instructions carefully. Familiarize yourself
with the controls and the proper use of the equipment.
1.2.3 Never allow children, teenagers, or people unfamiliar
with these instructions to use the mower.
1.2.4 Avoid mowing while people, especially children or pets,
are nearby. Keep in mind that the operator or user is
responsible for accidents or hazards occurring to other
people or their property.
1.3 PREPARATION
1.3.1 The use of personal protective equipment, such as (but not
limited to) protection for the eyes, ears, feet and head
is recommended.
1.3.2 While mowing, always wear substantial footwear and long
trousers. Do not operate equipment when barefoot or when
wearing open sandals.
1.3.3 Thoroughly inspect the area where the equipment is to be
used and remove all stones, sticks, wires, bones and
other foreign objects which may damage the equipment or
cause personal injury to the operator or bystanders.
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1.4 OPERATION
1.4.1 Give complete, undivided attention to the job at hand.
1.4.2 Mow only in daylight or good artificial light.
operate the mower when children or others are in the area!
Fuel is
••••
while refueling. Refuel only in a well
ventilated area, or refuel outdoors.
Store fuel in containers specifically
••••
designed for this purpose.
Add fuel before starting the engine.
••••
Never
or add fuel when engine is running or
when the engine is hot.
Never fill the fuel tank so that the fuel
••••
level rises above a level that is 1/2” below
the bottom of the filler neck to allow for
fuel expansion and prevent fuel spillage.
If fuel is spilled,
••••
start the engine. Move away from the
area of the spill and avoid creating
any source of ignition until fuel
vapors have dissipated.
Highly Flammable. DO NOT
remove the cap of the fuel tank
DO NOT
attempt to
smoke
Do Not
1.4.3 When feasible, avoid operating the equipment in wet grass.
1.4.4 Use
1.4.5 Stop the blades when crossing surfaces other than grass; and
1.4.6 Never operate the mower with defective guards, shields,
EXTREME
as loss of traction and/or control could occur. Mow
across
Loss of control and/or loss of operator’s footing could
result in a fall with an arm or leg getting under the
mower or engine deck and sustaining serious injury. Drive
slower on slopes.
20 degrees. Watch for ditches, holes, rocks, dips, and
rises which can cause erratic handlebar movement and loss
of footing. Keep away from drop-offs and steep banks.
Avoid sudden starts. Look down and behind you before and
while moving backwards.
wet - slippery conditions create hazardous footing, affect
steering, and reduce traction and braking. The operator
is responsible for safe operation on slopes. See inside
back cover to determine the approximate slope angle of the
area to be mowed.
when transporting the mower to and from the area to be
mowed.
or covers. Always have safety shields, guards, switches, and
other devices in place and in proper working condition.
slopes with walk behind mowers, never up and down.
caution when mowing and/or turning on slopes
DO NOT
operate on slopes greater than
DO NOT
mow slopes when grass is
1.4.7
1.4.8 Place transmission in neutral, disengage blade drive before
Do Not
the engine. Operating an engine at excessive speed may
increase the hazard of personal injury.
starting engine.
change the engine governor settings or over-speed
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1.4.9 Start the engine carefully with feet well away from blades.
1.4.10 Keep hands, feet and clothing away from rotating parts
while the mower is being operated.
1.4.11 Stop the engine and remove spark plug wire(s) or ignition key:
Before checking, cleaning or working on the mower.
•
After striking a foreign object (inspect the mower
•
for damage and make repairs before restarting and
operating the mower).
1.4.12 Stop the engine:
Before clearing blockages.
•
Whenever you leave the mower.
•
Before removing the grass catcher.
•
Before refueling.
•
Before making height adjustments.
•
1.4.13 Before stopping the engine, return the throttle control
to the idle position for 30 seconds to allow the engine
to cool down.
1.4.14 The fuel system is provided with a shut-off valve. The
fuel shut-off valve is used to shut off the fuel when:
The machine will not be used for a few days.
•
During transport to and from the job.
•
When parking inside a building.
•
1.4.15 This mower was designed for one operator only. Keep all
others away from mower during operation.
1.4.16
Do Not
collection system in place and in proper working condition.
mow without the grass deflector or entire grass
DO NOT
••••
confined area where dangerous carbon
monoxide fumes can collect.
Failure to follow safety instructions
••••
and cautious operating practices can
result in serious injury.
operate the engine in a small
Although hazard control and accident
••••
prevention partially are dependent upon the
design and configuration of the equipment, these
factors are also dependent upon the awareness,
concern, prudence and proper training of the
personnel involved in the operation, transport,
maintenance and storage of the equipment. It is
essential that all Operator Safety Mechanisms be
connected and in operating condition prior to use
for mowing.
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1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maintenance, follow the engine manufacture’s
recommendations precisely as stated in the engine manual.
1.5.2 If carburetor adjustment is necessary, stand to one
side and keep feet and hands clear while making adjustments.
1.5.3 Keep engine and engine area free from accumulation of
grass, leaves, excessive grease or oil and other debris
which can accumulate in these areas. These materials can
become combustible and may result in a fire.
1.5.4 Store fuel in a container specifically designed for this
purpose in a cool, dry place.
1.5.5 Keep the mower and fuel container in locked storage to
prevent children from playing or tampering with them.
1.5.6 Gasoline powered equipment or fuel containers should not
be stored in a basement or any enclosed area, where open
pilot lights or heat appliances are present.
1.5.7 Maximum mowing results and safety can only be achieved if
the mower is properly maintained and operated correctly.
1.5.8. Check all bolts frequently to maintain proper tightness.
1.5.9. Keep all guards, shields and all safety devices in place
and in safe working condition.
1.5.10 Frequently check for worn or deteriorating components
that could create a hazard.
1.5.11 All replacement parts must be the same as or equivalent
to the parts supplied as original equipment.
1.6 RIDING ATTACHMENTS
1.6.1 Use only
Exmark riding attachments may create a hazardous condition
resulting in injury.
Exmark
riding attachments. The use of other than
1.7 SAFETY SIGNS
1.7.1 Keep all safety signs legible. Remove all grease, dirt
and debris from safety signs.
1.7.2 Safety signs must be replaced if they are missing or
illegible.
1.7.3 When new components are installed, be sure that current
safety signs are affixed to the replaced components.
1.7.4 New safety signs may be obtained from your authorized
Exmark equipment dealer or distributor or from
Exmark Mfg. Co. Inc.
1.7.5 Safety signs may be affixed by peeling off the backing
to expose the adhesive surface. Apply only to a clean,
dry surface. Smooth to remove any air bubbles.
1.7.6 Familiarize yourself with the following safety signs and
instruction labels. They are critical to the safe
operation of your Exmark commercial mower.
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14 HP Kawasaki,Briggs & Stratton, & Kohler
(Serial No.s 150,000-189,999: 17 HP Kawasaki
PART NO. 323688
LOCATION: Console
Serial No.s 190,000 & Higher 17 HP Kawasaki
PART NO. 323699
A
14 HP Kawasaki & Kohler
PART NO. 323689
LOCATION: RH Side of
Console
17 HP Kawasaki
PART NO. 323691
LOCATION: RH Side of
Console
PART NO. 303508
LOCATION: Front of Mower
Deck, Top Surface
17hp Kawasaki & B&S
Serial No. 150,000-189,999
PART NO. 403120
LOCATION: On Switch Bracket
at Front Left of
Fuel Tank Support
PART NO. 303293
LOCATION: On Top RH Side
of Fuel Tank
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PART NO. 403005
LOCATION: RH & LH Corners
of Mower Deck
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PART NO. 403143
LOCATION: RH Side of Rear
Surface of Engine Deck
PART NO. 553049
LOCATION: Front of Mower Deck Top Surface
PART NO. 303517
LOCATION: LH Side of Rear
Surface of Mower Deck
Briggs & Stratton
PART NO. 543631
LOCATION: RH Side Console
PART NO. 323540
LOCATION: Front of Mower Deck
Top Surface
PART NO. 303518
LOCATION: Transmission Shifter Plate
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PART NO. 413421
LOCATION: Left Rear on Top of
PART NO. 323550
LOCATION:Upper
Handle
PART NO. 513746
LOCATION: On Engine Blower
Housing next to
Muffler & on Center
Belt Cover
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PART NO. 413206
LOCATION: Top of Cutter Deck, Under
Center Belt Shield (36”)
PART NO. 413327
LOCATION: Top of Cutter Deck, Under
Belt Shield (48” & 52” Decks)
2. SPECIFICATIONS
2.1 MODEL NUMBER:
Serial No.s 150,000 – 189,999 Serial No.s 150,000 & Higher
MHP4816BV; MHP5216BV; MHP3614KA; MHP3615KC;
MHP4814KA; MHP4815KC;
MHP4817KA; MHP5217KA.
2.2 ENGINE
2.2.1 Engine Specifications:
See your Engine Owner's Manual.
2.2.2 3600 RPM (No Load).
2.3 FUEL SYSTEM
2.3.1 Capacity: 5.0 gal.(18.9 L.)
2.3.2 Type of Fuel: Regular
87 octane or higher. In countries using the research
method, it should be a 90 octane
2.3.3 Fuel Filter: Replaceable in-line
2.3.4 Fuel Shut-Off Valve: 1/4 turn
unleaded
gasoline,
minimum
.
2.4: SAFETY INTERLOCK SYSTEM
Operator must have transmission in neutral and blade clutch
disengaged to start engine. Release of OPC levers will cause
the engine to stop if
and/or
blade clutch is engaged
2.5 STEERING/BRAKE CONTROL:
Fingertip drive control levers provide independent speed
control, braking and neutral to each drive wheel for moving,
stopping and power turning. Parking brakes are engaged by
locking drive control levers in the “brake” position.
2.6 TRANSMISSION:
2.6.1 Peerless 700-061, five speeds forward and one reverse.
2.6.2 Speed Range:
1
2
3
st
2.0 mph (3.22 km/h) 4th 4.1 mph (6.60 km/h)
nd
2.7 mph (4.35 km/h) 5th 6.2 mph (9.98 km/h)
rd
3.5 mph (5.63 km/h) Rev. 3.1 mph (4.99 km/h)
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transmission is not in neutral
.
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2.7 WHEEL DRIVE SYSTEM:
Banded double A-Section V-Belts, single top side idlers
and replaceable bolt-on drive sheaves and brake drums.
2.8 TIRES
Drive Front Caster
Size .......... 16 x 6.50-8 ......... 9 x 3.50-4
Quantity ............2................... 2
Tread ...... Turf Saver/Turf Master ... Smooth
Ply Rating ..........4................... 4
Pressure ..... 14 psi(97 kPa) ..... 22 psi(152 kPa)
2.9 Deck
2.9.1 Cutting Width:
Model 36 in. .................. 35.25 in.(89.5 cm)
Model 48 in. .................. 47.25 in.(120.0 cm)
Model 52 in. .................. 52.00 in.(132.1 cm)
2.9.2 Discharge: Right Side
2.9.3 Blade Size:
Model 36 in. ..... 18.00 in.(45.7 cm)...Qty. 2
Model 48 in. ..... 16.25 in.(41.3 cm)...Qty. 3
Model 52 in. ..... 18.00 in.(45.7 cm)...Qty. 3
2.9.4 Type of Drive: Manual engagement of belt with over-center
lock. Belt tension is adjustable via turnbuckle.
2.9.5 Deck Mounting: Full floating deck is attached to out-front
support frame, removable for service.
2.9.6 Cutting Height: Adjusts in 1/2”(.63 cm) increments
from 1.5”(3.8 cm) to 4 1/2”(11.4 cm).
2.10 DIMENSIONS
2.10.1 Overall Width:
Discharge chute down
Discharge chute up
(Transport only)
2.10.2 Overall Length:
Overall Length
2.10.3 Curb Weight:
36” 48” 52”
46.25” 58.25” 62.6”
(117.5 cm) (148.0 cm) (159.0 cm)
36.1” 48.1” 53.0”
(91.7 cm) (122.2 cm) (134.62 cm)
36” 48” 52”
77.7” 73.7” 75.9”
(197 cm) (187 cm) (193 cm)
36” 48” 52”
Curb Weight
Weights will vary slightly depending on engine option.
∗
2.10.4 Overall Height: 42” (107 cm)(all units)
∗
507 lbs. 555 lbs. 583 lbs.
(230 kg) (252 kg) (264 kg)
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2.10.5 Tread Width (to outside of tires):
36” Model ....... 35.2” (89.4 cm)
48” Model ....... 35.2” (89.4 cm
52” Model ....... 35.2” (89.4 cm)
2.11 TORQUE REQUIREMENTS
BOLT LOCATION TORQUE
Blade Mounting Bolt ...................... 75-80 ft-lbs.
Cutter Housing Spindle Nut ............... 75-80 ft-lbs.
Anti-Scalp Roller Bolts .................. 40-45 ft-lbs.
Mower Deck Support/Engine Deck Mount ..... 30-35 ft-lbs.
Engine Mounting Bolts
Briggs
Kohler
Transmission Shifter-lever Nut..... 30-35 ft-lbs.
Stratton & 17 HP Kawasaki .. 15-20 ft-lbs.
&
& 14
HP Kawasaki ............ 25-30 ft-lbs.
3. ASSEMBLY INSTRUCTIONS
3.1 Uncrate unit, and remove upper handle assembly,
fuel tank, and linkages from top of crate.
3.2 Remove and open the bolt bag.
3.3 Loosen the 5/16" hardware at the two (2) discharge
deflector hinge points so that the deflector is snug, but
can be moved up and down freely.
3.4 Refer to Parts Manual to help you identify and locate parts
and their proper position.
3.5 Apply retaining adhesive “Fel-Pro Retaining I or Retaining
II” or “Loctite RC609 or 680” on the two threaded studs from
the bolt bag and install into the two left holes underneath
fuel tank. Install the fuel tank on top of the fuel tank
support with the studs going through the slots in the support.
Install two 5/16-18 x 3/4” screws with a 5/16” SAE flatwasher
and 5/16” lockwasher into the threaded holes in the right
side of the fuel tank.
SAE flatwasher, then a spring, over each of the studs and
fasten with a 5/16 nyloc nut. Tighten 3/16 nylock nut fully
then cack off a 1/2 turn. This is to allow for normal fuel
tank expansion with changes in temperature and fuel levels.
3.6 Attach the fuel tank hose to the tank fitting and secure
with the clamp provided. Make sure that fuel hose is not
between engine and throttle plate on engine.
3.7 Position the lower end of the handle assembly on the
outside of the upper rear section of the fuel tank &
handle support. Install four 3/8-16 x 1" bolts (with four
spring disk washers against the head of each bolt) from
the outside in. Secure using four 3/8" whizlock nuts on
the inside of each handle support and tighten until the
spring disk washers are flat (See Figure 1).
Do not over tighten
. Place a 5/16”
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UPPER HANDLE MOUNTING
3.8 Route the throttle cable along the right side of the upper
handle, under the fuel tank support, and position the cable
on the
right side
Attach throttle cable to engine:
For Kohler and Kawasaki engines with “positive” detents
in throttle cable for the full throttle and idle positions.
a) Position the throttle control lever (on console) in the
full throttle (but not choke) position. You will feel a
detent when the throttle lever is approximately 3/4” from
the upper end of the slot (this is full throttle position).
b) Loosen clamp on engine control plate (See Figures 2, 3 & 4).
Attach inner wire of the throttle cable to the control
plate lever and position cable clamp,
side of the engine
left
of engine
FIG. 1
(B&S)
(Kaw & Kohler) or
.
do not
to the
tighten clamp.
FIG 2
KOHLER SPEED CONTROL
(THROTTLE CABLE HOOK-UP)
FIG 3
14 HP KAWASAKI SPEED CONTROL
(THROTTLE CABLE HOOK-UP)
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Choke Link
Control Plate Lever
Control Alignment Holes
Clamp
Choke Adjusting Screw
Control Cable
FIG 4
17 HP KAWASAKI SPEED CONTROL
(THROTTLE CABLE HOOK-UP)
c) Pull cable upward (rearward for 17 HP Kawasaki) until
alignment holes in control plate lever and control plate
line up. For Kawasaki 15/64”(6mm) drill bit can be inserted
through these two holes to align them. For Kohler use a
19/64” drill bit. Once the holes are aligned, tighten clamp
onto throttle cable.
d) Be sure the
lever
when the throttle control is in the full throttle
choke adjusting screw just contacts the choke
position. Choke link should not move when throttle control
is moved to the full throttle position. Choke must be
completely closed when throttle lever is moved to the full
forward “CHOKE” position.
e) This step needs to be done after the
and the engine has been started
. Refer to Section 4.
unit has been assembled
(Operation Instructions).
For Kohler and 14 HP Kawasaki engines
:
Check the engine “STOP” position by moving the throttle
control fully to the rear. (Note: There is a detent toward
the lower end of the slot in the console for “IDLE”; the
“STOP” position is rearward from this detent).
For Kohler engines
:
If the engine continues to run in the "STOP" position,
turn the kill switch adjusting screw inward until engine
stops, then give it an additional 1/2 to 3/4 turn to assure
it will always function properly.
(The 14 HP Kawasaki kill switch is not adjustable)
For 17 HP Kawasaki engines
:
.
There is not a “STOP” position. The engine will continue to
run when the throttle control is moved past the rear detent.
Turn the ignition switch to the “off” position to stop the
engine.
For B&S Vanguard Engines:
a) Position the throttle control lever (on console) 1/8"
from the upper end of the slot. Route the throttle cable
along the right side of the upper handle, under the fuel
tank support, and position the cable on the
right
side
of the engine between the oil fill tube and engine.
b) Attach the inner wire to the appropriate throttle control
lever on the engine. Loosen the cable clamp on the engine,
place the cable behind it and pull up on the cable to move
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the throttle linkage to the
the cable clamp screw.
3.9 Connect the blade engagement linkages. Loosen jamnut and remove
turnbuckle from lower linkage. Screw turnbuckle onto both upper
and lower linkages simultaneously. (See figure 5) Note that the
threads on upper linkage are left hand. See 5.2.2 for linkage
adjustment.
FIG 5
BLADE ENGAGEMENT LINKAGE
3.10 Install and adjust shifter lever.
a) Remove the 3/8” nyloc nut and spring disc washer from the
stud on top of the transmission. Install the shifter lever
through slot in shifter lever plate and onto the stud on top
of transmission. Be sure the square-hole washer remains
between the lever and transmission. Replace the spring disc
washer and nyloc nut(see figure 6). Torque the 3/8” nut to
35ft. lbs. (47N.M).
b) Shift lever to second gear and check alignment of lever in
slot of shifter plate. Clearance between top of lever and
the top of the slot should be about equal to the clearance
between bottom of the lever and the bottom of the slot
(See figure 7). If it is not, remove lever and bend it
slightly to adjust. DO NOT Bend lever while it is attached
to transmission. Reinstall lever and tighten hardware.
c) Shift to neutral position. Lever Should not contact the left
edged of the upper slot. Push lever down. Lever should not
contact the right edge of the bottom slot (See Figure 8).
Shifter plate can be adjusted side to side to adjust
position of lever relative to the slot in plate. Loosen the
two bolts securing the shifter plate to the shifter lever
legs. Adjust shifter plate and retighten bolts.
full throttle
position. Tighten
THIS CLEARANCE SHOULD BE EQUAL
FIG. 6 SHIFTER LEVER TO TRANSMISSION
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FIG. 7
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FIG. 8
3.11 Install and adjust wheel drive linkages.
a) Screw threaded end of drive linkages into swivels in
wheel drive idler arms.
b) Insert clevis pin from bolt bag through drive linkage,
lever and slot in the neutral lock/park brake latches
(See Figure 9). Make proper adjustments before adding
hairpins.
THIS CLEARANCE SHOULD BE EQUAL
Neutral Lock/Park Brake Latch
Clevis Pin
Drive Linkage
Drive Lever
FIG. 9
LEVER AND ROD ADJUSTMENT
c) Adjust drive linkage length by threading into or out of the
swivel until there is a 3/16” to 1/4” clearance between the
linkage assembly and the bottom of the slot in the neutral
lock/park brake latch. (See Figure 10)
3/16” TO 1/4”
Neutral Lock/ Park
Brake Latch
Drive Linkage
1/4” Clearance
FIG. 10
NEUTRAL LOCK LEVER CLEARANCE
Note: Neutral lock/park brake latch clearance should be
checked when there is a slight upward force placed
on the drive levers to remove any “slack” in the
linkage.
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After clevis pin has been inserted, install hairpin into
hole on the clevis pin between the neutral lock/park
brake latch and drive lever (See Figure 11). Repeat
procedure on opposite side of unit.
Clevis Pin
Drive
Lever
Hairpin
FIG. 11
DRIVE LEVER HARDWARE LOCATION
d) Adjust brakes by adjusting wingnut on upper end of each
brake rod so that when brakes are engaged there is
approximately 1/4” of clearance between ends of drive
levers and handle grips (See Figure 10)
Note: Adjustment should allow the brakes to be engaged, yet
allow the neutral lock/park brake latches to be moved
into the park brake position, if not the brake
linkages must be adjusted again.
e) Squeeze the drive levers and move both neutral lock/park
brake latches into the neutral lock position. Mower
should move forward and backward freely, if not, readjust
as stated in Sections 3.11c and 3.11d.
Drive Linkage
Left Side
Shown
Reference for
Position Only
Neutral
Lock/Park
Brake Latch
3.12 Route the long unattached wiring harness lead, up the left
hand side of the handle and connect the two terminals (in
any order) to the operator presence control switch
terminals underneath the control console.
Fasten the lead to the handle with two small wire ties
from the bolt bag, one at the upper end of the handle
next to the console, and one at the very lower end of
the handle where it attaches to the fuel tank support.
3.13 If machine is shipped without muffler installed, install
muffler with hardware provided.
3.14 For Briggs and Stratton Engines install debris guard to top
of engine.
3.15 Service Engine: Refer to Engine Owner’s Manual.
3.16
GREASE UNIT: NOTE:
Refer to 5.1.13, for locations and grease amounts.
3.17 Follow pre-start instructions as outlined in 4.2.
3.18 Perform any needed adjustments as outlined in the
Adjustment Section.
4. OPERATION INSTRUCTIONS
4.1 Controls
UNIT IS NOT GREASED AT THE FACTORY.
4.1.1 Operator Presence Control (OPC) Levers: Located on the upper
handle assembly directly above the handle grips.
When these
levers are depressed, the OPC system senses that the operator
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is in the normal operator's position. When the levers are
released, the OPC system senses that the operator has moved
from the normal operating position
if either the transmission shift lever is
position or the
blade clutch is engaged
4.1.2 Drive Levers: Located on each side of the upper handle
assembly directly below the handle grips. These levers
individually control the clutching action of the wheel drive
belts and brakes. When the drive levers are all of the way
down, the wheel drive belts engage and the brakes disengage.
Squeezing the left or right hand drive lever causes the left
hand or right hand wheel to slow down or stop, which makes
the machine turn to the left or right respectively. The
sharpness of the turn varies by how much the lever is
squeezed. If both levers are squeezed all the way back,
both brakes will engage and the machine will stop. For
straight ahead motion, smoothly release both drive levers
to engage both drive wheels simultaneously.
4.1.3 Neutral Lock/Parking Brake Latch: Located directly above the
drive levers. The purpose of these latches is to allow the
operator to lock the drive levers in a "neutral" position
where neither the wheel drive belts nor the brakes engage,
or in a “park brake” position where the wheel drive belts are
are not engaged and the park brake is engaged. To lock the
drive levers in “neutral”, squeeze the drive levers back, place
thumbs on the upper portion of the neutral lock/park brake latches
and move them to the rear. Release drive levers. To lock the
levers in “park brake”, squeeze the drive levers back, place
thumb on the upper portion of the neutral lock/park brake latches
and move them ahead. Release drive levers (See Figure 12).
and will kill the engine
not in the neutral
.
Apply parking brakes whenever leaving the operators position.
ROTATE FORWARD FOR
PARK BRAKE POSITION
ROTATE BACK FOR
NEUTRAL LOCK POSITION
PARK
BRAKE
FULL SPEED
FORWARD
NEUTRAL
LOCK
LATCH IS IN
THE DRIVE
POSTION
NEUTRAL - HOLD IN THIS POSITION
FORWARD - RELEASE DRIVE LEVER
REVERSE - SQUEEZE DRIVE LEVER
FIG. 12
DRIVE LEVER, NEUTRAL LOCK/PARK BRAKE LATCH OPERATION
4.1.4 Blade Engagement: Located on the left side of the upper
handle. To engage the blades, push the lever forward, or
away from the operator, until the linkage locks over-center.
To disengage the blades, pull the lever to the rear, or
towards the operator.
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4.1.5 Choke Control: Choke is used to aid in starting a cold engine.
On the B&S engine the choke control is located on the left
hand, front corner of the engine and is activated by pulling
the control outward. On Kawasaki and Kohler engines, the
choke is part of the throttle control lever and is activated
by moving the throttle control to the full forward position.
Once the engine has started move the choke control to the
off position and move the throttle to the medium or full
throttle position.
4.1.6 Throttle Control: Located on the control console’s right
side. The throttle is used to control engine speed. Moving
the throttle control forward will increase engine speed and
moving it to the rear will decrease engine speed. All Kohler
and 14 HP Kawasaki units are equipped with throttle kill as a
standard feature. Moving the throttle to the full rear “Stop”
position will shut off the engine (B&S and 17 HP Kawasaki units
use a key switch to shut off engine).
4.1.7 “Off-Run” Switch
console (Serial No.s 190,000 and higher) or front, left corner
of the fuel tank support (Serial No.s 150,000-189,999). Turn key
to the “Run” position to allow the engine to be started. Turn
key to the “Off” position to shut engine off.
4.1.8 Fuel Shut-Off Valve: Installed in the fuel line midway between
the tank and the engine. The fuel shut-off valve is used to shut
off the flow of fuel when parking inside a building, during
transportation to and from the job sites, and when the machine
will not be used for a few days. Rotate valve 1/4 turn clockwise
to shut fuel off. Rotatevalve 1/4 turn counter-clockwise to turn
fuel on.
4.1.9 Transmission Shift Lever:
Located under the control console and behind the fuel tank.
It shifts the 5-speed transmission into five forward gears,
neutral and reverse. Shift transmission only when drive
levers are in the
levers in neutral may cause damage to the transmission.
NOTE: Reverse is “reverse assist” only, meaning when the
transmission is in reverse, the operator has to pull the unit
backward to “assist” with the movement of the unit.
(B&S
and 17 HP Kawasaki only)
neutral
position. Shifting without drive
: Located on the
4.2 Pre-Start
4.2.1 Fill fuel tank. For best results use only clean fresh
regular grade
87 or higher. Regular grade leaded gasoline may also be used;
however, combustion chamber and cylinder head will require
more frequent service. See Engine Owner's Manual.
Do not add oil to gasoline.
Never fill the fuel tank so that the fuel level rises above
a level that is 1/2” below the bottom of the filler neck to
allow for fuel expansion and prevent fuel spillage.
4.2.2 Refer to Maintenance and Adjustment Section 5 and perform
all of the necessary inspection and maintenance steps.
4.2.3 Familiarize yourself with the controls and operation of unit.
See Controls section 4.1 and Operating Instructions section 4.3.
unleaded
gasoline with an octane rating of
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4.3 OPERATING INSTRUCTIONS
4.3.1 Refer to Engine Owner’s Manual for detailed operating
instructions regarding the engine.
4.3.2 Starting Engine: Operator must have
and
transmission in neutral
fuel shut-off valve.
Open
NOTE: Always engage the left and right neutral lock/park brake
latches in the “park brake” position when starting the engine
(See Section 4.1.3).
For Kohler and Kawasaki engines:
On a cold engine, place the throttle in the full forward
“Choke” position. For a 17 HP Kawasaki engine turn key to
“Run” position. Pull recoil rope to start engine.
With a cold engine, gradually return choke to the full
throttle position after the engine starts and warms up.
On a warm engine, place the throttle control
the “Slow” and “Fast” positions.
NOTE: Kawasaki engines generally need to be “choked” even
when warm.
For B&S engines:
Turn key to the “Run” position.
On a cold engine, place the throttle in the full forward
position, and pull the choke control, on the engine, fully
outward to the engaged position. Pull recoil rope to start
engine.
With a cold engine, gradually return choke to the full
throttle position after the engine starts and warms up.
On a warm engine, place the throttle control
the “Slow” and “Fast” positions.
.
DO NOT
blade drive disengaged
midway
midway
choke B&S when warm.
between
between
Always engage the “park brakes” when starting the engine,
•
See Controls Section 4.1.3.
4.3.3 Stopping Engine: Disengage blade drive, position speed control
lever in neutral and lock the drive levers in the “park brake”
position. Move throttle to the “Slow” position. Allow engine
to idle for 30 seconds to allow cool down.
For 14 HP Kawasaki and Kohler engines; after cool down time,
move throttle lever to the full rear (“Stop”) position. For
B&S and 17 HP Kawasaki engines; After cool down time, turn
key to the “Off” position.
4.3.4 Drive Lever/Neutral Lock/Park Brake Latch Operation: To lock
the drive levers in neutral, squeeze the drive levers back
to the “neutral” position. Place thumbs on the upper portion
of the neutral lock/park brake latches and move them to the
rear. Release drive levers (See Figure 12).
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To lock the drive levers in “park brake”, squeeze the drive
levers back to brake position. Place thumbs on the upper
portion of the neutral lock/park brake latches and move them
to the front. Release drive levers. (See Figure 12)
Be sure the pins protruding through the slots of each
•
neutral lock latch are completely engaged in the rear
slot of each latch, if not, the drive levers could
unexpectedly slip into forward drive position.
To place the drive levers in the drive position, firmly hold
the drive levers, place thumbs on the upper portion of the
neutral lock/park brake latches and move them out of either
the “neutral” or “park brake” position to release drive levers.
Carefully
4.3.5 Drive Wheel Engagement and Turning: With drive levers in
“neutral” or “park brake” position, shift transmission into
desired gear. Squeeze both drive levers and move both neutral
lock/park brake latches from the “neutral” or “park brake”
position.
release the drive levers.
For straight ahead motion, smoothly release both drive
levers to engage drive wheels.
Squeeze the right hand drive lever to turn right
and the left hand drive lever to turn left (See Section 4.1.2).
4.3.6 To Stop: Squeeze drive levers back to engage brakes. Move
neutral lock/park brake latches into the “park brake” position
and release drive levers. Shift transmission to neutral.
4.3.7 Blade Engagement: Be sure that all persons are clear of mower
deck and discharge area before engaging the blades.
Set throttle to “midway” position. Push the blade engagement
arm forward and down to engage blades. Accelerate to full
throttle to begin mowing (See Section 4.1.4).
4.3.8 Blade Disengagement: Pull upward and back completely on the
blade engagement arm to disengage the blades. (See Section
4.1.4)
4.3.9 Changing Gears
When changing gears,
engage neutral lock latches or park brakes. The shift lever
may be moved with a knee or by hand.
NOTE: Reverse gear is reverse assist only, the operator
must pull the unit backwards.
always
squeeze drive levers and/or
4.4 TRANSPORTING
Use a heavy duty trailer to transport the machine. Engage
park brakes and block wheels.
Securely fasten the machine to the trailer with straps,
chains, cables or ropes.
Do not rely solely on parking brake to hold machine on
trailer.
Use a safety chain and be sure that the trailer has all
necessary lighting and marking as required by law.
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5. MAINTENANCE & ADJUSTMENTS
Disengage blade clutch, shut off engine
••••
and remove spark plug wire(s) before
servicing, cleaning or making adjustments.
The engine can become very hot. Always
••••
allow the engine to cool before servicing
or making repairs around the engine area.
5.1 PERIODIC MAINTENANCE
5.1.1 Check engine oil level.
Service Interval:
a) Make sure engine is stopped and on a level surface.
b) Check with engine cool.
c) Clean area around dipstick. Remove dipstick and wipe oil
off. Reinsert the dipstick (
Kohler and Kawasaki engines; DO screw into place for
B&S engines). Remove dipstick and check oil level.
See Engine Owner's Manual
DO NOT
screw into place for
d) If the oil level is low, add oil as specified in the
Engine Owner’s Manual to bring the oil level up to the
“F” mark on the dipstick.
DO NOT OVERFILL
IMPORTANT:
the “L” mark or over the “F” mark.
5.1.2 Clean engine air cooling system.
Service Interval:
a) Stop engine and remove spark plug wire(s).
b) Clean all debris from engine air intake screen and from
around engine shrouding.
5.1.3 Clean grass build-up under deck and check mower blades.
Service Interval:
DO NOT
.
operate the engine with oil level below
See Engine Owner's Manual
Daily
CAUTION
When it is necessary to raise the deck
••••
or mower for service or maintenance,
rely solely on mechanical or hydraulic jacks
for support. Use adequate jack stands or
equivalent support.
a) Disengage blade clutch.
DO NOT
b) Stop engine and remove spark plug wire(s).
c) Raise deck and block up using proper safety precautions.
d) Clean out any grass build-up from underside of deck and
in deck discharge chute.
e) Inspect blades and sharpen or replace as required.
f) If blade removal is necessary, be careful for the sharp
cutting edges of the blades.
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g) Re-install the blades (if they were removed) and torque
blade bolts to 75-80 ft. lbs. Be sure the spring
disc washer cone is installed toward the bolt head
(See Figure 13).
h) Remove jack stands (or equivalent support) and lower
deck to ground.
FIG. 13
BLADE BOLT INSTALLATION
5.1.4 Check safety interlock system.
Service Interval:
Daily
a) For your safety, your Exmark mower is equipped with
Operator Presence Controls (OPC). When either the mower
blades are engaged, or the transmission shift lever is not
in neutral and both hands are removed from the handles,
the mower engine
b) Check OPC circuits. Clear the area. Run engine at
one-third throttle, then with drive levers and neutral
lock/park brake latches in
the transmission into gear and release OPC levers –
MUST stop.
Again, run engine at one-third throttle, move the transmission
shifter lever to
OPC levers -
c) If machine does not pass any of these tests,
operate. Contact your authorized
MUST stop.
“park brake” position
neutral
engine MUST stop.
, engage blade clutch and release
, Shift
engine
DO NOT
EXMARK SERVICE DEALER.
CAUTION
It is essential that all Operator
••••
Safety Mechanisms be connected and
in proper operating condition prior
to the use of the mower.
When checking starting problems, be
••••
sure to keep body, hands and clothes
away from areas where moving parts
can suddenly engage.
5.1.5 Check for loose hardware.
Service Interval:
a) Stop engine and remove spark plug wire(s).
Daily
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CAUTION
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b) Visually inspect machine for any loose hardware or any
other possible problem. Tighten hardware or correct the
problem before operating.
5.1.6 Check Brake and Wheel Drive Linkage Adjustment
Service Interval:
Refer to Section 3.11. Note any bent linkage or hardware
which may need servicing or replacing.
5.1.7 Service pre-cleaner element and air cleaner.
Service Interval:
5.1.8 Change engine oil.
Service Interval:
NOTE: Change oil after first five (5) hours of operation.
Follow engine manufacturers recommendations for future oil
changes.
a) Disengage blade clutch.
b) Stop engine and remove spark plug wire(s).
c) Drain oil while engine is warm from operation.
Daily
See Engine Owner's Manual
See Engine Owner's Manual
d) Remove the oil drain plug from the right hand side of
the engine. Allow oil to drain, then replace drain plug.
e) Replace the oil filter as per Engine Owner's Manual.
Clean around oil filter and unscrew filter to remove.
Before reinstalling new filter, apply a thin coating of
oil on the surface of the rubber seal. Turn filter
clockwise until rubber seal contacts the filter adapter
then tighten filter an additional 2/3 to 3/4 turn.
f) Clean around oil fill cap and remove cap. Fill to the
specified capacity and replace cap. Use oil as specified
in Engine Owners Manual.
g) Start the engine and check for leaks. Stop engine and
recheck oil levels.
5.1.9 Check grease level, input and output shaft bearing wear on
Peerless Transmission. (Replace gearbox grease yearly)
Service Interval:
a) Stop engine and remove spark plug wire(s).
b) Place drive levers and neutral lock/park brake latches in
the neutral lock position.
c) Remove shifter lever from top of transmission.
d) Remove shifter plate from top of transmission and the two
leads from the neutral start switch.
e) Release the tension on the transmission belt.
f) Check for side play caused by bearing wear on the input
and out put shafts of the transmission. Replace bearings
if necessary.
g) Remove the six bolts that fasten the upper case to the
lower case and carefully remove the upper case half.
h) Check the grease level in the lower case. The grease
level should be approximately 1-1/2” to 1-3/4” from the
gearbox bottom. If necessary, fill to proper level with
Peerless grease (Part No. 788067)
160 hrs.
Do not overfill.
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i) Reinstall upper case half and fasten in place with six
bolts previously removed.
j) Reinstall all parts removed in Steps c and d. Install
drive belt and adjust tension as stated in Section
5.2.5.
5.1.10 Check tire pressures.
Service Interval:
a) Stop engine and remove spark plug wire(s). Check air
pressure in tires; recommended tire pressure is: rear, 12
to 16 psi; pneumatic casters, 22 psi.
b) Inflate tires to pressures stated above. Measure
circumference of each drive tire. Adjust tire pressures
within the above range to try to make tire circumferences
match as closely as possible.
NOTE: Front caster tires have permanent tire sealant installed
5.1.11 Inspect Belt wear.
40 hrs.
.
Service Interval:
a) Stop engine and remove spark plug wire(s).
b) Remove deck support belt shield to check mower deck drive
belt condition.
c) Look under engine deck to check the transmission drive
and clutching belt condition.
d) Inspect wheel drive belt conditions
e) Check all idler arms to be sure they pivot freely.
Disassemble, clean and grease pivot bushings if necessary.
5.1.12 Inspect Blade Clutching Belt Tension.
Service Interval:
operation then check every 40 hrs. thereafter.
a)
Stop engine.
b) Engage blade drive lever.
c) Look through the round hole in the left rear corner of the
engine deck to inspect blade clutching belt tension. Bolt
on blade engagement linkage bellcrank and indicator arm
should align within 1/16” (See fig. 15). Refer to section
5.2.2 for adjustment.
5.1.13 Lubrication
Service Interval:
a) Stop engine and remove spark plug wire(s).
40 hrs.
Check every 2 hrs. for first 8 hrs.
Refer to Chart.
b) Lubricate fittings with one to two pumps of SAE No. 2
multi-purpose gun grease.
Refer to the following chart for fitting locations and
lubrication schedule.
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GREASE LUBRICATION CHART
FITTING
LOCATIONS
1. Caster Wheel Bearings 12 2 2 2 Daily
2. Caster Pivots 2 2 2 3 Daily
3. Blade Engagement Bellcrank 1 1 1 1 Weekly
4. Drive Wheel Idler Arm 2 2 2 2 Weekly
5. Clutch Arm Pivot 1 1 1 1 Weekly
6. Cutter Deck Idler Pivots 2 1 1 1 Weekly
7. Trans. Output Shaft Coupler 2 2 2 2 Weekly
8. Cutter Spindles
(S/N’s 150,000 to 159,999)
†
Under severe cutting conditions, two pumps of
INITIAL
PUMPS
10 2 3 3 † Weekly
QUANTITY
36”
48” 52”
SERVICE
INTERVAL
grease twice weekly may be more beneficial.
No. 5 (Clutch Arm Pivot)
Located Under Engine Deck
No. 7 (Trans. Coupler)
Located Below Fuel Tank Support
No. 4 & 7 (Idler Arm Pivots)
Disassemble and grease once a
Month under a “No Load” condition
c) Lubricate pivot points with a spray penetrating
lubricant as directed below.
SPRAY LUBRICANT CHART
PIVOT POINT
1. Blade Engagement Lever 1 Weekly
d) Lubricate drive wheel hubs once a year. First remove
wheel, then remove hub cap. Lubricate the grease fitting
on each wheel hub with an SAE No. 2 multipurpose gun
grease, until grease appears through outer bearing.
Reinstall hub caps and wheels.
e) Replace 5-speed gearbox grease yearly. Use 18 oz. Of
Peerless grease (Part No. 788067). See Section 5.1.9.
NO. OF
PLACES
SERVICE
INTERVAL
5.1.14 Check spark plugs.
Service Interval:
a) Remove spark plugs, check condition and adjust plug gap
or replace with new plugs. See Engine Owner's Manual.
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160 hrs.
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5.1.15 Remove engine shrouds and clean cooling fins.
Service Interval:
a) Stop engine and remove spark plug wire(s).
b) Remove cooling shrouds from engine and clean cooling
fins. Also clean dust, dirt and oil from external
surfaces of engine which can cause improper cooling.
c) Make sure cooling shrouds are properly reinstalled.
Operating the engine without cooling shrouds will cause
engine damage due to overheating.
5.1.16 Change fuel filter.
Service Interval:
a) A fuel filter is installed in the fuel line between the
fuel tank and the engine. Replace when necessary.
5.1.17 Refer to Engine Operators Manual for detailed maintenance
regarding the engine.
5.1.18 Thread locking adhesives such as “Loctite 242” or
“Fel-Pro, Pro-Lock Nut-Type” are used on the following
fasteners:
a) Transmission drive sheave setscrew.
b) Wheel drive sheave setscrews on transmission output shafts.
c) OPC lever setscrews.
d) Sheave retaining bolt in end of engine crankshaft.
e) Lower Sheave retaining bolt on clutch arm.
Adhesives such as “Loctite RC/609 or RC/680” or
“Fel-Pro Pro-Lock Retaining I or Retaining II” are
used on the following:
See Engine Owner's Manual
As Required
a) OPC lever hubs and cross-shaft
NOTE: Care must be used
each OPC hub, to the cross shaft which could cause
binding of the OPC levers and erratic operation.
5.1.19 An anti-seize compound is used on the following locations:
a) Between engine crankshaft and transmission and blade
drive sheaves.
b) On clutch arm assembly between bearings and shaft and
between lower sheave and shaft.
c) Between transmission shaft and sheaves.
5.1.20 Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
5.2 ADJUSTMENTS
Disengage blade clutch, shut off engine
••••
and remove spark plug wire(s) before
servicing, cleaning or making adjustments.
to bond the bearing, next to
not
CAUTION
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5.2.1 Cutting height and anti-scalp roller adjustment.
CAUTION
Front end of support frame may rise up
••••
suddenly if not held down securely when
the front two deck support rod hairpins
are removed.
a) Install hairpin clips in the holes shown on sketch below
for the desired cutting height (See Figure 14).
FIG 14
ANTI-SCALP ROLLER BOLT INSTALLATION
ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT
b) Adjust anti-scalp rollers for Normal Operating Conditions.
Stop engine. Place rollers in one of the positions shown
in Fig 14. Rollers will maintain 3/4 in. (19 mm) clearance
to the ground to minimize gouging and roller wear or damage.
For Maximum Deck Flotation
lower. Rollers should maintain 1/4 in. (6.4 mm) minimum
clearance to ground.
deck. Be sure roller bolts and nuts are installed with the
spring disc washer between head of bolt and mounting bracket.
Torque to 40-45 ft-lbs., or loss of roller may result
c) When operating in extremely rough conditions it may be
necessary to position the anti-scalp rollers one or two
holes higher than described in "b" to prevent damage to
the rollers and/or bolt failure(See Figure 14).
NOTE:
positions, reduced deck flotation will result.
5.2.2 Blade engagement Linkage: Located between the blade
engagement lever on the left handle and the left rear
corner of the engine deck.
a) Stop engine and remove spark plug wire(s).
b) With blade drive engaged, adjust the linkage length by
loosening the locknut on the turnbuckle and adjusting
the turnbuckle so that the bolt on the bellcrank and the
indicator arm align with each other within 1/16”. See
Figure 15. Tighten locknut against turnbuckle.
When anti-scalp rollers are placed in these
Do Not
, place rollers one hole position
adjust rollers to support the
.
FIG. 15
BLADE ENGAGEMENT LINKAGE
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5.2.3 Blade Safety Switch:
a) Stop engine and remove spark plug wire(s).
b) With blades disengaged and the bellcrank touching the
rear of the slot in the engine deck, adjust the blade
safety switch (if needed) until the bellcrank arm is
5/16” from the switch body.
c) Be sure the bellcrank
damage to the switch could occur.
d) Retighten blade switch mounting hardware.
5.2.4 Engine to Cutter Deck Belt:
No adjustment necessary
5.2.5 Transmission Belt Adjustment:
a) Stop engine and remove spark plug wire(s).
b) To tighten transmission belt, loosen the 3/8” nyloc nut
on transmission belt idler pulley. Slide bolt inward in
slot and retighten nyloc nut.
c) When properly adjusted, the belt should have 1/2” of
deflection with three pounds of pressure on the belt
midway between the transmission and engine pulley.
5.2.6 Wheel drive belts and scrapers:
a) If wheel traction appears to be slipping, drive lever rods
may be touching bottom of neutral lock/park brake latch
slot. To adjust, refer to directions in Section 3.11
NOTE: Wheel drive springs have three tension settings.
Refer to Section 5.2.11.
b) Be sure mud and grass scraper, on each side, is adjusted
properly and centered in the pulley grooves. The pointed
part of the scraper should be centered and as deep in the
pulley groove as possible without rubbing at any point.
5.2.7 Brake Adjustment:
See 3.11
5.2.8 Wheel drive linkage adjustment:
See 3.11
5.2.9 Shifter lever adjustment:
See 3.10
5.2.10 Shifter detent adjustment:
Transmission shifter detent can be adjusted by adjusting the
setscrew on the backside of transmission located just behind
the neutral start switch. Turn setscrew in (clockwise) to
hold the transmission shifter more positively in each gear
and to increase the force on the lever required to shift
gears.
Turn setscrew out (counterclockwise) to decrease force on
lever required to shift gears. Factory setting is to turn
setscrew all the way in then back out 1-1/2 turns.
IMPORTANT: Screwing setscrew in too far will prevent the
transmission from shifting
5.2.11 Wheel drive spring tension adjustment:
It may be necessary to increase wheel drive belt tension
under certain conditions such as, wet grass, hilly terrain,
or while pulling a sulky.
a) Stop engine and remove spark plug wire(s).
DOES NOT
.
.
touch the switch body or
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b) Disengage neutral lock/park brake latches and release
drive levers to lower spring force.
c) Remove the 5/16-18 whizlock nut securing the adjustment
bolt to the drive wheel shield. Locate bolt assembly in
the desired position as follows
Position A - Normal Conditions
Position B - More Severe
Position C - Most Severe
NOTE: Lever force is lowest with bolt assembly in Position A
and will increase in Positions B and C (See Figure 16).
DRIVE BELT TENSION
ADJUSTMENT POSITIONS
5.2.12 Adjust Throttle Lever Tension (B&S Engines only):
a) Stop engine and remove spark plug.
b) Tension in throttle levers can be increased or decreased
by adjusting the tightness of the lever pivot bolt which
is located under the console.
6. TROUBLE SHOOTING
6.1 MOWER PULLING LEFT OR RIGHT.
a) Check idler arm pulleys and drive sheaves for mud and/or
grass buildup. Check for proper scraper position. See
5.2.6.
b) Check to be sure idler arms pivot freely, if not
lubricate idler pivots.
c) Check for worn drive belts.
NOTE: Wheel drive belts should be replaced as a set. A new
belt should not be mixed with a worn belt.
d) Check drive linkage adjustment - See 3.11
FIG. 16
e) Check for proper tire pressure in drive tires.
Recommended tire pressure for the drive tires is 12 to 16
psi. Higher pressures may be used in the tire on the side
that it pulls to (up to 28 psi).
Note
:
Different pressures may make mower cut unevenly.
6.2 MOWER CUTS UNEVENLY.
a) Check the drive tire pressure and tire circumference.
See 5.1.10.
A more uniform cutting height may be obtained with higher
tire pressure on rough terrain. A lower tire pressure
provides more flotation.
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b) Check deck support pins. Hairpin clips must be in the
same hole position on each support pin.
c) Check deck support alignment and check mounting brackets
to be sure all bolts are tight.
d) Check blades tip to tip for straightness. (They should
be within 3/16”, or one blade width from being in line.)
6.3 ENGINE WILL NOT START.
a) Check that choke is in the “ON” position for a cold
engine or in the “OFF” position for a warm engine. See
4.3.2.
NOTE: Kawasaki engines may need to be choked even when warm.
b) Make sure the key switch is in the “ON” position
(B&S and 17 HP Kawasaki engines only).
c) Make sure transmission is in “true neutral” position.
(See section 3.10c).
d) Check that the blades are disengaged and the blade switch
is depressed.
e) Check that there is fuel in the tank and that the fuel
valve is open.
f) Check that the spark plug wire(s) are properly connected.
g) Check for loose or faulty wiring connections. If it is
necessary to disconnect wire connectors,
the wires while disconnecting.
h) Check for corrosion at all wiring connections.
Even minor corrosion may cause a faulty connection.
Clean connector terminals thoroughly with electrical
contact cleaner, apply dielectric grease and reconnect.
It is essential that all operator safety
••••
mechanisms be connected and in proper
operating condition prior to mower use.
NOTE: After carefully checking the above steps, attempt
to start the engine. If it does not start, contact your
authorized Exmark service dealer.
ENGINE TROUBLESHOOTING
CAUTION
Do Not
pull on
CAUTION
When checking starting problems, be
••••
sure to keep body, hands and clothes
away from areas where moving parts
can suddenly engage.
CAUTION
When performing maintenance, servicing
••••
or repairing the unit, allow the engine
ample time to cool down. Serious burns
can result from hot metal.
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When a problem occurs, do not overlook the simple
causes. For example, starting problems could be caused
by an empty fuel tank.
The following table lists some of the common causes of
trouble.
Do not attempt to service or replace major items or
any items that call for special timing or adjustment
procedures (such as valves, governor, etc.). Have this
work done by your
ENGINE TROUBLESHOOTING TABLE
Engine Service Dealer.
PROBLEM
Will not start
Hard starting
Stops suddenly
Lacks power
Operates
erratically
Knocks or pings
Skips or misfires
Backfires
Overheats
High fuel
consumption
NO
FUEL
IMPROPER
FUEL
DIRT IN
FUEL LINE
DIRTY AIR
FILTER
FAULTY
SPARK
PLUG
ENGINE
OVERLOADED
BLOCKED
FUEL
FILTER
INCORRECT
OIL
LEVEL
DIRTY
AIR
SCREEN
X X XXXX
XXX XXXX
XXX XXXX
XX XXXXXX
XX XXXX X
XXX
X
X
X
X
XX X
XX X X
XXXX
XX X X
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7. WIRING DIAGRAM
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8. WARRANTY
Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg. Co. Inc.
("Exmark") warrants on the terms and conditions herein, that it will
repair, replace or adjust any part manufactured by Exmark and found by
Exmark(in the exercise of its reasonable discretion)to be defective in
factory material or workmanship.
This warranty is limited to one year from the date of original retail
purchase (90 days for rental use) for any Exmark mower that is used for
commercial or any other income producing purpose. The Blade Spindle
assemblies will be warranted for three years, one year parts and labor
with an additional two years parts only, from date of original retail
purchase against defects in materials or workmanship. The hydrostatic
traction drive system, excluding hoses, will be warranted for two full
years from date of original retail purchase against defects in materials
or workmanship. Exmark Mfg. will extend the Peerless 5-speed
transmission manufacturer's warranty from 90 days to one year. Belts and
tires are warranted for 90 days against defects in materials or
workmanship.
The engine warranty is covered by its respective engine manufacturer.
Please refer to the engine manufacturers warranty statement that is
included in the literature packet. Exmark is not authorized to handle
warranty adjustments on engines. Engine warranties should be referred to
the nearest authorized service outlet of the engine manufacturer.
This warranty extends only to the original retail purchaser of the
equipment. The warranty may not be assigned or transferred without the
prior express written consent of Exmark. The warranty commences upon the
date of the original retail purchase.
The Exmark turf equipment, including any defective part, must be returned
to an authorized Exmark service dealer within the warranty period. The
warranty shall extend to cost to repair or replace(as determined by
Exmark) the defective part, including labor. The expense of delivering
the mower to the dealer for warranty work and the expense of returning it
back to the owner after repair or replacement will be paid for by the
owner. Exmark's responsibility in respect to claims is limited to making
the required repairs or replacements, and no claim of breach of warranty
shall be cause for cancellation or rescission of the contract of sale of
any Exmark mower. Proof of purchase may be required by the dealer to
substantiate any warranty claim. All warranty work must be performed by
an authorized Exmark service dealer.
This warranty extends only to turf equipment operated under normal
conditions and properly serviced and maintained. The warranty expressly
does not cover: (i) any defects, damage or deterioration due to normal use,
wear and tear, or exposure; (ii) normal maintenance services, such as oil
change, cleaning, lubrication, adjustment; (iii) replacement of service
items, such as oil, lubricants, spark plugs, belts, rubber hoses or other
items subject to normal service replacement; (iv) damage or defects
arising out of or relating to misuse, neglect, alteration, negligence or
accident; (v) repair or replacement arising from operation of or use of
the turf equipment which is not in accordance with operating instructions
as specified in the operator's manual or other operational instructions
provided by Exmark; (vi) repair or replacement arising as a result of
any operation from turf equipment that has been altered or modified so as
to, in the determination of Exmark, adversely affect the operation,
performance or durability of the equipment or that has altered, modified or
affected the turf equipment so as to change the intended use of the
product; (vii) repair or replacement necessitated by use of parts,
accessories or supplies, including gasoline, oil or lubricants,
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incompatible with the turf equipment or other than as recommended in the
operator's manual or other operational instructions provided by Exmark;
(viii) repairs or replacements resulting from parts or accessories which
have adversely affected the operation, performance or durability of the
turf equipment; or (ix) damage or defects due to or arising out of repair
of turf equipment by person or persons other than an authorized Exmark
service dealer or the installation of parts other than genuine Exmark or
Exmark recommended parts.
As a condition to this warranty, customer shall have read the operator's
manual and shall have returned to Exmark, within the prescribed time, the
enclosed warranty registration card.
The sole liability of Exmark with respect to this warranty shall be
repair and replacement as set forth herein. Exmark shall have no
liability for any other cost, loss or damage, including but not limited
to, any incidental or consequential loss or damage. In particular,
Exmark shall have no liability or responsibility for: (i) expenses
relating to gasoline, oil or lubricants; (ii) loss, cost or expense
relating to transportation or delivery of turf equipment from the
location of owner or location where used by owner to or from any
authorized Exmark service dealer; (iii) travel time, overtime, after
hours time or other extraordinary repair charges or charge relating to
repairs or replacements outside of normal business hours at the place of
business of the authorized Exmark service dealer; (iv) rental of like or
similar replacement equipment during the period of any warranty, repair
or replacement work; (v) any telephone or telegram charges or travel
charges; (vi) loss or damage to person or property other than that
covered by the terms of this warranty; (vii) any claims for lost
revenue, lost profit or additional cost as a result of a claim of breach
of warranty; or (viii) attorney's fees.
There are no representations or warranties which have been authorized and
provided to the buyer of the turf equipment, other than as set forth in
this warranty. Any and all statements or representations made by any
seller of this equipment, including those set forth in any sales
literature or made orally by any sales representative, are superseded by
the terms of this warranty. Any affirmation of fact or promise made by
Exmark or any of its representatives to the buyer which relates to the
goods that are the subject of this warranty shall not be regarded as
part of the basis of the bargain and shall not be deemed to create any
express warranty that such goods shall conform to the affirmation or
promise.
`
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES,
EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED TO ANY REGARDING THE
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), NOT SPECIFIED
HEREIN, RESPECTING THE EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY.
This warranty applies to all Exmark turf equipment sold in the United
States and Canada and intended to be used for commercial purposes.
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ALIGN THIS EDGE WITH A VERTICAL SURFACE
(TREE, BUILDING, FENCE POST, POLE ETC.)
T
H
I
S
I
S
A
5
°
S
L
O
P
E
T
H
I
S
I
S
A
1
0
°
S
L
O
P
E
T
H
I
S
I
S
A
1
5
°
S
L
O
P
E
P
E
T
H
I
S
I
S
A
2
0
°
S
L
O
EXAMPLE: COMPARE
SLOPE WITH FOLDED
EDGE.
FOLD ALONG APPROPRIATE LINE
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SEE EXMARK’S COMPLETE
LINE OF PRODUCTS FOR TURF CARE
LAZER Z
™
LAZER Z™ HP
EXPLORER
TURF RANGER
TURF TRACER
®
®
®
TURF TRACER® HP
VIKING HYDRO
METRO
™
METRO™ HP
SELF STEERING SULKY
GRASS CATCHER
™
MICRO-MULCH
©1997,1998 EXMARK MFG. CO. INC. PART NO. 850614
INDUSTRIAL PARK BOX 808 (402) 223-6300
BEATRICE, NE 68310 FAX (402) 223-5489
ACCESSORY
ALL RIGHTS RESERVED PRINTED IN U.S.A.
www.mymowerparts.com
MFG. CO. INC.
®
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