Exmark Mhp4816bv, MHP4815KC, MHP3614KA, Mhp5216bv, Mhp4814ka User Manual

...
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The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
WARNING
When the mower is used or oper ated on any California forest, brush or g rass covered land, a working spark arrester must be at t ached t o the muffler. If not, the operator is violating state law, Section 442 Public Resource Code. To acquire a spark ar r ester for your unit, see your Engine Service Dealer.
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 condit ion.
Stop engine and remove spark plug wire(s) or r emove key and
wait for all moving parts to stop before adjusting, servicing, or performing maint enance.
If mower deck becomes clogged, stop engine and remove spark
plug wire(s) or remove key and wait for all m oving par ts to stop before cleaning blockage.
Keep hands, feet and clothing away from power driven parts.
Keep off mower unless seat platf o r m is pr ovided.
Keep others off mower.
WARNING
WARNING
POTENTIAL HAZARD
Gasoline is harmful or f at a l 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.
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.
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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 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.
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

order of six (6) line items or less.

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 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. 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 3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus

orders must be received by Exmark by

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.

order
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
designed and manufactured to give you a maximum amount of dependability and years of trouble­free operation.
on the purchase of your Exmark Mower. This product has been carefully
OPERATOR'S MANUAL
This manual contains assembly, operating, m aint enance, 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 eff iciency and promote safe operation.
If additional informat ion 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 distribut or s ar e kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their ser vice stations. They carry ample stock of service parts or can secure them promptly for you fr om the factory.
All Exmark parts are thoroug hly test ed and inspect ed 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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TABLE OF CONTENTS
1. SAFETY.............................................................................................PAGE
1.1 Safety Alert Symbol...................................................................................... 1
1.2 Training........................................................................................................ 1
1.3 Preparation................................................................................................1-3
1.4 Operation..................................................................................................3-4
1.5 Maintenance & Storage.............................................................................4-5
1.6 Riding Attachments......................................................................................5
1.7 Safety Signs..............................................................................................5-8
2. SPECIFICATIONS
2.1 Model Number.............................................................................................. 8
2.2 Engine.......................................................................................................... 8
2.3 Fuel System.................................................................................................8
2.4 Safety Interlock System................................................................................8
2.5 Steering/Brake Control................................................................................. 8
2.6 Transmission................................................................................................ 9
2.7 Wheel Drive System..................................................................................... 9
2.8 Tires ............................................................................................................9
2.9 Deck ............................................................................................................9
2.10 Dimensions.............................................................................................9-10
2.11 Torque Requirements................................................................................10
3. ASSEMBLY INSTRUCTIONS
3.1 to 3.18 Assembly................................................................................... 10-15
4. OPERATION INSTRUCTIONS
4.1 Controls.................................................................................................15-17
4.2 Pre-Start................................................................................................17-18
4.3 Operation Instructions...........................................................................18-21
4.4 Transporting...............................................................................................21
5. MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance............................................................................ 21-27
5.2 Adjustments..........................................................................................27-30
6. TROUBLE SHOOTING
6.1 Mower Pulling Left or Right ........................................................................ 30
6.2 Mower Cuts Unevenly.................................................................................30
6.3 Engine Will Not Start.............................................................................30-31
7. WIRING DIAGRAM
.
8
WARRANTY
..............................................................................................34-35
...................................................................................32-33
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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 t he 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 t he word WARNING: IT DENOTES THAT A HAZARD EXISTS WHICH CAN RESULT IN INJURY OR DEATH IF PROPER PRECAUTIONS ARE NOT TAKEN.
When used with t he 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
1.2 TRAINING
1.2.1 Regard the Exmark mower as a piece of power equipm ent and teach this regard to all who operate this unit.
1.2.2 Read the instructions carefully. Familiarize yourself with the cont r ols and the proper use of the equipment.
1.2.3 Never allow children, teenagers, or people unfamiliar with these inst r uctions 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.
CAUTION.
, or
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 f or eign objects which may damage the equipment or cause personal injury to the operat or or bystanders.
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POTENTIAL HAZARD
Engine exhaust contains carbon monoxide, which is
an odorless deadly poison.
WHAT CAN HAPPEN
Carbon monoxide can kill you and is also known to the
State of California t o cause birth defects.
HOW TO AVOID THE HAZARD
Do not run engine indoors or in a small confined area
where dangerous carbon monoxide fumes can collect.
WARNING
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 hers,
and cause property damage.
HOW TO AVOID THE HAZARD
♦ DO NOT
an open flame or where gasoline fumes m ay be ignited by spark.
Refuel only in a well ventilated area, or refuel
outdoors.
Store gasoline in an approved container and keep it
out of the reach of children.
Add fuel before start ing the engine.
cap of the fuel tank or add fuel when engine is running or when the engine is hot.
Never fill the fuel tank so that the gasoline level rises
above a level that is 1/2” below the bottom of the filler neck to allow for gasoline expansion and prevent fuel spillage.
If fuel is spilled,
Move away from the area of the spill and avoid creating any source of ignition unt il fuel vapors have dissipated.
smoke while refueling, and stay away from
DO NOT
DANGER
Never
attempt to start the engine.
remove the
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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 inter ior car pets 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 refuel the equipment with its wheels on the ground.
If this is not possible, then refuel such equipment on a
truck or trailer from a portable container, rather t han 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
1.4 OPERATION
Although hazard control and accident prevention are parti al l y 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 i nvol ved in the operation, transport, maintenance and storage of the equipment. It is essential that all Operator Safet y M echanisms be connected and in operating condition prior to use for mowing.
1.4.1 Give complet e, undivided att ent ion to the job at hand.
1.4.2 Mow only in daylight or good artificial light. children or others are in the area!
1.4.3 When f easible, avoid operating the equipment in wet grass.
1.4.4 Use
EXTREME
traction and/or control could occur. Mow mowers, never up and down. Loss of control and/or loss of oper at or ’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. slopes greater than 20 degrees. Watch for dit ches, 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. grass is 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.
caution when mowing and/or turning on slopes as loss of
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Do Not
across
operate the mower when
slopes with walk behind
DO NOT
DO NOT
operate on
mow slopes when
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1.4.5 Stop the blades when crossing surfaces other than g r ass; and when transporting the mower to and fr om the area to be mowed.
1.4.6 Never operate the mower with defective guards, shields, or covers. Always have safety shields, guards, switches, and other devices in place and in proper working condition.
1.4.7
Do Not
change the engine governor setting s or over- speed t he engine. Operating an engine at excessive speed may increase the hazard of personal injury.
1.4.8 Place transmission in neutral, disengage blade dr ive before starting engine.
1.4.9 Start the engine caref u lly with feet well away from blades.
1.4.10 Keep hands, feet and clothing away from rotat ing 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 work ing on the mower.
After striking a foreign object (inspect the mower f or damage and make
repairs before restart ing 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 heig ht 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 f r om 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
mow without the grass deflector or entire grass collection system in
place and in proper working condition.
1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maint enance, follow the engine manufacture’s recom m endations precisely as stated in the engine manual.
1.5.2 When mak ing adjustments while the engine is running, such as carburetor and motion control linkage adjust m ent s, stand to one side and keep clear of moving/rotating components, such as engine screen, drive belts and sheaves.
Do Not
moving/rotating components..
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 f uel in a container specifically designed for this purpose in a cool, dry place.
wear loose fitting clothing or jewelry that could get tangled in
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1.5.5 Keep the mower and fuel container in locked storage to prevent children fr om 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 safet y can only be achieved if the m ower 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. 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 gr ease, dir t and debris from safety signs.
1.7.2 Safety signs must be replaced if t hey are m issing or illegible.
1.7.3 When new components are installed, be sur e 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 fr om Exmark Mfg. Co. Inc.
1.7.5 Safety signs may be affixed by peeling of f 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 inst r uction labels. They are critical to the safe operat ion of your Exmark commercial mower.
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14 HP Kawasaki,Briggs & Stratton, & 15HP Kohler – All Serial Nos. (Serial Nos. 150,000-189,999: 17 HP Kawasaki PART NO. 323688 LOCATION: Console
Serial Nos. 190,000 & Higher 15 & 17 HP Kawasaki PART NO. 323699 LOCATION: Console
14 HP Kawasaki & 15HP Kohler PART NO. 323689 LOCATION: RH Side of
15 & 17 HP Kawasaki PART NO. 323691 LOCATION: RH Side of Console
PART NO. 303508 LOCATION: Front of Mower Deck, Top Surface
17HP Kawasaki & 16HP B&S Serial Nos. 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
16 HP 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
PART NO. 413421 LOCATION: Left Rear on Top of Engine Deck
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”)
2. SPECIFICATIONS
2.1 MODEL NUMBER:
PART NO. 413327 LOCATION: Top of Cutter Deck, Under Belt Shield (48” & 52” Decks)
Serial Nos. 150,000 – 189,999: Serial Nos. 150,000 – 219,999: Serial Nos. 150,000 & Higher: Serial Nos. 160,000 & Higher: Serial Nos. 190,000 & Higher: Serial Nos. 220,000 & Higher:
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 using the research method, it should be a 90 oct ane
2.3.3 Fuel Filter: Replaceable in- line
2.3.4 Fuel Shut-Off Valve: 1/4 turn
2.4 SAFETY INTERLOCK SYSTEM
Operator must have transmission in neutral and blade clut ch disengaged to start engine. Release of O PC levers will cause the eng ine to stop if
transmission is
not
in neutral
MHP4816BV; MHP5216BV
MHP3614KA; MHP4814KA MHP3615KC; MHP4815KC MHP4817KA; MHP5217KA MHP4815KA MHP3615KA
unleaded
and/or
gasoline, 87 octane or higher. I n count r ies
blade clutch is
minimum
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 tur n ing. Parking brakes are engaged by locking dr ive contr ol levers in the “brake” position.
2.6 TRANSMISSION:
2.6.1 Peerless 700-061, f ive speeds f orward and one reverse.
2.6.2 Speed Range:
st
1 3
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)
2
rd
3.5 mph (5.63 km/h) Rev. 3. 1 m ph ( 4. 99 km/h)
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2.7 WHEEL DRIVE SYSTEM:
Banded double A-Section V-Belts, single top side idlers and r eplaceable bolt­on drive sheaves and brake drums.
2.8 TIRES
Size16 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 k Pa)..................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 suppor t 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).
Drive Front Caster
2.10 DIMENSIONS
2.10.1 Overall Width: 36” 48” 52”
Discharge chute down
Discharge chute up
(Transport only)
2.10.2 Overall Length: 36” 48” 52”
Overall Length
2.10.3 Curb Weig ht : 36” 48” 52”
Curb Weight
Weig ht s will vary slightly depending on engine option.
2.10.4 Overall Height: 42” (107 cm) ( all units)
2.10.5 Tread Widt h ( 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)
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)
77.7” 73.7” 75.9”
(197 cm) (187 cm) (193 cm)
507 lbs. 555 lbs. 583 lbs. (230 kg) (252 kg) (264 kg)
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Page 15
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
Stratton & 15 & 17 HP Kawasaki.......... 15-20 ft-lbs.
&
HP Kawasaki..................................25-30 ft-lbs.
& 14
Transmission Shifter-lever Nut...........................30-35 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) discharg e deflector hinge points so that the deflector is snug , but can be m oved up and down freely.
3.4 Refer to Parts Manual to help you identif y and locate par ts and their proper position.
3.5 Apply retaining adhesive “Fel-Pro Retaining I or Retaining II” or “ Loct it e RC609 or 680” on the two threaded studs from t he bolt bag and install into the two left holes underneath fuel tank. I nstall the fuel tank on top of the fuel tank support with the studs going through the slot s in t he suppor t. 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. flatwasher, then a spring, over each of t he studs and fasten with a 5/16 nyloc nut. Tighten 3/16 nylock nut fully then cack off a 1/2 t ur n. This is to allow for normal fuel tank expansion with changes in temper at ure and fuel levels.
3.6 Attach the fuel tank hose to the tank fitting and secur e with the clam p pr ovided. 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" bolt s ( with four spring disk washers against the head of each bolt) from the out side 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” SAE
FIG. 1
UPPER HANDLE MOUNTING
3.8 Route the throttle cable along the right side of the upper handle, under t he fuel tank support, and position the cable on the
Kohler) or
to the
right side
of engine
(B&S)
left
side of the engine
.
(Kaw &
Attach throttle cable to engine:
For Kohler and Kawasaki engines with “positive” detents in throttl e cabl e for the full throttle and idle positions.
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Page 16
a) Position the throttle control lever (on console) in t he full throttle (but not
choke) position. You will feel a detent when the thr ottle lever is approximately 3/4” from the upper end of the slot (this is full thr ot tle position).
b) Loosen clamp on engine control plate (See Figures 2, 3 & 4). Attach inner
wire of the throttle cable to the cont r ol plate lever and position cable clamp,
do not
tighten clamp.
FIG 2
KOHLER SPEED CONTROL
(THROTTLE CABLE HOOK-UP)
14 HP KAWASAKI SPEED CONTROL
(THROTTLE CABLE HOOK-UP)
Choke Link
Choke Adjusting Screw
15 & 17 HP KAWASAKI SPEED CONTROL
(THROTTLE CABLE HOOK-UP)
FIG 3
Control Plate Lever
Control Alignment Holes
Clamp
Control Cable
FIG 4
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Page 17
c) Pull cable upward (pull the cable to the right when facing the control plate
on 15 & 17 HP Kawasaki units) until alignment holes in contr ol plate lever and control plate line up. For Kawasaki 15/64” (6mm ) drill bit can be inserted through these two holes to align t hem. For Kohler use a 19/64” drill bit. Once the holes are aligned, tighten clamp onto throttle cable.
d) Be sure the
choke adjusting screw just contacts the choke l ever
when the throttle control is in the full throttle position. Choke link should not move when throttle control is moved to the full t h r ot tle 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
engine has been started
. Refer to Section 4. (O per ation Instructions).
unit has been assembled and the
For Kohler and 14 HP Kawasaki engines
:
Check the engine “STOP” posit ion by moving the throttle control fully to th e 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 r un in the "STOP" position, turn the kill switch adjusting screw inward until engine stops, then give it an addit ional 1/ 2 t o 3/4 turn to assure it will always function properly.
(The 14 HP Kawasaki kill switch is not adjustable)
For 15 & 17 HP Kawasaki engines
:
.
There is not a “STOP” posit ion. The engine will continue to run when the throttle control is moved past the rear det ent.
Turn the ignition switch to the “off” position to stop the eng ine.
For B&S Vanguard Engines:
a) Position the throttle control lever (on console) 1/8" from the upper end of
the slot. Route the thrott le cable along the right side of the upper handle, under the fuel tank support , and position the cable on 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 pullup on the cable to move the throttle linkage to the
full throttle
Tighten 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 f ig ure 5) Note that the threads on upper link age are left hand. See 5.2.2 for linkage adjustment.
right
side of the
position.
- 12 -
Page 18
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 transm ission. 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 fig u r e 7) . If it is not, remove lever and bend it slig htly to adjust. DO NOT Bend lever while it is attached t o 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 edg e of the bottom slot (See Figure 8) . Shifter plate can be adjusted side to side to adjust position of lever relative to t he slot in plate. Loosen the two bolts securing the shifter plate to the shifter lever legs. Adjust shifter plate and retighten bolts.
FIG. 6
SHIFTER LEVER
TO TRANSMISSION
FIG. 7
THIS CLEARANCE SHOULD BE EQUAL
- 13 -
Page 19
FIG. 8
THIS CLEARANCE SHOULD BE EQUAL
3.11 Install and adjust wheel drive linkag e s.
a) Screw threaded end of drive linkages into swivels in wheel drive idler arms. b) Insert clevis pin from bolt bag t hr ough drive linkage, lever and slot in the
neutral lock/park brake latches (See Figure 9). Make proper adjust m ents before adding hairpins.
Neutral Lock/Park Brake Latch
Clevis Pin
Drive Linkage
Drive Lever
FIG. 9
LEVER AND ROD ADJUSTMENT
c) Adj ust drive linkage length by threading into or out of the swivel until
there is a 3/16” to 1/4” clearance between the link age assembly and the bottom of the slot in the neutral lock/park brake lat ch. (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 dr ive levers to r emove any “slack” in the linkag e.
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.
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Page 20
Drive Linkage
Clevis Pin
Drive
Lever
Hairpin
Left Side
Shown
Reference for
Position Only
Neutral
Lock/Park
Brake Latch
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 appr oximat ely 1/4” of clearance between ends of drive levers and handle grips (See Figure 10)
Note: Adjustment should allow the brakes t o be engaged, yet allow the neutral lock/park brake latches to be moved into the park brak e posit ion, if not the brake link ages 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.
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 pr esence 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 t he very lower end of the handle where it attaches to the fuel tank support.
3.13 If machine is shipped without muffler installed, inst all 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 O wner’s Manual.
3.16
GREASE UNIT: NOTE:
UNIT IS NOT GREASED AT THE FACTORY.
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
4.1.1 Operator Presence Control (OPC) Levers: Locat ed on the upper handle assembly directly above the handle grips.
the OPC system senses that the operator 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
engine if either the tr ansm ission shift lever is
blade clutch is engaged
4.1.2 Dr ive 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 disengag e. 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.
When these levers are depressed,
and will kill the
not in the neutral
position or the
.
- 15 -
Page 21
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 m achine will stop. For straight ahead motion, sm oot hly release bot h drive levers to engage both drive wheels simultaneously.
4.1.3 Neut ral Lock/Parking Brak e 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 ar e 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).
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 t he 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 t he rear, or towards the operator.
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 t o 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 t he cont rol console’s right side. The throttle is used to control engine speed. Moving the throttle cont r ol 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 standar d feature. Moving the throttle to the full r ear “ Stop” position will shut off the engine ( B&S and 15 & 17 HP Kawasaki units use a key switch to shut off eng ine).
- 16 -
Page 22
and 15 & 17 HP Kawasaki only)
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. T ur n key to the “Off” posit ion t o shut engine off.
4.1.8 Fuel Shut-Off Valve: I nstalled 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 transporta t ion t o 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 t ank. It shifts the 5-
speed transmission into five forward gear s, neutral and reverse. Shift transmission only when drive levers are in the without drivelevers 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
neutral
: Located on the
position. Shifting
4.2 Pre-Start
DANGER
POTENTIAL HAZARD
In certain conditions gasoline is extremely flamm able and
highly explosive.
WHAT CAN HAPPEN
A fire or explosion from gasoline can bur n you, ot hers, and
cause property damage.
HOW TO AVOID THE HAZARD
♦ DO NOT
flame or where gasoline fumes may be ig nit ed by spark.
Refuel only in a well ventilated area, or refuel outdoor s.
Store gasoline in an approved container and keep it out of the
reach of children.
Add fuel before start ing the engine.
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” below the bottom of t he filler neck to allow for gasoline expansion and prevent fuel spillage.
If fuel is spilled,
away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated.
smoke while refueling, and stay away from an open
remove the cap of
DO NOT
Never
attempt to start the engine. Move
4.2.1 Fill fuel tank. For best r esults use only clean fresh regular grade gasoline with an octane rating of 87 or higher. Regular grade leaded gasoline may also be used; however, combustion chamber and cylinder head will require more fr equent service. See Engine Owner's Manual.
Do not add oil to gasoline.
- 17 -
unleaded
Page 23
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 inter ior car pets 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 refuel the equipment with its wheels on the ground.
If this is not possible, then refuel such equipment on a
truck or trailer from a portable container, rather t han 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
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 contr ols and oper ation of unit. See Controls section 4.1 and Operating I nst r uctions section 4.3.
4.3 OPERATING INSTRUCTIONS
4.3.1 Refer to Engine Owner’s Manual for detailed operat ing instructions regarding the engine.
4.3.2 Starting Engine: Operat or m ust have
transmission in neutral Open
fuel shut-off valve.
NOTE: Always engage the left and right neutral lock/park brake latches in the “park brake” position when start i ng the engine (See Section 4.1.3).
.
blade drive disengaged
and
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Page 24
POTENTIAL HAZARD
Engine exhaust contains carbon monoxide, which is
an odorless deadly poison.
WHAT CAN HAPPEN
Carbon monoxide can kill you and is also known to the
State of California t o cause birth defects.
HOW TO AVOID THE HAZARD
Do not run engine indoors or in a small confined area
where dangerous carbon monoxide fumes can collect.
For Kohler and Kawasaki engines: On a cold engine, place the thrott le in t he full forward “Choke” position. For a
15 & 17 HP Kawasaki engine turn key to “Run” position. Pull recoil rope to start engine.
With a cold eng ine, gradually return choke to the full throttle position after t he engine starts and warms up.
On a warm engine, place the throttle cont r ol “Fast” positions.
WARNING
midway
between the “Slow” and
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 thrott le in t he 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 t he engine starts and warms up.
On a warm engine, place the throttle cont r ol “Fast” positions.
4.3.3 Stopping Engine: Disengage blade dr ive, posit ion 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, m ove thr ottle lever to the full rear (“ St op”) position. For B&S and 15 & 17 HP Kawasaki engines; After cool down time, m ove the t hr ottle to the “midway” position. Turn key to the “Off” position and remove key.
4.3.4 Drive Lever/Neutral Lock/Park Brak e 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).
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)
DO NOT
choke B&S when warm.
midway
between the “Slow” and
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Page 25
POTENTIAL HAZARD
If the nuetral lock latches are not completely 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, fir m ly hold the dr ive 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 “ par k brake” position, shift transmission into desired gear. Squeeze both drive levers and move both neutral lock/park br ake latches from the “neutr al” or “park brake” position.
For straight ahead motion, sm oot hly release bot h dr ive 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.
release the drive levers.
CAUTION
POTENTIAL HAZARD
The rotating blades under the mower deck are
dangerous.
WHAT CAN HAPPEN
Blade contact can cause serious injury or kill you.
HOW TO AVOID THE HAZARD
♦ DO NOT
deck when the blades are engaged.
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 “ m idway” position. Push the blade engagement arm forward and down to engage blades. Accelerate to full throt t le t o begin mowing (See Section 4.1.4).
4.3.8 Blade Disengagement: Pull upward and back completely on the blade engagement arm to diseng age the blades. (See Section 4.1.4)
put hands or feet under the mower or mower
DANGER
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Page 26
4.3.9 Changing Gears When changing gears,
lock latches or park brak es. 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.
4.3 TRANSPORTING
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 ruck or
trailer.
Keep feet and legs out f r om under the unit when
loading and unloading.
If necessary, use assistance when loading.
always
squeeze drive levers and/or engage neutral
WARNING
Use a heavy duty trailer to transport the machine. Eng age 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 necessar y lig ht ing and marking as required by law.
5. MAINTENANCE & ADJUSTMENTS
5.1 PERIODIC MAINTENANCE
For B & S and 15 & 17 HP Kawasaki units
WARNING
POTENTIAL HAZARD
If you leave the key in the ignition switch, 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 pull the
wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug( s) .
- 21 -
Page 27
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.
5.1.1 Check engine oil level.
WARNING
Service Interval:
a) Make sure engine is stopped and on a level surface. b) Check with engine cool. c) Clean area around dipst ick. Remove dipstick and wipe oil off. Reinsert
the dipstick (
DO
screw into place for B&S engines). Remove dipstick and check oil
level.
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: 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 intak e scr een and from around engine
shrouding.
5.1.3 Clean grass build-up under deck and check mower blades. Service Interval:
See Engine Owner's Manual
DO NOT
DO NOT
See Engine Owner's Manual
Daily
screw into place for Kohler and Kawasaki engines;
.
operate the engine with oil level below the “L”
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 misfunction allowing the unit to fall, which could cause injury.
HOW TO AVOID THE HAZARD
DO NOT rely solely on mechanical or hydraulic jacks
for support. Use adequate jack stands or equivalent support.
- 22 -
Page 28
a) Disengage blade clutch. 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 t he sharp cutting edges of
the blades. g) Re-install the blades (if they were removed) and torque blade bolt s to 75-
80 ft. lbs. Be sure the spring disc washer cone is installed t oward the bolt
head (See Figure 13). h) Remove jack stands (or equivalent support) and lower deck t o ground.
FIG. 13
BLADE BOLT INSTALLATION
5.1.4 Check safet y 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 t hrottle, then
with drive levers and neutral lock/park brak e lat c hes in
position
, Shift the transmission int o gear and release OPC levers –
engine MUST st op.
Again, run engine at one-thir d throttle, move the transmission shift e r lever t o
neutral
, engage blade clutch and release OPC levers -
c) If machine does not pass any of these tests,
your authorized
EXMARK SERVICE DEALER.
IMPORTANT: It is essential that all Operator Safety Mechanisms, be in place and in proper operating condition prior to mowing.
5.1.5Check for loose hardware. Service Interval:
Daily
a) Stop engine and remove spark plug wire(s). b) Visually inspect machine for any loose hardware or any other possible
problem. Tighten hardware or correct the problem before operating.
MUST stop.
DO NOT
“park brake”
engine MUST stop.
operate. Contact
- 23 -
Page 29
5.1.6 Check Brake and Wheel Drive Linkage Adjustment Service Interval:
Daily
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:
See Engine Owner's Manual
5.1.8 Change engine oil. Service Interval:
See Engine Owner's Manual
NOTE: Change oil after first five (5) hours of operat ion. Follow engine manufacturers recommendations for future oil changes.
a) Disengage blade clutch. b) Stop engine and remove spark plug wire(s). c) Dr ain oil while engine is warm from operation. d) Remove the oil drain plug from t he r ight hand side of the engine. Allow oil
to drain, then replace drain plug.
e) Replace the oil filter as per Engine O wner's Manual. Clean around oil filter
and unscrew filter to remove. Bef o r e r e inst alling 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.
Do not overfill.
g) Start the engine and check for leaks. Stop engine and recheck oil levels.
5.1.9 Check grease level, input and output shaf t bearing wear on Peerless Transmission. (Replace gearbox grease yearly)
Service Interval:
160 hrs.
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 fr om t op of transmission. d) Remove shifter plate from top of transmission and the two leads from t he
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 tr ansm ission. Replace bear ings 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” f rom the gearbox bottom. If necessary, fill
to proper level with Peerless grease (Part No. 788067) i) Reinst all 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.
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Page 30
5.1.10 Check tire pressures. Service Interval:
40 hrs.
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 stat ed above. Measure circumference of each
drive tire. Adjust tire pressures within the above range to t ry to make tire circumferences match as closely as possible.
NOTE: Front caster tires have permanent tire sealant installed
.
5.1.11 Inspect Belt wear.
Service Interval:
40 hrs.
a) Stop engine and remove spark plug wire(s).
b) Remove deck support belt shield to check mower deck dr ive belt
condition.
c) Look under engine deck t o check the transmission drive and clutching
belt condition. d) Inspect wheel drive belt conditions e) Check all idler arms to be sure they pivot f reely. Disassemble, clean and
grease pivot bushings if necessary.
5.1.12 Inspect Blade Clutching Belt Tension. Service Interval:
Check every 2 hrs. for first 8 hrs.
operation then check every 40 hrs. thereafter.
a) Stop engine. b) Engage blade drive lever. c) Look through the r ound hole in t he 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 adjust m ent .
5.1.13 Lubrication
Service Interval:
Refer to Chart.
a) Stop engine and remove spark plug wire(s). b) Lubricate fittings with one to two pumps of SAE No. 2 multi-purpose gun
grease. Refer to t he following chart for fitt ing locations and lubrication schedule.
GREASE LUBRICATION CHART
FITTING LOCATIONS
INITIAL
PUMP
QUANTITY 36”
48” 52”
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 I dler 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
10 2 3 3 † Week ly
(S/N’s 150,000 to 159,999)
Under severe cutting conditions, two pumps of
SERVICE
INTERVAL
grease twice weekly may be more beneficial.
- 25 -
Page 31
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
NO. OF
PLACES
1. Blade Engagement Lever 1 Week ly d) Lubricate drive wheel hubs once a year. First remove wheel, then remove
hub cap. Lubricate the grease f itting on each wheel hub with an SAE No. 2 multipurpose gun grease, unt il 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.
5.1.14 Check spark plugs.
SERVICE
INTERVAL
Service Interval:
160 hrs.
a) Remove spark plugs, check condition and adjust plug gap or replace with
new plugs. See Engine Owner's Manual.
5.1.15 Remove engine shrouds and clean cooling fins. Service Interval:
See Engine Owner's Manual
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 sur faces 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:
As Required
a) A fuel filter is installed in t he fuel line between the fuel tank and the
engine. Replace when necessary.
5.1.17 Refer to Engine Operators Manual for det ailed maintenance regarding the engine.
5.1.18 Thread locking adhesives such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut­Type” 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.
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e) Lower Sheave retaining bolt on clutch arm.
Adhesives such as “Loctite RC/609 or RC/680”or“Fel-Pr o Pr o- Lock Retaining I or Retaining II” are used on the following:
a) OPC lever hubs and cross-shaft
NOTE: Care must be used hub, to the cross shaft whi ch 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. d) Between the cutter housing spindles 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
5.2.1 Cutting heig ht and anti-scalp roller adjustment.
not
to bond the bearing, next to each OPC
POTENTIAL HAZARD
When the two f r ont support rod hairpins are removed
from the mower deck, the weight of the tractor section may cause the front frame to rise suddenly
WHAT CAN HAPPEN
If the unit rises suddenly, injury may occur.
HOW TO AVOID THE HAZARD
Securely hold down the front of the unit when the f ront
support rod hairpins are removed.
a) Install hairpin clips in the holes shown on sketch below for the desired
cutting height (See Figur e 14) .
WARNING
FIG 14
ANTI-SCALP ROLLER BOLT INSTALLATION
ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT
b) Adjust ant i- 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. position lower. Rollers should maintain 1/4 in. (6.4 mm) minimum
For Maximum Deck Flotation
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, place rollers one hole
Page 33
clearance to ground.
Do Not
adjust rollers to support the deck. Be sure roller bolts and nuts are installed with the spring disc washer between head of bolt and mounting bracket.
roller may result
.
Torque to 40-45 ft-lbs., or loss of
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 r ollers and/or bolt failure(See Figur e 14) .
NOTE:
When anti-scalp rollers are placed in these 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 r ear corner of the engine deck.
a) Stop engine and remove spark plug wire(s). b) With blade drive eng aged, adjust the linkage length by loosening the
locknut on the turnbuckle and adjust ing the turnbuckle so that the bolt on the bellcrank and the indicator arm align with each other within 1/16”. See Figure 15. Tighten lock nut against turnbuckle.
FIG. 15
BLADE ENGAGEMENT LINKAGE
5.2.3 Blade Safety Switch:
a) Stop engine and remove spark plug wire(s). b) With blades diseng aged 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” f r om the switch body.
c) Be sure the bellcrank
DOES NOT
touch the switch body or 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 pr operly adjusted, the belt should have 1/2” of deflect ion with thr ee
pounds of pressure on the belt midway between the transmission and engine pulley.
5.2.6 Wheel drive belts and scraper s:
a) If wheel traction appears to be slipping, drive lever rods may be touching
bottom of neutral lock /park brake latch slot. T o adj ust, refer to directions in Section 3.11
NOTE: Wheel drive springs have three tension settings. Refer to Section
5.2.11.
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Page 34
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 Br ake Adjustment:
See 3.11
5.2.8 Wheel drive linkage adjustm ent:
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 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 for ce on t he lever r equired to shift gears.
Turn setscrew out (counterclockwise) to decrease force on lever required to shift gears. Factory setting is to tur n set screw 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). b) Disengage neutral lock/park brake latc hes and r elease dr ive levers to
lower spring force.
c) Remove the 5/16-18 whizlock nut securing the adjust m ent 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).
FIG. 16
DRIVE BELT TENSION
ADJUSTMENT POSITIONS
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5.2.12 Adjust Thr ot tle 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 e) Check for proper tire pr essur e in dr ive tires. Recommended tire pressure
for the drive tires is 12 to 16 psi. Hig her pr essures 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 circum ference. See 5.1.10. A
more uniform cutting height may be obtained with higher tire pressure on
rough terrain. A lower tire pressure pr ovides mor e flotation. 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 t he “ 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 15 & 17 HP
Kawasaki engines only). c) Make sure transmission is in “true neutral” posit ion. (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 fuelvalve is open. f) Check that the spark plug wire(s) ar e pr oper ly connected. g) Check for loose or faulty wiring connections. If it is necessary to
disconnect wire connectors, h) Check for corrosion at all wiring connections. Even minor corrosion may
cause a faulty connection. Clean connector terminals thor oughly with
electrical contact cleaner, apply dielectric grease and r econnect.
IMPORTANT: 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, cont act your authorized Exmark service
dealer.
Do Not
pull on the wires while disconnecting.
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ENGINE TROUBLESHOOTING
When a problem occur s , do not overlook the simple causes. For example, starting problems could be caused by an empty fuel tank.
The following table lists some of t he common causes of trouble. Do not attempt to service or replace major items or any items that call for
special timing or adjustment procedur es ( such as valves, governor , et c.). Have this work done by your
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
ENGINE TROUBLESHOOTING TABLE
NO
FUEL
IMPROPER
FUEL
DIRT IN
FUEL LINE
DIRTY AIR
FILTER
FAULTY
SPARK
PLUG
ENGINE
OVERLOADED
X XXXXX XXXXXXX XXX XXXX
XXXXXXXX XXXXXX X XXX
XXXX X
XXXX X XX X XX
XXX X
BLOCKED
FUEL
FILTER
INCORRECT
OIL
LEVEL
DIRTY
AIR
SCREEN
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7. WIRING DIAGRAM
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Page 38
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Page 39
8. WARRANTY
Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg. Co. Inc. ("Exmark") warrants on the terms and conditions herein, that it will repair , r eplace 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 y ear s, 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 wa r r ant ed for t wo full years from date of original retail purchase against defects in materials or workmanship. Exmark Mfg. will extend the Peerless 5-speed transmission manufacture r 's w ar r anty 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 respectiv e engine manufacturer. Please refer to t he engine manufacturers warranty statement that is included in the literature packet. Exmark is not authoriz ed 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 warrant y 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 warrant y 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 cov er: (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) r eplacement of ser vice 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, 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 r eplacement s r e sult ing from parts or accessories which have adver sely 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 t he operat or's manual and shall hav e returned to Exmark, within the prescribed time, the enclosed warranty registration card.
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Page 40
The sole liability of Exmark with respect to this warranty shall be repair and replacement as set for th herein. Exmark shall have no liability for any ot her cost, loss or damage, including but not limited to, any incidental or consequential loss or damage. In part icular, 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 aut hor ized 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 t he t erms of this warranty; (vii) any claims for lost revenue, lost profit or additional cost as a r e sult of a claim of br each of warranty; or (v iii) 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 lit erat ure 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 NO T 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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Page 41
SERVICE RECORD
Date
Description of Work Done
Service Done By
- 36 -
Page 42
NOTES
- 37 -
Page 43
ALIGN THIS EDGE WITH A VERTICAL SURFACE
(TREE, BUILDING, FENCE POST, POLE ETC.)
EXAMPLE: COMPARE
SLOPE WITH FOLDED
EDGE.
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
FOLD ALONG APPROPRIATE LINE
- 38 -
Page 44
SEE EXMARK’S COMPLETE
LINE OF PRODUCTS FOR TURF CARE
LAZER Z
LAZER Z™ HP
TURF RANGER
TURF TRACER
®
®
TURF TRACER® HP
VIKING HYDRO
METRO
METRO™ HP
SELF STEERING SULKY
GRASS CATCHER
MICRO-MULCH
©1997,1998, 1999 PART NO. 850662 EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 FAX (402) 223-5489 BEATRICE, NE 68310 ALL RIGHTS RESERVED PRINTED IN U.S.A.
(402) 223-6300
ACCESSORY
MF G . C O. INC .
®
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