Exmark Metro Series Operator's Manual

For Serial Nos.

510,000 & Higher

Part No. 103-8850

WARNING

POTENTIAL HAZARD
♦ This product is a piece of power equipment.
WHAT CAN HAPPEN
♦ Failure to follow safe operating pr actices can result in serious

operator injury or even death.
HOW TO AVOID THE HAZARD
♦ Keep all shields, guards, and safety devices (especially the grass

discharge system) in place and in proper working condition.
♦ Stop engine and wait for all moving parts to stop. Remove spark

plug wire(s) or remove key before adjust ing, servicing, or

performing maint enance.
♦ If mower deck becomes clogg ed, stop engine and wait for all

moving parts to stop. Remove spark plug wire(s) or r em ove k ey

before cleaning blockage.

♦ Keep hands, feet, and clothing away from power driven parts .
♦ Keep off mower unless seat platf orm is provided.
♦ Keep others off mower.

WARNING

POTENTIAL HAZARD
♦ Gasoline is harmful or f at al if swallowed. Long-term exposure to

vapors has caused cancer in laboratory animals.
WHAT CAN HAPPEN
♦ Failure to use caution may cause serious injury or illness.
HOW TO AVOID THE HAZARD

♦ Avoid prolonged breathing of vapors.
♦ Keep face away from nozzle and gas tank/container opening .
♦ Keep away from eyes and skin.
♦ Never siphon by mouth.

When the mower is used or oper ated on any California forest, brush or grass covered land, a working
spark arrester must be at t ached t o t he muffler. If not, the operator is violating state law, Section 4442
Public Resource Code. To acquire a spark arrester for your unit, see your Eng ine Ser vice Dealer.

This spark ignition system complies with Canadian ICES-002
Ce système d’allumage par ètincelle de vèhicule est conform e à la norme NMB-002 du Canada

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and the California Emission Control Regul ation of
emission systems, maintenance and warranty.

Keep this engine Owner’s M anual with your unit. Should this engine Owner’s Manual become
damaged or illegible, replace immediately. Replacements may be ordered through the engine
manufacturer.

Exmark reserves the right to make changes or add improvements to its products at any time without
incurring any obligation to make such changes to products manufactured previously. Exmark, or its
distributors and dealers, accept no responsibility f or variations which may be evident in the actual
specifications of its product s and t he statements and descriptions contained in this publication.

IMPORTANT

i

EXMARK PARTS PLUS® PROGRAM

EFFECTIVE DATE: September 1, 1995
Program

If your Exmark dealer does not have the Exmark part in stock,
Exmark will get the parts to the dealer the next business day or
the part will be FREE* Guaranteed!!

How the Program Works

1. If dealer does not have part in stock for a "down" unit at

2. Distributor ships part(s) to dealer or customer, as

3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus

4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by

5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus® and if it arrives in

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:

2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus® order

3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,

4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark

the time of request by customer, the dealer contacts his
distributor by 1:00 p.m., local time, and requests Exmark
Parts Plus

®

shipment of six (6) line items or less.

requested by dealer, same day, overnight UPS
Distributor bills dealer for part and freight charges where
applicable.

®

order, he contacts Exmark by 3:00 p.m.,

central time, with an Exmark Parts Plus

®

order of six (6) line items or less.

distributor, same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.

accordance to the program.

®

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.

to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.

Exmark pays for the part and freight.

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. Parts Plus service is available
only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental
United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air
charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no
responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus® orders must be received by Exmark by
3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus

®

Program are:
Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and
5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United
Parcel Service size and weight restrictions.

Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day
or Second Day Air.

Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be
ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.

ii

CONGRATULATIONS on the purchase of your Exmark Mower. This product has been
carefully designed and manufactur ed to give you a maximum amount of dependability and
years of trouble-free oper at ion.

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, maint enance, 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 dist r ibut or .

All Exmark equipment dealers and distr ibut or s are kept informed of the latest methods
of servicing and are equipped to provide prompt and efficient service in the f ield or at their
service stations. They carry ample stock of ser vice parts or can secur e t hem pr omptly for you
from the factor y.

All Exmark parts are thoroughly tested and inspected before leaving the f actory,
however, attention is required on your part if you are t o obt ain the fullest measure of
satisfaction and performance.

iii

TABLE OF CONTENTS

1. SAFETY PAGE

1.1 Safety Alert Symbol................................................................................1

1.2 Training..................................................................................................1

1.3 Preparation........................................................................................ 1-3

1.4 Operation........................................................................................... 3-6

1.5 Maintenance & Storage..........................................................................6

1.6 Riding Attachments................................................................................6

1.7 Safety Signs....................................................................................... 6-9

2. SPECIFICATIONS

2.1 Model Numbers......................................................................................9

2.2 Engine....................................................................................................9

2.3 Fuel System........................................................................................... 9

2.4 Safety Interlock System.........................................................................9

2.5 Steering/Brake Control...........................................................................9

2.6 Transmission........................................................................................10

2.7 Wheel Drive System ............................................................................10

2.8 Tires.....................................................................................................10

2.9 Deck ....................................................................................................10

2.10 Dimensions....................................................................................10-11

2.11 Bolt Torque Requirements..................................................................11

3. ASSEMBLY INSTRUCTIONS

3.1 to 3.19 Assembly .............................................................................11-17

7. OPERATION INSTRUCTIONS

4.1 Controls..........................................................................................17-19

4.2 Pre-Start..............................................................................................19

4.3 Operating Instructions.....................................................................19-22

4.4 Transporting.........................................................................................23

5. MAINTENANCE & ADJUSTMENTS

5.1 Periodic Maintenance......................................................................23-28

5.2 Adjustments....................................................................................28-33

6. WASTE DISPOSAL

6.1 Motor Oil Disposal...............................................................................33

7. TROUBLE SHOOTING

7.1 Mower Tracks Left or Right..................................................................33

7.2 Mower Cuts Unevenly.....................................................................33-34

7.3 Blades Do Not Stop When Disengaged ...............................................34

7.4 Engine Will Not Start............................................................................34

8. BELT ROUTING (MOWER DECKS)

9. WIRING DIAGRAMS

10. WARRANTY

............................................................................................37

..............................................................................36

....................................................35

iv

1. SAFETY

1.1 SAFETY ALERT SYMBOL

This SAFETY ALERT SYMBOL
identify important safet y messages which must be followed to avoid accidents. This
symbol means:

The safety alert symbol appears above information which alerts you to unsafe actions or

situations and will be followed by the word DANGER, WARNING, or CAUTION.

DANGER: White lett er ing/Red background. Indicates an im m inent ly hazardous situation

which, if not avoided, WILL result in death or serious injur y.

WARNING: Black lettering/Orange background. Indicates a potentially hazardous

situation which, if not avoided, COULD result in deat h or ser ious inj ury.

CAUTION: Black lettering/Yellow background. Indicates a potentially hazardous situation

which, if not avoided, MAY result in minor or moderate injury.

is used both in this manual and on the machine to

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

1.2 TRAINING

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. Familiar ize yourself with the cont r ols and the
proper use of the equipment. If the operator(s) or m echanic(s) can not read
English it is the owner’s responsibility to explain this material t o t hem.

1.2.3 Do not allow operation of this machine by untrained personnel. Never allow

children, teenagers, or people unfamiliar with these instructions to use the mower.
Local regulations may restrict the age of the operator.

1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in mind

that the operator or user is responsible for accidents or hazards occurring to other
people or their property.

1.3 PREPARATION

1.3.1 Evaluate the terrain to determine what accessories and attachment s ar e needed

to properly and safely perform the job. Only use accessories and attachments
approved by Exmark.

1.3.2 The use of per sonal pr ot ective equipment, such as (but not limited to) pr ot ection

1.3.3 While mowing, always wear substantial footwear and long trousers. Do not

for the eyes, ears, feet , and head is r ecom m ended.

CAUTION

POTENTIAL HAZARD
♦ This machine produces sound levels in excess of 85

dBA at the operator’s ear when in operation.
WHAT CAN HAPPEN
♦ Exposure to sound levels of 85 dBA or above for

extended periods of time can cause hearing loss.
HOW TO AVOID THE HAZARD
♦ Wear hearing protection when operating this machine.

operate equipment when barefoot or when wearing open sandals.

- 1 -

1.3.4 Thoroughly inspect the area where the equipment is t o be used and r em o ve all
stones, sticks, wires, bones, and other foreign objects which may damage the
equipment or cause personal injury to the operat or or bystander s.

POTENTIAL HAZARD
♦ Engine exhaust contains carbon monoxide, which is

an odorless deadly poison.
WHAT CAN HAPPEN
♦ Carbon monoxide can kill you.
HOW TO AVOID THE HAZARD
♦ Do not run engine indoors or in a small confined area

where dangerous carbon monoxide fumes can collect.

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable

and highly explosive.
WHAT CAN HAPPEN
♦ A fire or explosion from gasoline can bur n you, ot her s,

and cause property damage.
HOW TO AVOID THE HAZARD
♦ DO NOT smoke while refueling , and st ay away from

an open flame or where gasoline fumes may be

ignited by spark.

♦ Refuel only outdoors.
♦ Store gasoline in an approved container and keep it

out of the reach of children.
♦ Add fuel before starting the engine. Never remove the

cap of the fuel tank or add fuel when engine is running

or when the engine is hot.
♦ Never fill the fuel tank so t hat the gasoline level rises

above a level that is 1/2” (1.3 cm) below the bottom of

the filler neck to allow for gasoline expansion and

prevent fuel spillage.
♦ If fuel is spilled, DO NOT attempt to start the engine.

Move away from the area of the spill and avoid

creating any source of ignition unt il fuel vapors have

dissipated.
♦ Do not operate without entire exhaust system in place

and in proper working condition.

WARNING

DANGER

- 2 -

POTENTIAL HAZARD
♦ In certain conditions gasoline is extremely flammable

and highly explosive.
WHAT CAN HAPPEN
♦ A static charge can ignite g asoline vapors. A fire or

explosion from gasoline can burn you, others, and

cause property damage.
HOW TO AVOID THE HAZARD
♦ Purchase and store gasoline only in an approved

container.
♦ Always place gasoline containers on the ground away

from your vehicle before f illing.
♦ Do not fill gasoline containers inside a vehicle or on a

truck or trailer bed because interior car pet s or plastic

truck bed liners may insulate the container and slow

the loss of any static charge.
♦ When practical, r emove gas-powered equipment from

the truck or trailer and r efuel the equipment with its

wheels on the ground.
♦ If this is not possible, then refuel such equipment on a

truck or trailer from a portable container, rather than

from a gasoline dispenser nozzle.
♦ If a gasoline dispenser nozzle must be used, keep the

nozzle in contact with the rim of the fuel tank or

container opening at all times until fueling is complete.

DANGER

POTENTIAL HAZARD
♦ Gasoline vapor can collect inside enclosed trailers and

may be ignited by electrical sparks or hot

engine/exhaust components.
WHAT CAN HAPPEN
♦ Explosion and fire may occur, resulting in proper t y

damage, personal injury and/or death.
HOW TO AVOID THE HAZARD
♦ Provide adequate ventilation of any enclosed trailer to

prevent build up of gasoline vapors, especially at floor

level.

♦ Refuel only outdoors, never inside an enclosed trailer.
♦ Be sure all fuel tanks and gasoline st or age containers

have proper caps installed to prevent spillage and

minimize vapor escaping into the trailer.
♦ Do not place any equipment that is leaking gasoline in

an enclosed trailer.

WARNING

1.4 OPERATION

Although hazard control and accident prevention are partially dependent upon the
design and configuration of the equipment, t hese factors are also dependent upon
the awareness, concern, prudence, and proper training of t he personnel i nvol ved in
the operation, transport, maintenance, and st orage of t he equi pment . It is essential
that all Operator Safety Mechanisms be connect ed and i n operat i ng condi t ion prior
to use for mowing.

- 3 -

WARNING

POTENTIAL HAZARD
♦ Operating engine parts, especially the m uffler, become

extremely hot.

WHAT CAN HAPPEN

♦ Severe burns can occur on contact.
♦ Debris, such as leaves, grass, brush, etc. can catc h fire.

HOW TO AVOID THE HAZARD
♦ Allow engine parts, especially the muff ler, to cool before

touching.

♦ Remove accumulated debris from muffler and engine area.
♦ Install and maintain in working order a spar k arrester before

using equipment on forest - covered, grass-covered, brush­covered unimproved land.

WARNING

POTENTIAL HAZARD
♦ Hands, feet, hair, clothing, or accessories can become

entangled in rotating part s.
WHAT CAN HAPPEN
♦ Contact with rotating parts can cause traum at ic am put ation

or severe lacerations.
HOW TO AVOID THE HAZARD
♦ Do not operate the machine without guards , shields and

safety devices in place and working.
♦ Keep hands, feet, hair, jewelry, or clot hing away from

rotating parts.

1.4.1 Give complete, undivided attention t o t he job at hand.

1.4.2 Mow only in daylight or in good artificial light, keeping away from holes or hidden
hazards. DO NOT operate the mower when children or others are in t he ar ea.

1.4.3 When f easible, avoid operating the equipment in wet grass.

1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr action
and/or tip-over could occur. The operator is r esponsible for safe operation on slopes.

DANGER

POTENTIAL HAZARD
♦ Mowing on wet grass or steep slopes can cause sliding and

loss of control.

WHAT CAN HAPPEN
♦ Loss of control and/or loss of operator’s footing could result

in a fall with an arm or leg getting under the mower or
engine deck, which may result in serious injury or death.

HOW TO AVOID THE HAZARD

♦ Mow across slopes, never up and down.
♦ Do not mow slopes when grass is wet.
♦ Do not mow near drop-offs or near water.
♦ Do not mow slopes greater than 20 degrees.
♦ Reduce speed and use extreme caution on slopes.
♦ Avoid sudden turns or rapid speed changes.

- 4 -

• See inside the back cover to determine the approximate slope angle of the area
to be mowed.

• Progressively greater care is needed as the slope increases.

• Always avoid sudden starting or stopping on a slope. If tires lose traction,

disengage the blades and proceed slowly off the slope.

• Be aware that loss of traction may occur going downhill. Weight transfer to
the front wheels may cause drive wheels to slip and cause loss of braking and
steering.

• Watch for ditches, holes, rocks, dips, and r ises t hat change the operating
angle, as rough terrain could overtur n the machine.

• Remove or mark obstacles such as rocks, t r ee lim bs, et c. from the mowing
area. Tall grass can hide obstacles.

• Use extreme care with grass catchers or attachments. These can change the
stability of the machine and cause loss of contr ol.

1.4.5 Use EXTREME caution when backing up. LOOK BEHIND YO U!!

1.4.6 Stop the blades when crossing surfaces other than grass, if mower must be tilted
for transportation, and when transporting the mower to and from the area t o be
mowed.

1.4.7 Never operate the mower with damaged g uards, shields, or covers. Always have
safety shields, guards, switches, and other devices in place and in proper work ing
condition.

1.4.8 Do Not change the engine governor sett ing s or overspeed t he engine. Operating
an engine at excessive speed may increase the hazard of personal injury.

1.4.9 Place transmission in neutr al, disengage PTO, and latch dr ive levers in “par k
brake” position before st ar t ing engine.

1.4.10 Start the engine carefully with feet well away from the blades.

1.4.11 Keep hands, feet, and clothing away from rotat ing parts while the mower is being
operated.

1.4.12 Stop the engine, wait for all m o ving par t s t o stop, and remove the spark plug
wire(s) and/or remove key:

a) Before checking, cleaning, or working on the mower.
b) After striking a foreign object (inspect the m ower for damage and make

repairs before restart ing and operating the mower).
c) Before clearing blockages.
d) Whenever you leave the mower.

1.4.13 Stop the engine and wait for all m oving parts to stop:
a) Before removing the grass catcher.
b) Before refueling.
c) Before making height adjustments.

1.4.14 Before stopping the engine, place the th r ot t le cont r o l midway between the “slow”

and “fast” positions. Allow the engine to r un a m inim um of 15 seconds; then stop
the engine.

1.4.15 The fuel system is provided with a shut-of f valve. The fuel shut-off valve is used

to shut off the fuel when:
a) The machine will not be used for a few days
b) During transport to and from the job
c) When parking inside a building

- 5 -

1.4.16 This mower was designed for one operator only. Keep all others away from

mower during operation.

1.4.17 Do Not mow with the discharge deflector raised, rem oved or alt er ed unless there

is a grass collection system or mulch kit in place and working properly.

1.4.18 Be aware of the mower discharge and direct dischar ge away from others.

1.4.19 Do Not operate mower under the influence of alcohol or dr ugs.

1.4.20 Use care when approaching blind corners, shrubs, tr ees, or other objects that

may obscure vision.

1.5 MAINTENANCE AND STORAGE

1.5.1 For engine maint enance, follow the engine manufacturer' s r ecom m endations

precisely as stated in the engine manual.

1.5.2 Keep engine and engine area free from accumulation of grass, leaves, excessive

grease or oil, and other debris which can accumulate in these areas. These

materials can become combustible and may result in a fir e.

1.5.3 Store f uel in a container specifically designed for this pur pose. Store the fuel

container in a cool, dry place.

1.5.4 Keep the mower and fuel cont ainer in locked storage to prevent children f r om

playing or tampering with them.

1.5.5 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.

1.5.6 Maximum mowing results and safety can only be achieved if the mower is

properly maintained and operated correctly.

1.5.7 Check all bolts frequently to maintain proper t ightness.

1.5.8 Keep all guards, shields and all safety devices in place and in safe working

condition.

1.5.9 Frequently check for worn or damaged components that could creat e a hazard.

1.5.10 All replacement parts must be the same as or equivalent to the parts supplied as

original equipment.

1.6 RIDING ATTACHMENTS

Use only

Exmark riding attachments. The use of other than Exmark riding attachments

may create a hazardous condition resulting in injury.

1.7 SAFETY SIGNS

1.7.1 Keep all safety signs legible. Remove all grease, dirt and debris from safety signs

and instructional labels.

1.7.2 Safety signs must be replaced if they are missing or illegible.

1.7.3 When new components are installed, be sure that current safety signs are aff ixed

to the replaced components.

1.7.4 New safety signs may be obtained from your authorized Exmark equipment

dealer or distributor or fr om Exmar k Mfg. Co. Inc.

1.7.5 Safety signs can 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 f ollowing safety signs and instruction labels. They are

critical to the safe operation of your Exmark commercial mower.

- 6 -

PART NO. 103-5626
LOCATION: 48” Decks Under Belt Shield

PART NO. 1-303517
LOCATION: Left Side, Rear Surface Engine Deck

PART NO. 1-403005
LOCATION: Front Corners of Deck
32” & 36” – RH Front
48” – RH & LH Front

PART NO. 1-303518
LOCATION: Transmission Shifter Plate

PART NO. 1-323427

Kawasaki Units
PART NO. 103-1798
LOCATION: RH Side of
Console

ECS Handle Units
PART NO. 103-2244
LOCATION: LH Side of Console

LOCATION: 32” & 36” Decks Under Belt

Shield

PART NO. 1-513746
LOCATION: Engine Blower

Housing

Next to Muffler

ECS Handle Units
PART NO. 103-2245
LOCATION: RH Side of Console

PART NO. 1-303508
LOCATION: Right Rear Corner of Deck

PART NO. 98-5954
LOCATION: Under Mower Deck Belt Shield

- 7 -

Kohler ECS Handle Units
PART NO. 103-1641
LOCATION: Console

Kawasaki Pistol Grip Handle Units
PART NO. 103-1967
LOCATION: Console

Pistol Grip Handle Units
PART NO. 1-323550
LOCATION: Upper Handles

(Both Sides)

Kohler Units
PART NO. 1-323689
LOCATION: RH Side of

Console

- 8 -

Kawasaki ECS Handle Units
PART NO. 103-1623
LOCATION: Console

2. SPECIFICATIONS

PART NO. 1-403143
LOCATION: Right Rear of Engine Deck

2.1 MODEL NUMBER:

M3213KA; M3613KA; M4815KA; M3613KAC; M3615KCC; M4815KCC; M4815KAC

2.2 ENGINE

2.2.1 Engine Specifications: See your engine owner's manual.

2.2.2 RPM (No Load): 3600 rpm

2.3 FUEL SYSTEM

2.3.1 Capacity: 5 gal. (18.9 liter)

2.3.2 Type of Fuel: Use only clean, fresh, r e gular grade, unleaded gasoline with the

pump sticker octane rating of 87 or higher. In countries using t he r esear ch m ethod,
it should be 90 octane minimum.

2.3.3 Fuel Filter: Replaceable in-line

2.3.4 Fuel Shut Off Valve: in- line, 1/4 turn

2.4 SAFETY INTERLOCK SYSTEM

Operator must have the transmission in neutr al and PTO disengaged to start engine.

Release of Operator Presence Contr ol (OPC) levers will cause engine to stop if
transmission is not in neutral and/or PTO is engaged.

2.5 STEERING/BRAKE CONTROL

Fingertip drive control levers provide independent control of traction, braking, and neutral

to each drive wheel for moving, stopping, and power turning. Parking brakes ar e engaged
by locking drive control levers in the “brak e ” posit ion.

- 9 -

2.6 TRANSMISSION

2.6.1 Peerless 700-070A, five speeds forward and one reverse.

2.6.2 Speed rang e: 1st 2.0 mph ( 3.22 km/h) 4th 4.1 mph (6.60 km / h)
2nd 2.7 mph (4.35 k m / h) 5th 6.2 mph (9.98 km/h)
3rd 3.5 mph (5.63 km/h) Rev 3.1 mph (4.99 km/h)

2.7 WHEEL DRIVE SYSTEM

Banded double A-Section V-belts, single top-side idler s and r eplaceable bolt -on drive

sheaves and brake drums. (Single B-Section V-belts for the 32" Model)

2.8 TIRES

Pneumatic (Air-Filled) Semi-Pneumatic

Deck Size 32” 36” & 48” All Decks

Size 13 x 5.0-6 13 x 6.5-6 9 x 3.50-4

Quantity 2 2 2

Tread Turf Saver Turf Master Sm oot h

Ply Rating 4 4

Pressure 14 psi (97 kPa) 14 psi (97 kPa)
Bearings Replaceable Ball Replaceable Ball Replaceable Roller

Drive Front Caster

2.9 DECK

2.9.1 Cutting Width: Model 32.........31.75 in. (80.7 cm)

Model 36.........35.38 in. (89.9 cm)

Model 48.........47.25 in. (120.0 cm)

2.9.2 Discharg e : Right Side

2.9.3 Blade Size: Model 32.........16.25 (41.3 cm) - Qty. 2

Model 36.........18.00 (45.7 cm) - Qty. 2

Model 48.........16.25 (41.3 cm) - Qty. 3

2.9.4 Type of Drive: Manual engagement of belt with over-center lock. Blade belt tension

is adjustable via turnbuckle.

2.9.5 Blade Brak e: When the blade engagement control is moved to the disengaged

position a friction brake pad stops t he rotation of the blades.

2.9.6 Deck Mounting : Bolted directly to engine deck

2.9.7 Cutting Height: Adjusts in 1/4" (. 64 cm ) or smaller increments by various

adjustments of caster spacers, blade spacers and axle height, from 1” to 4 1/4”
(2.5 cm - 10.8 cm).

2.10 DIMENSIONS

2.10.1 Overall Width

Discharge chute down 43.3 in (110.0 cm) 47.0 in (119.4 cm) 57.9 in (147.1 cm)
Discharge chute up

(transport only)

32" 36" 48”

32.7 in (83.1 cm) 36.4 in (92.5 cm) 48.1 in (122.2 cm)

2.10.2 Overall Length

Standard Pistol Grip Handles 78.0 in (198.1 cm) 78.0 in (198.1 cm) 73.0 in (185.4 cm)
ECS Handles 77.3 in (196.3 cm) 77.3 in (196.3 cm) 72.3 in (183.6 cm)

2.10.3 Curb Weight∗

Standard Pistol Grip Handles 420 lbs (191 kg) 430 lbs (195 kg) 475 lbs (215 kg)
ECS Handles 435 lbs (197 kg) 446 lbs (202 kg) 490 lbs (222 kg)

∗ Weights will vary slightly depending on engine option.

32" 36" 48”

32" 36" 48”

- 10 -

2.10.4 Tread Width∗∗

Standard Pistol Grip &
ECS Handles

∗∗ To outside of tires.

2.10.5 Overall Height

Standard Pistol Grip Handles 40.0 in (101.6 cm)
ECS Handles 42.1 in (106.9 cm)

2.11 TORQUE REQUIREMENTS

32" 36" 48”

32.1 in (81.4 cm) 35.6 in (90.4 cm) 35.6 in (90.4 cm)

BOLT LOCATION TORQUE

Blade/Cutter Housing Spindle Bolt..................................75-80 ft-lbs. (102-109 N-m)

Caster Bracket Mounts....................................................30-35 ft-lbs. (41-48 N-m)

Mower Deck/Engine Deck Mount....................................30-35 f t -lbs. (41-48 N-m)

Engine Mounting Bolts

Kawasaki............................................................15-20 ft-lbs. (20-27 N-m)

Kohler ................................................................25-30 ft-lbs. (34-41 N-m)

Transmission Shifter Lever Nut.......................................30-35 ft-lbs. (41-48 N-m)

3. ASSEMBLY INSTRUCTIONS

3. 1 Uncrate unit, leaving it on the pallet, place upper handle assembly, fuel tank , and

shifter lever at the rear of the machine. Place casters at the f ront of the unit.

3. 2 Place a length of 4" x 4" (10 x10 cm) block between the front of the mower deck

and the pallet.

3. 3 Remove the bolt bag from under the mower deck belt shield.

3. 4 Refer to Parts Manual to help you identify and locate parts and their proper position.

3. 5 Install casters t o front of deck using appropriate hardware from the bolt bag ( eight

3/8” x 3/4" bolts and eight 3/8" whizlock nuts) ; tightening the lower four bolts first,
then the top four.

3. 6 Loosen the 5/16" hardware at t he t wo (2) dischar ge deflector hinge points so that

the deflector is snug, but can be moved up and down freely.

3. 7 Mount the fuel tank on the tank support.

Apply ret aining adhesive Fel-Pro Pro-Lock ‘Retaining T ype I or Retaining II’ or

Loctite RC 609 or 680 on the two threaded studs fr om t he bolt bag and install into
the two left holes underneath fuel t ank. 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 x 3/4
screws with a 5/16” flatwasher and 5/16” lockwasher into the threaded holes in the
right side of the f uel tank. Do not over tighten. Place a 5/16” flatwasher, then a
spring, and a 5/16 nyloc nut over each of the studs. Com plet ely tig hten nyloc nut
then back off a 1/ 2 t u r n. This will allow for normal fuel expansion and contraction
with changes in temperature and fuel levels. Do not over tighten.

3. 8 Install Handle Assembly
Position the lower end of the handle assembly on the outside of t he upper r ear

section of the fuel tank & handle support. Install one 3/8-16 x 1" bolt (from the
outside in) in the upper hole on each side of the handle.

Loosely secure each screw with a 3/8" nyloc nut. The handle can now be pivoted to

allow positioning in one of the three holes allowing various adjustments for operator
comfort (See Figures 1 & 2) . Once a proper position is found, install one 3/ 8 x 1"
bolt in the bottom mounting holes on each side of the handle. Secure each bolt with
a 3/8" nyloc nut. Tighten all hardware.

- 11 -

FIGURE 1

UPPER HANDLE MOUNTING
IMPORTANT: If the mower has been completely assembled and the handle

position is changed, it will be necessary to readjust the drive and brake linkage.

FIGURE 2

UPPER HANDLE HEIGHT ADJUSTMENT

3.9 Attach thrott le cable to engine.

For Kohler engines with "positive" detents in throttle cable for both idle and

full throttle positions.

a) Position the throttle control lever (on console) in the full throttle (but not chok e)

position. You will feel a detent when the throttle cont r ol lever is appr oximat ely
3/4" (2 cm) from t he upper end of the slot -- this is the full throttle position.

b) Route the throttle cable along the right side of the upper handle, under the fuel

tank support and to the lef t side of the engine.

c) Loosen clamp on engine control plat e. ( See Figure 3). Attach inner wire of the

throttle cable to the control plate lever and posit ion cable under clamp, do not
tighten clamp.

FIGURE 3

KO HLER SPEED CONTROL

( THROTTLE CABLE HOOK-UP)

- 12 -

d) Pull cable upward until alignment holes in control plate lever and control plate

line up. For Kohler units a 19/64” drill bit can be inser t ed through these two
holes to align them. Once holes are alig ned, tighten clamp onto thrott le cable.

e) Check that the choke adjusting screw just comes in contact with the choke lever

when throttle control is in the full t hr ottle position. Choke link should not mo ve
when throttle control is moved to the full throttle position. Be sure choke is fully
closed when throttle lever is moved fully forward to the " CHOKE" position.

For Kawasaki engines:
Route the throttle cable along the left side of the upper handle, thr ough the clip,

under the fuel tank support , and position the cable on the front of t he engine.
Attach throttle cable to engine:
f) Position the throttle control lever (located on console) ¼” (. 64 cm) from the upper

end of the slot.

g) Attach inner wire of the throttle cable to the top hole in the throttle control lever as

shown in Figure 4.

h) Loosen the clamp, place the cable behind it, and pull on the cable to move the

throttle linkage to t he full throttle position. T ig hten the cable clamp screw.

FIGURE 4

SPEED CONTROL

(THROTTLE CABLE HOOK-UP)

i) This step needs to be done after t he unit has been assembled and the engine

has been started. Refer to Section 4 (Operation Instructions).

For Kohler engines:
Check the engine "STOP" posit ion by moving t hr o t tle control fully to the rear.

(Note: There is a detent toward the lower end of t he slot in the console for
"IDLE", the "STOP" posit ion is r earward from this detent). If engine continues to
run in the "STOP" position, t urn kill switch adjusting screw inward until engine
stops, then give it an additional 1/2 to 3/4 t ur n to assure it will always function
properly.

For Kawasaki engines:

There is not a “STOP” posit ion. Turn the ignition switch to the “off” position to

stop the engine.

3.10 Attach the fuel tank hose to t he tank fitting and secure with the clamp pr ovided.

3.11 Install the blade engagement linkage to the bell crank on the Left Hand side of the

engine deck. Insert rod t hr ough the hole from the outside and fasten with cotter hairpin.

3.12 Inst all and adjust shifter lever.
a) Remove the 3/8" nyloc nut and spring disk washer from the stud on top of the

transmission. Install the shif ter lever through slot in shift er lever plat e and ont o
the stud on top of transmission. Be sur e t he square-hole washer remains
between the lever and transmission. Replace the spring disk washer and

nyloc nut (See Figure 5) . Torque the 3/8" nut to 35 ft. lbs. (47 N⋅m).

- 13 -

g

b) Shift lever t o 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 6).

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 t ighten hardware.

c) Shift to neut r al position. Lever should not contact the left edge of the upper

slot. Push lever down. Lever should not contact the right edge of the bottom

S

slot (See Figure 7). Shifter plate can be adjusted

ide to side to adjust position
of lever relative to the slot in plate. Loosen the t wo bolts secur ing the shifter
plate to the shifter lever leg s . Adjust shifter plate and ret ighten bolts.

FIGURE 6

THIS CLEARANCE SHOULD BE EQUAL

FIGURE 5
SHIFTER LEVER
TO TRANSMISSION

FIGURE 7

THIS CLEARANCE SHOULD BE EQUAL

3.13 Install and adjust wheel drive linkages.
For Pistol Grip Handles:
a) Screw threaded end of dr ive link ages into swivels in wheel drive idler arms.
b) Insert clevis pin f r om bolt bag through drive linkage , lever and slot in t he

neutral lock/park brake latches (See Figure 8). Make proper adj ust m ents
before adding hairpins.

Neutral Lock/Park Br ake

Clevis Pin

Drive Linka

e

Drive Lever

FIGURE 8

LEVER AND ROD ADJUSTMENT

c) Adjust drive linkag e length by threading into or out of the swivel until there is a

3/16" to 1/4" (.47-.64 cm ) clear ance bet ween the linkage assembly and the
bottom of the slot in the neutral lock/park brak e latch (See Figure 9).

- 14 -

3/16” TO 1/4”(.47-.64 cm)

Neutral Lock /

Park Brake Latch

Drive Linkage

FIGURE 9

PISTOL GRIP HANDLES

NEUTRAL LOCK LEVER CLEARANCE

NOTE: Neutral lock/park brake lat ch cl earance should be checked when

there is a slight upward force placed on the drive levers to remove any
"slack" in the linkage.

After clevis pin has been inserted, install hair pin into hole on the clevis pin

between the neutral lock/park brake latch and dr ive lever (See Fig ur e 10) .

Repeat procedure on opposite side of unit.

Drive
Lever

Clevis Pin

Drive Linkage

Left Side

Shown

Hairpin

Neutral Lock /

Park Brake Latch

FIGURE 10

PISTOL GRIP HANDLES

DRIVE LEVER HARDWARE LOCATION

For ECS Handles:

a) Locate the drive lever linkages which have the balljoint and jam nut s installed on

one end. Locate the (2) 5/16-18 x 1 3/4 Hex cap screws and (2) 5/16-18 nyloc
nuts in the bolt bag. Thread dr ive lever link age into the swivel located on the
wheel drive idler arm. Thread in until the f lat edge of the drive lever aligns with
bottom of the roller not ch in the neutral lock/park brake latch when the 5/16-18 x 1
3/4 hex cap screw is inserted through the hole in the drive lever and the hole in
the balljoint. Secure with the 5/16-18 nyloc nut. T ig hten nut. Repeat for the
other side. See Figures 11 and 12.

- 15 -

FIGURE 11

ECS HANDLE DRIVE LEVER LINKAGE INSTALLATION

FIGURE 12

ECS HANDLE DRIVE LEVER SETTING

3.14 Adjust brakes by adjusting wingnut on the upper end of each br ake rod. Tighten
the wingnut until the brakes engag e when the drive levers are sq ueezed enoug h t o
allow the neutral lock/park brak e latches to be placed into the “park brake” position.
See Figure 15 for Standard Pist ol Grip handles and Figure 16 for ECS handles.

Check for correct adjust m ent:
Place the drive levers in the “park brake” position. The mower should not move

forward or backward. If it does, t ighten the wingnuts.

Place the drive levers in the “neutral lock” position. The m ower should move

forward and backward freely. If it does not, loosen the wingnuts.

NO TE: The neutral lock/park brake latches must be able to be moved into the

park brake position, if not, the brake l i nkages must be adjust ed agai n.

3.15 Route the long, unattached wiring harness lead up the left hand side of the handle
and connect the flag terminals, in any order , t o the operator presence control switch
terminals on the inside of the contr ol console. On Kawasaki units connect the
connector on the end of the other lead t o t he key switch. Fasten the lead to the
handle with two small wire ties, from 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. On ECS models fasten leads to the small hole in the channel
under the console.

3.16 If the unit is shipped without the muf fler attached, install with hardware provided. For
Kawasaki units the muffler is inst alled onto the engine exhaust manifold but rotated
rearward to fit the crate. Loosen the clam p, rotate the muff ler ahead and secur e t he
bracket on the muffler to the bracket on the eng ine with the hardware provided.
Tighten the clamp.

- 16 -

3.17 Service Engine: Follow the recommendations in the Engine Operat or s Manual.

3.18 Grease unit.

NOTE: UNIT IS NOT GREASED AT THE FACTORY! Refer to Section 5.1.12 for

locations and grease amounts.

3.19 Follow pre-start instructions as outlined in Section 4.2.

4. OPERATION INSTRUCTIONS

4.1 CONTROLS

4. 1. 1 Fam iliar ize yourself with the cont r ols and operation of the unit.

Carefully read the following information about the controls and their operation.

4. 1. 2 O per ator Presence Control (OPC) Levers

Located on the upper handle assembly direct ly above the handle gr ips. When

these levers are depressed, the OPC system senses that the operator is i n t he
normal operator's position. When the levers are released, the OPC system
senses that the operator has moved from the normal operating positi on and

will kill the engine if either the transmission shift lever is not in the neut ral position
or the PTO is engaged. See Figures 13 and 14.

4.1.3 Drive Levers

:

Located on each side of the upper handle assembly directly below the handle grips.

See Figures 13 and 14. These levers individually control clutching action of the
wheel drive belts and brakes. When the drive levers are all the way down, the
brakes disengage and the wheel drive belts engag e.

Gradually squeezing the left or r ight hand drive lever disengages the wheel drive

belts, causing the left hand or r ight hand wheel to slow down until they reach
neutral or stop. This mak es t he m a chine ur n t o t he left or right respectively.
Squeezing further engages the park brakes. T he shar pness of the turn varies by
how much the lever is squeezed. For straight ahead motion, smoothly release both
drive levers to engage both drive wheels simultaneously.

4. 1. 4 Neut r al Lock/Park Brake Latches

:

The latches allow the operator to lock t he dr ive levers in a "neut r al" position where

neither the wheel drive belts nor the brakes engage or in a “park brake” posit ion
where the wheel drive belts are not engaged and the park brake is engaged. See
Figures 13 and 14.

Apply parking brakes whenever leaving the operators position.

FIGURE 13

PISTOL GRIP HANDLE

NEUTRAL LOCK/PARK BRAKE LATCH

:

- 17 -

FIGURE 14

ECS HANDLE

NEUTRAL LOCK/PARK BRAKE LATCH

4. 1. 5 PTO Engagement Lever

:
Located on the left side of the upper handle.
To engage the blades, push the lever forward, or away from t he oper at or, until the

turnbuckle locks over-center.

To disengage the blades, pull the lever to the rear, or t owards the oper ator.

4. 1. 6 Thrott le-Choke-Kill Control (Kohler engines):
The throttle-choke-kill control lever is locat ed on the control console right side.

Choke aids in starting a cold engine. The choke control is a part of t he throttle
control and activates by moving the throttle control lever t o the full forward
position. You will notice a detent at the “f ull t hrottle” position (approximately 3/4”
(2 cm) from top of slot) continue pushing forward into the “choke” position.

Once the engine has started, move the throttle control lever t o t he m idway point

and allow the engine to warm-up before going to full throttle.

All Kohler engines are equipped with “throttle kill” as a standard feature. Moving

the throttle control lever t o t he full rear position will kill the engine. You will notice
the control lever will fall into a detent at t he idle position, continuing rearward past
this detent will shut off the engine.

4. 1. 7 Throttle Cont r ol (Kawasaki engines)

: The throttle control is locat ed on t he control
console right side. The thrott le is used t o cont r ol engine speed. Moving the
throttle control for ward will increase engine speed and m oving it t o t he r ear will
decrease engine speed.

4. 1. 8 Choke Control (Kawasaki engines)

:
Choke aids in starting a cold engine.
The choke control is located on the front left corner of the fuel tank support and

is activated by pulling the control outward.

Once the engine has started, move the choke control to t he off position and

move the throttle to the medium or full throttle position. DO NO T run the engine
wit the choke in the “ON” position.

4.1.9 “Off-Run” Switch (Kawasaki

engines):

Located on the console. Turn key to the “ Run” posit ion t o allow the eng ine to be
started. Turn key to t he “ O ff” position to shut eng ine off.

- 18 -

4. 1. 10 Transmission Shift Lever

:

Locat ed under the control console and behind the fuel tank. I t shifts the 5-speed

transmission into five forward gear s, neut ral and reverse. Shift transmission only
when drive levers are in the neutral position. Shifting without dr ive 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" wi t h t he
movement of the unit.

4. 1. 11 Fuel Shut-Off Valve

:

I nstalled on the fuel line midway between the fuel tank and the engine. The fuel

shut off valve shuts off the flow of fuel when the machine will not be used for a
few days, when parking inside a building, and during tr anspor t to and from the
job. Rotate the valve 1/4 turn clockwise to shut off fuel. Rotat e t he valve 1/4
turn counter-clockwise to turn on f uel.

4.2 PRE-START

4. 2. 1 Refer to the Maintenance Section 5.1 and perfor m all of the necessary inspection

4.2.2 Fill fuel tank. For best results, use only clean, fresh regular grade unleaded

Do not add oil to gasoline.
Do not overfill fuel tank. Never fill the fuel tank so that the fuel level rises above a

4. 2. 3 Make sure you understand the controls, their locations, their functions, and their

and maintenance steps.

gasoline with an octane rating of 87 or higher. Regular grade leaded ga soline
may also be used; however, combustion chamber and cylinder head will require
more frequent service. See Engine Owner's Manual.

level that is 1/2” (1.3 cm) below the bottom of the filler neck t o allow f or fuel
expansion and prevent fuel spillage.

safety requirements.

4.3 OPERATING INSTRUCTIONS

4. 3. 1 Read the Engine Owner's Manual carefully for detailed operat ing instructions and

maintenance regarding the engine.

Before attempting to operate the unit, refer to Section 1 (Safety) and follow all

safety, operating, and prepar at ion guidelines as stated in that section.

4.3.2 Starting Engine
Posit ion m ower on a level surface. Disengage PTO and place tr ansm ission in neut r al.
O pen fuel shut-off valve.

NO TE: Always engage the left and right neutral lock/park brake latches in

the “park brake” position when start i ng t he engine (See Section 4.3.4).

For Kohler units: With a cold engine, place the throt tle in the full "choke" position.

With a warm engine, place the throttle midway between the “Slow” and “Fast”
positions.

Pull recoil rope to start engine. After engine starts, move thrott le cont r ol out of the

choke position. DO NOT run warm engine with the choke in the “ON” position.

For Kawasaki units: Pull out the choke control. Place the t hr ottle control midway

between the “Slow” and “Fast” positions. Turn the key switch to the “Run” position.

Pull recoil rope to start engine. After t he engine warms up, gradually push in the

choke control. DO NOT r un warm engine with the choke in the “ON” position.

NOTE: Kawasaki engines generally need to be "choked" even when warm.

- 19 -

4.3.3 Stopping Engine

:

Lock the drive levers in “park brake” position, disengage PTO, and posit ion

transmission to neutral. Place the thr ottle control midway between the “slow” and

“fast” positions. Allow the engine t o r un a m inim um of 15 seconds.
For Kohler engines: Move throttle to full rear position to stop the engine.
For Kawasaki engines: Turn the key to the “Off” position.
Close fuel shut-off valve if machine will not be used for a few days; when parking

inside a building; or when transporting the unit.

4. 3. 4 Drive Lever/Neutral Lock/Park Brake Latch Operation

:

For Pistol Grip Handles: To lock the drive levers in “neutral”, squeeze the drive

levers back to the neutral position. Place thumbs on the upper portion of the

neutral lock/park brake latches and move them to the rear. Release t he dr ive

levers (See Figure 15).
To lock the levers in “park brake”, squeeze the drive levers back to the brake

position. Place thumbs on the upper portion of the neutral lock/park br ake latches

and move them to the front. Release t he drive levers (See Figure 15).

CAUTION

POTENTIAL HAZARD
♦ If the neutral lock/ park brake latches are not comp let ely

engaged the drive levers could unexpectedly slip into the

forward drive position.
WHAT CAN HAPPEN
♦ If the drive levers slip into the drive position, the unit could lurch

forward and cause injury or property damage.
HOW TO AVOID THE HAZARD
♦ Be sure the pins protruding throug h the slots of each neutral

lock latch are completely engaged in t he r ear slot of each latch.

To place the drive levers in the drive position, firmly hold the dr ive levers, place

thumbs on the upper portion of the neut ral lock/park brake lat ches and move
them out of the “neutr al” or the “park brake” posit ion. Slowly and smoothly
release the drive levers.

PARK
BRAKE

ROTATE FORWARD FOR
PARK BRAKE POSITION

ROTATE BACK FOR
NEUTRAL LOCK POSITION

LATCH IS IN
THE DRIVE
POSTION

FULL SPEED
FORWARD

NEUTRAL
LOCK

NEUTRAL - HOLD IN THIS POSITION
FORWARD - RELEASE DRIVE LEVER
REVERSE - SQUEEZE DRIVE LEVER

FIGURE 15

DRIVE LEVER, NEUTRAL LOCK/PARK BRAKE OPERATION

- 20 -

For ECS Handles: To lock the dr ive levers in “neutral lock”, squeeze the drive

levers to the “neutral” position. See Figure 16 (b). Place thumbs on the inner
thumb lobe of the neutral lock / park brake latches and rotat e t hem to the “neutral”
position. See Figure 16 (c). Release t he dr ive levers.

To lock the drive levers in “park brake”, squeeze the drive levers f ar t her to the

“brake” position. Place thumbs on the inner thumb lobe of the neutral lock/park
brake latches and rotate them t o the “park” position. See Figur e 16 ( d ) . Release
drive levers.

CAUTION

POTENTIAL HAZARD
♦ If the neutral lock/ park brake latches are not comp let ely

engaged the drive levers could unexpectedly slip into the

forward drive position.
WHAT CAN HAPPEN
♦ If the drive levers slip into the drive position, the unit could lurch

forward and cause injury or property damage.
HOW TO AVOID THE HAZARD
♦ Be sure the drive levers are securely seated at the bottom of the

“neutral” or “park” ar eas of the neutral lock latches.

To place the drive levers in the “drive” position, slightly squeeze the drive levers

while placing thumbs on the outer thumb lobe of t he neut ral lock/park brake
latches (or the index finger on the front lobe) and rotate them from under the drive

4. 3. 5 Drive Wheel Engagement and Tur ning
With drive levers in the “neut r al” or “park brake” posit ion, shift transmission into

For straight ahead motion: Smoothly release both drive levers to engage drive

For turning: Squeeze the right hand drive lever to turn right and left hand drive

levers. Slowly and carefully re lease t he dr ive levers. See Figure 16 (a).

(a) (b)

(c)

FIGURE 16

DRIVE LEVER, NEUTRAL LOCK/PARK BRAKE LATCH OPERATION

desired gear. Squeeze both drive levers and move both neutral lock/park brake
latches from the “neutral” or “park brake” position to the “drive” position.

wheels.

lever to turn left (See Section 4. 1. 3) .

(d)

:

- 21 -

4.3.6 To Stop
Squeeze drive levers all the way back to engage brakes. Move neutral lock/par k

brake latches into the “park brake” position and release drive levers. Shift
transmission into neutral.

4.3.7 PTO Engagement

POTENTIAL HAZARD
♦ The rotating blades under the mower deck ar e

WHAT CAN HAPPEN
♦ Blade contact can cause serious injury or kill you.

HOW TO AVOID THE HAZARD
♦ DO NOT put hands or feet under t he m ower or m ower

POTENTIAL HAZARD
♦ An uncovered discharge opening will allow objects to

WHAT CAN HAPPEN
♦ Thrown objects or blade contact can cause serious

HOW TO AVOID THE HAZARD
♦ Never operate the mower with the discharge deflector

:

:

dangerous.

deck when the blades are engaged.

be thrown in an operator’s or bystander’s direction.

Also, contact with the blade could occur.

injury or death.

raised, removed, or altered unless there is a g r ass

collection system or mulch kit in place and working

properly.

DANGER

DANGER

Be sure that all persons are clear of mower deck and discharge area before

engaging the blades. Set throttle to "midway" (half throttle) position. Push the

PTO lever forward to engage blades. Accelerate to full thr ot tle to begin mowing.
(See Section 4.1.5).

4.3.8 PTO Disengagement
Pull t he blade engagement lever to the fu ll r ear ward position to disengage the

blades (See Section 4.1.5)

4.3.9 Changing Gears
When changing gears, always squeeze drive levers to the neutral position. The

shift lever may be moved with a knee or by hand (engage the neutral lock latches
if shifting by hand).

NOTE: Reverse gear is reverse assist only, the operator must pull the unit

backwards.

- 22 -

4.4 TRANSPORTING

WARNING

POTENTIAL HAZARD
♦ Loading the mower onto a trailer without strong enough

or properly supported ramps could be dangerous.
WHAT CAN HAPPEN
♦ The ramps could collapse causing the unit to fall, which

could cause injury.
HOW TO AVOID THE HAZARD
♦ Use proper ramps that are secured to the t r uck or

trailer.
♦ Keep feet and legs out f r om under the unit when

loading and unloading.
♦ If necessary, use assistance when loading.

Be sure fuel shut-off valve is closed.
Use a heavy duty trailer t o t r ansport the machine. Engage the park brakes and

block wheels. After the wheels have been properly blocked, securely fast en the
machine to the trailer with straps, chains, cables, or ropes. Be sure that the trailer
has all necessary lighting and marking as r e quired by law and use a safety chain.

NOTE: When transporting machine, be sure to engage the park brakes.

Failure to do so can result in damage and/or premature wear to drive train.

Do not rely solely on the parking brake to hold machine on trailer.

5. MAINTENANCE AND ADJUSTMENTS

5.1 PERIODIC MAINTENANCE

POTENTIAL HAZARD
♦ While maintenance or adjustments are being made,

someone could start the engine.
WHAT CAN HAPPEN

♦ Accidental starting of the engine could seriously injure

you or other bystanders.
HOW TO AVOID THE HAZARD

♦ Remove the key from the ig nit ion switch and/or pull t he

wire(s) off the spark plug(s) before you do any

maintenance. Also push the wire(s) aside so it does

not accidentally contact the spark plug(s ) .

WARNING

POTENTIAL HAZARD
♦ The engine can become very hot.

WHAT CAN HAPPEN
♦ Touching a hot engine can cause severe burns.
HOW TO AVOID THE HAZARD
♦ Allow the engine to cool completely before service or

making repairs around the eng ine area.

WARNING

- 23 -

5.1.1 Check engine oil level.
Service Interval: See Engine Owner's Manual
a) Stop engine and wait for all moving parts to stop. Make sure machine is on a

level surface.
b) Check with engine cold.
c) Clean area around dipstick. Remove dip stick and wipe off oil. Reinsert the

dipstick (Do not screw into place).
Remove dipstick and check oil level.
d) If the oil level is low, add oil as specified in the engine owners manual to bring

the oil level up to the "FULL" mark on the dipstick. DO NOT OVERFILL.

IMPORTANT: Do Not operate the engine with oil level below the "LOW"

(or “ADD”) mark on the dipstick or over the "FULL" mark.

5. 1. 2 Clean engine air cooling system

.
Service Interval: See Engine Owner's Manual
a) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).

b) Clean all debris from engine air intake screen and fr om around engine

shrouding.

5. 1. 3 Clean grass build-up under deck and check mower blades

.

Service Interval: Daily

CAUTION

POTENTIAL HAZARD
♦ Raising the mower deck for service or m aint enance

relying solely on mechanical or hydraulic jacks could be

dangerous.
WHAT CAN HAPPEN
♦ The mechanical or hydraulic jacks may not be enough

support or may malfunction allowing the unit t o fall, which

could cause injury.
HOW TO AVOID THE HAZARD
♦ DO NOT rely solely on mechanical or hydraulic jacks for

support. Use adequate jack st ands or equivalent support.

a) Disengage PTO.
b) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).
c) Raise deck, support properly using safety precautions.
d) Clean out any grass build-up from under side of deck and in deck discharge chute.
e) Inspect blades and sharpen or replace as required.
f) If blade removal is necessary, be caref ul for the sharp cutting edg es of the blades.
g) Re-install the blades (if they were removed) and tor que blade bolts to 75-85

ft/lbs (102-115 N-m). Be sur e the spring disk washer cone is installed toward

the bolt head (See Figure 17).
h) Remove jack stands (or equivalent support ) and lower deck to ground.

- 24 -

FIGURE 17

(102-115 N-m)

BLADE BOLT INSTALLATION

5. 1. 4 Check safety interlock system

.
Service Interval: Daily
a) For your safety, your Exmark m ower is eq uipped with Operator Presence

Controls, referred t o as (OPC). When either the PTO is engag ed, or the
transmission shifter lever is not in neutr al and t he operator removes both
hands from the handles, the mower engine MUST stop.

b) To determine if the OPC is in operating condition, clear area of bystanders.

Run the engine at one-third throttle, then with the drive levers and neutral lock
latches in the “park brake” position, shift the transmission into g ear and
release the OPC levers – the engine MUST stop.

Again, run the engine at one- third throttle, move the transm ission shifter lever to

neutral, engage the PT O and release the OPC levers - the engine MUST stop.

If the mower engine does not st op under any of the above mentioned

conditions, DO NOT OPERATE. Contact your authorized Exmark service
dealer.

IMPORTANT: It is essential t hat al l Operator Safety Mechanisms, be in

place and in proper operating condition prior to mowing.

5. 1. 5 Check Brake and Wheel Drive Linkage Adjust ment

.
Service Interval: Daily
Refer to Sections 3.13 and 3.14. Note any bent linkage or hardware which may

need servicing or replacing.

5. 1. 6 Check for loose hardware

.
Service Interval: Daily
a) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).

b) Visually inspect machine for any loose hardware or any other possible

problem. Tighten or replace any hardware bef or e oper ating.

5. 1. 7 Service pre-cleaner element and air cleaner

.
Service Interval: See Engine Owners Manual
a) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).

b) See engine owners manual for cleaning instr uctions.

5. 1. 8 Change engine oil

.

Service Interval: See Engine Owner's Manual

- 25 -

NOTE: Change oil after f i rst five (5) hrs. of operation. Follow engine

manufacturer's recommendations for future oil changes.

a) Disengage PTO.
b) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).

c) Drain oil while engine is warm from operation or if oil is to be changed after t he

unit has been sitting for awhile, run eng ine for a few minutes to get it warm.

d) Remove the oil drain plug from the right hand side of the eng ine. Allow oil to

drain, replace drain plug.

e) Replace the oil f ilt er per the engine owners manual. Clean around oil filt er and

unscrew filter to remove. Bef or e t he new f ilt er is installed, apply a thin coating
of oil on the surface of the rubber seal. Turn f ilt er clockwise until rubber seal
contacts the filter adapt er , then tighten filter an additional 2/ 3 to 3/4 turn.

f) Clean around oil fill cap and remove. Fill to specified capacity and replace

cap. Refer to Engine Owner's Manual f or cor rect oil level and the SAE Grade

recommended by the manufacturer.
Do Not overfill.
g) Start the engine and check for leaks. Stop engine and r echeck oil levels.

5. 1. 9 Check tire pressures

.
Service Interval: Pneumatic (air-filled) Drive Tires- 40 hrs.
Semi-pneumatic Caster Tires – No maintenance
a) Stop engine and wait for all moving parts to st op. Rem ove spark plug wire(s).

Check air pressure in drive tires; recomm ended t ir e pr essur e is: 12 to 16 psi
(83-110 kPa).

b) Inflate tires to pressures stated above. Measure the circumference of each

drive tire. Adjust tire pressures within the above range to t r y to m ake tire
circumferences match as closely as possible.

5.1.10 Check grease level, input and output shaft bearing wear on Peerless
Transmission. (Replace gearbox grease yearly)

Service Interval: 160 hrs.
a) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).
b) Place drive levers and neutral lock/park brake latches in neutral lock posit ion.
c) Remove shifter lever from top of transmission.
d) Remove shifter plate from top of transmission and t he t wo leads f r om 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 t he 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" (3.8 t o 4. 4 cm ) from the gearbox bottom . If

necessary, fill to proper level with Peerless grease (Part No. 788067).
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 5.2.3.

- 26 -

5. 1. 11 Inspect belt wear

.
Service Interval: 40 hrs.
a) Stop engine and wait for all m oving par ts to stop. Remove key or spark plug

wire(s).

b) Remove the mower deck belt shield to check mower blade drive belt

condition.
c) Look under engine deck to check the transm ission drive belt condit ion.
d) Inspect wheel drive belt conditions.
e) Check all idler arms to be sur e t hey pivot freely. Disassemble, clean and grease

pivot bushings if necessary.

5.1.12 Lubrication

:
Service Interval: Refer to Chart
a) Stop engine and wait for all m oving par ts to stop. Remove key or spark plug

wire(s).

b) Lubricate fittings with one to two pumps of SAE No. 2 multi-purpose g un grease.

Refer to the following chart for fitting locations and lubr icat ion schedule.

LUBRICATION CHART

FITTING LOCATIONS

1. Caster Wheel Bearings 12 2 2 2 Daily

2. Caster Pivots 2 2 2 2 Daily

3. Drive Wheels 18 2 2 2 Daily

4. Drive Wheel Idler Arm 2 2 2 2 Daily

5. Brake Arm 2 2 2 2 Weekly

6. Trans. Output Shaft Coupler 2 2 2 2 Weekly

7. Mower Deck Idler Pivots 2 1 1 1 Weekly

INITIAL
PUMPS

FITTING QUANTITY
32" 36" 48"

SERVICE
INTERVAL

No.6 (Trans. Coupler)
Located Below
Fuel Tank Support

No. 4 & 7 (Idler Arm Pivots)
Disassemble and grease once a
Month under a “No Load” condition

48” Deck Shown for Reference Only
c) Replace 5-speed gearbox grease yearly. Use 18 oz. of Peerless grease (Part

No. 788067). See Section 5.1.10.

d) Lubricate pivot points with a spray penetrating lubricant as dir ect ed below.

SPRAY LUBRICANT CHART

PIVOT POINTS

1. Blade Engagement Bellcrank 1 1 1 Weekly

NO. of PLACES
32" 36" 48"

SERVICE INTERVAL

5. 1. 13 Remove engine shrouds and clean cooling fins.
Service Interval: See Engine Owner's Manual
a) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).

b) Remove cooling shrouds from eng ine and clean cooling fins. Also clean dust,

dirt and oil from external surfaces of engine that can cause improper cooling.

- 27 -

c) Make sure cooling shrouds are properly reinstalled. Oper ating the engine

without cooling shrouds will cause engine damage due to overheating.

5. 1. 14 Check spark plugs

.
Service Interval: See Engine Owner's M anual
Remove spark plug, check condition and adjust plug gap, or replace with new

plug (See Engine Owner’s Manual).

5. 1. 15 Change fuel filter

.
Service Interval: As Required
A fuel filt er is installed in the fuel line between the fuel tank and the engine.

Replace when necessary.

5.1.16 Engine maintenance

.
Service Interval: See Engine Owner's M anual
Refer to t he Engine Owner's Manual regarding maintenance req uir ed for the engine.

5. 1. 17 Check all safety signs

for visibility. Replace as needed.

5. 1. 18 Thread locking adhesives Fel-Pro Pro-Lock "Nut-Type" or Loctite Thr eadlocker

"242" are used on the following:
a) All belt drive pulley setscrews.
b) OPC lever setscrews.
c) Pulley retaining bolt in end of engine cr ankshaft.
d) Fuel tank bulkhead fit t ing threads.
Adhesives such as Loctite "RC/609" or "RC/680" or Fel-Pro Pro-Lock "Retaining "

or "Retaining II" are used on the following:

a) OPC lever hubs and cross-shaf t .
NOTE: When applying any locking adhesives, care must be used not to bond

the bearing (next to each OPC hub) to the cross-shaf t . This could cause

binding of the OPC levers and erratic operation.

b) Fuel tank studs, where studs are inserted into tank.

5.1.19 An anti-seize compound

is used on the following locations:
a) Bet ween the blade drive and transmission drive pulleys and engine crankshaft.
b) Bet ween the tr ansm ission dr ive pulley and transmission dr ive shaf t.
c) Between the bearings and sheaves and transmission output shafts.

5. 1. 20 Mobil HTS gr ease (or food-grade antisieze) is used in the following locations:
a) Between the cutter housing spindle and bearings.
b) Between the cutter housing spindle and sheave.

5.1.21 Dielectric grease

is used on all blade type electrical connections to prevent

corrosion and loss of contact.

5.2 ADJUSTMENTS

5. 2. 1 Adjusting cutting height with blade spacers

.

Blades may be adjusted for cutting height by using the four 1/ 4" ( .64 cm) spacers

found on the blade spindle bolts (fact or y sett ing is two above and two below). This
allows a 1" (2.5 cm) range in 1/4" (.64 cm ) increments of cutting height in any axle
position. The same number of blade spacer s must be used on all blades to achieve
a level cut (two above and two below, one above and three below, etc.).

For the best cut and discharge, place a minimum of two spacers between the

blade and spindle shaft.

For the highest q uality cut, place all four spacers between the blade and the

spindle shaft.

- 28 -

If the mulching kit is installed, the highest qualit y cut can be obt ained with 3

spacers between the blade and spindle (minimum is 1 for a g ood cut).

If you need to cut hig her or lower than what the spacers will allow, it will be necessary

to adjust the rear axle height and caster posit ion. See Section 5.2.2 below.

5. 2. 2 Axle height and caster position

.

Desired cutting height range can be obtained by adjusting the rear axle and

placing caster spacers above or below the caster arm (See Figures 18 and 19
along with the Cutting Height Adj ust m ent Chart). It may be necessary to

readjust wheel drive and brake linkages.

To adjust rear axle:
a) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).
b) Place the drive levers in the neutral lock position.
c) Remove mower deck belt shield for access to axle adjustment bolt s .
d) Loosen but do not remove the two (2) axle pivot bolts and the two (2) axle

adjustment bolts (See Figure 19) .
e) Place a jack under the rear center of the engine deck.
f) Raise the back end of the eng ine deck up enough to remove the two (2) axle

adjustment bolts.
g) With t he jack, raise or lower the back end of t he engine deck so that two (2)

axle adjustment bolts can be reinstalled in desired hole location. A tapered

punch can be used to help align the holes.
h) Retighten all four ( 4) bolts, lower unit and remove jack.
i) Install mower deck belt shield.
j) Adjust wheel drive and brake linkages as required. (See Sections 3.13 and 3.14).
k) Adjust the caster spacers as directed in chart to match with the axle hole

selected. (See Figure 18).
l) Refer back to 5.2.1 for adjusting the cutting height with blade spacers.

(12 mm)

(5 mm)

Place Jack

Here

Axle Adjustment Holes are actually in
the side of the rear deck.

Axle Pivot Bolt

Axle

Adjustment

Holes

Pos. A
Pos. B
Pos. C

Pos. D
Pos. E

FIGURE 18 FIGURE 19
CASTER HEIGHT ADJUSTMENT AXLE HEIGHT ADJUSTMENT

T hese models have five (5) axle positions; four (4) 1/2" (1. 3 cm) caster spacers; one (1)

3/16" (.47 cm) caster spacer, and four (4) blade spacers.

NOTE: The axle positions are in 1/2" (1.3 cm) increments and the l arge cast er spacers

are 1/2" (1.3 cm) thick. Therefore, by adjusting the same number of 1/2" ( 1. 3 cm) cast er
spacers as axle hole positions the blades will retain the same front-to-back tip (rake).

- 29 -

CUTTING HEIGHT ADJUSTMENT (1" to 4 1/4")

AXLE

POSITION

(FIG. 20)

A 0 0 1" (2.5 cm) 1 1/4" (3.2 cm) 1 1/2" (3.5cm) 1 3/4" (4.4cm) 2" (5.0cm)
A 0 1 1 1/8" (2.9 cm) 1 3/8" (3.5 cm) 1 5/8" (4.1 cm) 1 7/8" (4.8 cm) 2 1/8" (5.4 cm)
A 1 0 1 3/8" (3.5 cm) 1 5/8" (4.1cm) 1 7/8" (4.8 cm) 2 1/8" (5.4 cm) 2 3/8" (6.0 cm)
B 0 1 1 3/8" (3.5 cm) 1 5/8" (4.1cm) 1 7/8" (4.8 cm) 2 1/8" (5.4 cm) 2 3/8" (6.0 cm)
B 1 0 1 5/8" (4.1 cm) 1 7/8" (4.8 cm) 2 1/8" (5.4 cm) 2 3/8" (6.0 cm) 2 5/8" (6.7 cm)
B 1 1 1 3/4" (4.4 cm) 2" (5.0 cm) 2 1/4" (5.7 cm) 2 1/2" (6.4 cm) 2 3/4" (7.0 cm)
B 2 0 2" (5.0 cm) 2 1/4" (5.7 cm) 2 1/2" (6.4 cm) 2 3/4" (7.0 cm) 3" (7.6 cm)
C 1 1 1 7/8" (4.8 cm) 2 1/8" (5.4 cm) 2 3/8" (6.0 cm) 2 5/8" (6.7 cm) 2 7/8" (7.3 cm)
C 2 0 2 1/8" (5.4 cm) 2 3/8" (6.0 cm) 2 5/8" (6.7 cm) 2 7/8" (7.3 cm) 3 1/8" (7.9 cm)
C 2 1 2 1/4" (5.7 cm) 2 1/2" (6.4 cm) 2 3/4" (7.0 cm) 3" (7.6 cm) 3 1/4" (8.3 cm)
C 3 0 2 1/2" (6.4 cm) 2 3/4" (7.0 cm) 3" (7.6 cm) 3 1/4" (8.3 cm) 3 1/2" (8.9 cm)
D 2 1 2 3/8" (6.0 cm) 2 5/8" (6.7 cm) 2 7/8" (7.3 cm) 3 1/8" (7.9 cm) 3 3/8" (8.6 cm)
D 3 0 2 1/2" (6.4 cm) 2 3/4" (7.0 cm) 3" (7.6 cm) 3 1/4" (8.3 cm) 3 1/2" (8.9 cm)
D 3 1 2 3/4" (7.0 cm) 3" (7.6 cm) 3 1/4" (8.3 cm) 3 1/2" (8.9 cm) 3 3/4" (9.5 cm)
D 4 0 3" (7.6 cm) 3 1/4" (8.3 cm) 3 1/2" (8.9 cm) 3 3/4" (9.5 cm) 4" (10.1 cm)
E 3 1 2 7/8" (7.3 cm) 3 1/8" (7.9 cm) 3 3/8" (8.6 cm) 3 5/8" (9.2 cm) 3 7/8" (9.8 cm)
E 4 0 3 1/8" (7.9 cm) 3 3/8" (8.6 cm) 3 5/8" (9.2 cm) 3 7/8" (9.8 cm) 4 1/8" (10.5cm)
E 4 1 3 1/4" (8.3 cm) 3 1/2" (8.9 cm) 3 3/4" (9.5 cm) 4" (10.1 cm) 4 1/4" (10.8cm)

# OF SPACERS

BELOW

CASTER

SUPPORT HUB

1/2" 3/16" 4 3 2 1 0

NUMBER OF 1/4" BLADE SPACERS

BELOW SPINDLE

IMPORTANT: To achieve the highest quality of cut, the blades should be level

wit h t he ground, or t i pped slightly down at the front.

5.2.3 Transmission belt adjustment

.

a) Stop engine and wait f or all moving par ts to st op. Remove key or spark plug

wire(s).
b) To tighten tr ansm ission belt , loosen t he 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" (1.3 cm) of deflection with

three pounds of pressure on the belt midway between the transmission and

engine pulley.

5. 2. 4 W heel dr ive belt pulley scrapers

.

a) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).
b) Be sure mud and grass scraper, on each side, is adjusted properly and centered

in the pulley grooves. The pointed part of t he scr aper should be centered and as

deep in the pulley groove as possible without rubbing at any point.

5. 2. 5 Engine to mower deck belt

.

a) Stop engine and wait f or all moving par ts to st op. Remove key or spark plug

wire(s).
b) Check the adjustment of the lower blade drive linkage located between the

bellcrank on the engine deck and assist ar m on t he m ower deck . Lengthen or

shorten the linkage. When properly adjusted, t her e should be 1/16" to 1/8" (2 –

3 mm) of clearance between bell-crank and t ransmission output shaft when belt

is engaged. Make sure the assist arm is ag ainst the rear assist arm stop on the

deck (See Figure 21). Push the lever down to the diseng aged position. The

assist arm should contact the front assist arm stop on the deck. If it does not

contact, readjust so that the bellcr ank is closer to the transmission output shaft.

- 30 -

c) Belt must be tight enough to not slip during heavy loads while cutting grass.

Overtensioning will reduce belt and spindle bearing life. To adjust belt tension,

loosen the 5/16" whizlock nut on turnbuckle and rotate t he t u r nbuckle; rotate

turnbuckle toward rear of mower to tig hten, and toward front of mower to

loosen belt tension (See Figure 20). Leave a minimum of 5/16” (.79 cm) of the

eyebolt threads engaged on both ends of t he t ur nbuckle.
For 48” Decks: If there is no adjustm ent left in the turnbuckle and t he belt is

still loose, the rear idler pulley can be repositioned in the front hole (See Figure

20). The belt guide located next to t he pulley must also be r eposit ioned in the

front hole when the pulley is moved. The turnbuckle will need to be readj ust ed.
Check belt tension after t he first hour of operation and at least twice during the

first 24 hours of operat ion. Adj ust as necessary.

48” Deck Shown

for Reference Only

FIGURE 20

MOWER DECK BELT ADJUSTMENT

d) Proper belt tension will require about 10 lbs. side pull on belt, halfway

between pulleys (See Figure 20, Point A) to deflect belt 1/2” (12 mm).

e) Check belt guide under the engine deck to see that it is proper ly set. ( See

Section 5.2.7). Also check the blade brake adjustment. (See Section 5.2. 6)

5. 2. 6 Blade Brake Adjustment:
a) Stop engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).
b) Disengage blades.
c) Make sure the blade brake pad rests against the sheave. Adjust the spring

mounting bolts to properly align t he pad on the sheave (See Figure 21).
d) Check the distance bet ween the spacer and t he nut at the end of the blade

brake rod. The distance should be between 1/8” and 3/16” (3 – 5 mm) (See

figure 21).
e) Engage t he blade cont r ol and check to make sure the blade brak e pad clear s

the sheave.

-

FIGURE 21

BLADE BRAKE ADJUSTMENT

- 31 -

5. 2. 7 Belt Guide Adjustm ent
a) Stop eng ine and wait for all moving parts to stop. Remove key or spark plug

wire(s).
b) Engage t he blade drive belt.
c) Check belt guide under the engine deck f or pr oper adjustment (See Figures

22 and 23). Adjust as necessary.
The diseng aged belt should not drag or fall off pulley when guides are

properly adjusted.

NOTE

FIGURE 22 FIGURE 23
32" & 36" BELT GUIDE LOCATION 48" BELT GUIDE LOCATION

5.2.8 Brake adjustment

5. 2. 9 Wheel drive linkage adjustm ent
a) For Standard Pistol Grip Handles: If wheel traction appears to be slipping,

5. 2. 10 Shifter lever adjustment

5. 2. 11 Shif ter detent adjustment

Turn setscrew out (counterclockwise) to decrease force on lever required to shif t

: These drawings are viewed from underneath the engine deck.

- See 3.14.

- See 3.13.

drive lever rods may be touching bottom of neut r al lock/park brake latch slot.

To adjust, refer to Section 3.13.

- See 3.12.

- Transmission shifter detent can be adjusted by adjusting
the setscrew on the back side of transmission locat ed j ust behind the neutral start
switch. Turn setscrew in (clockwise) to hold the transmission shifter more positively
in each gear and to increase the forc e on t he lever r equired to shift gears.

gears. Factory setting is to tur n 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. 12 PTO safety switch adjustment
a) Stop eng ine and wait for all moving parts to stop. Remove key or spark plug

wire(s).

b) With the blades disengaged and the bellcrank touching the engine deck,

adjust the blade safety switch (if needed) unt il t he bellcr ank depresses the
plunger by 1/4" (.64 cm).

c) Be sure the bellcr ank does not contact the switch body to prevent damage to

the switch.

d) Retighten switch mounting hardware.

5. 2. 13 Handle height adjustment
IMPORTANT: When the handle height adjustment is changed, it will

be necessary to readjust the wheel drive and brake linkage (See
Sections 3.13 and 3.14).

.

. See Section 3.8.

- 32 -

5.2.14 Wheel drive spring tension adj ust m ent
It may be necessary to increase wheel drive belt tension under certain operating

conditions such as, wet grass, hilly terrain, or while pulling a sulky.

a) St op engine and wait for all moving parts to stop. Remove key or spark plug

wire(s).

b) Disengage neutral lock/park br ake latches and release drive levers to lower

spring force.

c) Remove the 5/16-18 whizlock nut secur ing 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 24).

.

FIGURE 24

DRIVE BELT TENSION

ADJUSTMENT POSITIONS

6. WASTE DISPOSAL

6.1 MOTOR OIL DISPOSAL
Engine oil is a pollutant to the environment. Dispose of used oil at a certified recycling cent er

or according to your state and local regulat ions.

7. TROUBLE SHOOTING

7.1 MOWER PULLING LEFT OR RIGHT.
a) Check idler ar m pulleys and drive sheaves for mud and/or grass buildup. Check for

proper scraper position. See Section 5.2.4.
b) Check to be sure idler arms pivot freely, if not, lubricat e 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 adjust m ent - See Section 3.13.
e) Check for proper t ir e pr essur e in dr ive tires. Recommended tire pressure for t he

drive tires is 12 to 16 psi (82 –110 kPa). Higher pr essures may be used in the tire on

the side that it pulls to (up to 28 psi or 193 kPa).
Note: Different pressures may make mower cut unevenly.

7.2 MOW ER CUTS UNEVENLY.
a) Check the drive tire pressure and tire cir c um ference. See Section 5.1.9.
A more unif or m cutting height may be obtained with higher tir e pr essur e on rough

terrain. A lower tire pressure provides more flotation.

- 33 -

b) Check blade spacers, axle positions, and fr ont cast er spacers. They must be equal

on each blade.
c) Check caster mounting brack et s t o be sur e all bolt s ar e t ight.
d) Check blades tip to tip for straightness. (They should be within 3/16" (.47 cm) or one

blade width from being in line.)

7.3 BLADES DO NOT STOP WHEN DISENGAGED.

a) Check the blade brake adj ust m ent. (See Section 5.2.6)
b) Check the belt guide under the rear deck to make it is pr operly set (See Section

5.2.7) and check the PTO engagement adjustment. ( See Sect ion 5. 2. 5)

7.4 ENGINE WILL NOT START.

a) Refer to Section 4.3. 2 and follow directions to make sure engine is being properly

choked.
b) Make sure transmission is in "true neutr al" position. See Sections 3.12 (c).
c) Check that the PTO is disengaged and the PTO switch is depressed (See Section

5.2.12).
d) Check that there is fuel in the tank and that the fuel valve is open.
e) Check that the spark plug wire(s) is/are properly connected.
f) Check for loose or faulty wiring connections.
g) Check for corrosion at all wiring connections. Even minor corrosion may cause a

faulty connection. Clean connector terminals thor oughly, apply dielectric grease and
reconnect.

h) For Kawasaki: Check that the key switch is in the “Run” position.

NOTE: After carefully checking the previous steps, attempt to start t he engi ne. I f it

does not start, contact your authorized Exmark service dealer.

ENGINE TROUBLESHOOTING

When a problem occurs, do not overlook the simple causes. For example, starting

problems could be caused by an empty fuel tank, k ey switch not "O N" et c. The following
tables list some common causes of troubles. Do not attempt to ser vice or r eplace m ajor
items or any items that call for special t im ing or adjustment procedures (governor, valves,
etc.). Have this work done by your Engine Service Dealer.

PROBLEM

Will not start X X X X X X
Hard starting X X X X X X X
Stops suddenly X X X X X X X
Lack s power X X X X X X X X
Opera tes erratically X X X X X X X
Knocks or pings X X X X
Skips or misfires X X X X X
Backfires X X X X
Overheats X X X X X
High fuel consumption X X X X

ENGINE TROUBLESHOOTING TABLE

NO

FUEL

IMPROPER

FUEL

DIRT

IN FUEL

DIRTY

AIR

FILTER

FAULTY

SPARK

PLUG

ENGINE

OVER-

LOADED

BLOCKED

FUEL

FILTER

INCORRECT

OIL

LEVEL

DIRTY

AIR

SCREEN

- 34 -

8. MOWER DECK BELT ROUTING

FIGURE 26 FIGURE 27
32" and 36" MOWER DECK 48” MOWER DECK

- 35 -

9. WIRING DIAGRAMS

- 36 -

10.

2-Year Limited Warranty

Exmark Turf Equipment

Conditions and Products Covered

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

This warranty applies to Exmark turf equipment purchased on
or after October 1, 2004 sold in the US or Canada. This
warranty may only be assigned or transferred to a second (or
third) owner by an authorized Exmark dealer. The warranty
period commences upon the date of the original retail
purchase.

Products

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 Series 1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

*Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet. We are not authorized
to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized

• Any damage or deterioration due to normal use, wear

• Cost of regular maintenance service or parts, such as

• Any product or part which has been altered or misused

• Any repairs necessary due to use of parts, accessories

All warranty work must be performed by an authorized Exmark
Service Dealer using Exmark approved replacement parts.

1. Contact any Exmark Service Dealer to arrange service at

their dealership. To locate a dealer convenient to you,
access our website at www.exmark.com. U.S. Customers
may also call 402-223-6375.

2. Bring the product and your proof of purchase (sales

receipt) to the Exmark Service Dealer.

If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:

Exmark Customer Service Department
The Exmark Warranty Company
2101 Ashland Avenue
Beatrice, NE 68310

402-223-6375 or
[e-mail]

Warranty Period

Items and Conditions Not Covered

Exmark Service Dealer.
and tear, or exposure.
filters, fuel, lubricants, tune-up parts, and adjustments.
or required replacement or repair due to normal wear,

accidents, or lack of proper maintenance.
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.

Instructions for Obtaining Warranty Service

(For units purchased on or after October 1, 2004)

Owner’s Responsibilities

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

As a condition to this warranty, customer shall have read
the operator's manual and shall have completed and
submitted to Exmark Warranty Company, within the
prescribed time, the Exmark warranty registration.

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement
as set forth herein. Neither Exmark nor Exmark Warra n t y

Company shall have any liability for any other cost, loss
or damage, including but not limited to, any incidental
or consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• 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.

• 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.

There are no understandings, agreements, representations,
or warranties, express or implied, including but not limited to
any regarding the merchantability (that product is fit for
ordinary use) or fitness for use (that product is fit for a
particular purpose), not specified herein, respecting the
equipment which is the subject of this warranty.

Some states do not allow exclusions of incidental or
consequential damages, or limitations on how long an
implied warranty lasts, so the above exclusions and
limitations may not apply to you.

This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.

- 37 -

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

SL

O

PE

T

H

I

S

I

S

A

1

5

°

P

E

O

T

H

I

S

I

S

A

2

0

°

S

L

EDGE.

SLOPE WITH FOLDED

FOLD ALONG APPROPRIATE LINE

EXAMPLE: COMPARE

- 38 -

M

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

Check us out on the Web:

www.exmark.com

WARNING

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects, or

other reproductive harm.

©1997-2004 EXMARK MFG. CO. INC. PART NO. 103-8850
INDUSTRIAL PARK BOX 808 [phone]
BEATRICE, NE 68310 FAX [phone]

ALL RIGHTS RESERVED PRINTED IN U.S.A.

®

FG. CO. INC.