For Serial Nos.
510,000 &
Higher
Part No. 103-7195
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.
IMPORTANT
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.
ii
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
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
3:00 p.m., central time, with an 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 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
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m.,
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight
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
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.
®
shipment of six (6) line items or less.
®
order of six (6) line items or less.
p.m., the dealer pays for the part and freight.
®
order to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
Plus
central time, Exmark pays for the part and freight.
and Exmark pays for the part.
®
order, he contacts Exmark by
®
order to his Exmark distributor by 1:00
®
Program are: Any wholegood or
iii
CONGRATULATIONS on the purchase of your Exmark Mower. This product has been car efully
designed and manufactured to give you a maximum amount of dependability and years of troublefree operation.
OPERATOR'S MANUAL
This manual contains assembly, operating, m aint enance, adjustment, and safety instr uct ions
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 ef ficient service in the field or at their ser vice
stations. They carry ample stock of ser vice part s or can secure them promptly for you from t he
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.
iv
TABLE OF CONTENTS
1. SAFETY.............................................................................................PAGE
1.1 Safety Alert Symbol......................................................................................1
1.2 Training.........................................................................................................1
1.3 Preparation............................................................................................... 1-3
1.4 Operation.................................................................................................. 4-5
1.5 Maintenance & Storage............................................................................. 5-6
1.6 Riding Attachments.......................................................................................6
1.7 Safety Signs.............................................................................................. 6-8
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
2.11 Torque Requirements................................................................................10
3. ASSEMBLY INSTRUCTIONS
3.1 to 3.18 Assembly...................................................................................10-13
4. OPERATION INSTRUCTIONS
4.1 Controls.................................................................................................13-15
4.2 Pre-Start................................................................................................15-16
4.3 Operation Instructions............................................................................16-18
4.4 Transporting................................................................................................19
5. MAINTENANCE & ADJUSTMENTS
5.1 Periodic Maintenance.............................................................................19-25
5.2 Adjustments...........................................................................................25-28
6. WASTE DISPOSAL
6.1 Motor Oil Disposal.......................................................................................28
7. TROUBLE SHOOTING
7.1 Mower Pulling Left or Right.........................................................................28
7.2 Mower Cuts Unevenly.................................................................................29
7.3 Engine Will Not Start...................................................................................29
8. WIRING DIAGRAM
........................................................................................30
9
.
WARRANTY
v
...............................................................................................31-32
1. SAFETY
1.1 SAFETY ALERT SYMBOL
This SAFETY ALERT SYMBOL is used both in this manual and on the machine to
identify important safet y messages which must be followed to avoid accidents. This symbol
means:
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
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 letter 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. Indicat es a pot ent ially hazardous situat ion
which, if not avoided, COULD result in death or serious inj ury.
CAUTION: Black lettering/Yellow background. I ndicat es a potentially hazardous situation
which, if not avoided, MAY result in minor or moderate injury.
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 attachments are 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 for
the eyes, ears, feet, and head is recomm 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.
1.3.3 While mowing, always wear substantial footwear and long trousers. Do not 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.
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 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 m ay 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” 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.
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
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.
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 deat h.
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
- 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, or
brush-covered 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 to the job at hand.
1.4.2 Mow only in daylight or good artificial light, keeping away from holes and hidden
hazards. Do Not operate the mower when 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 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 tir es lose t r action,
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 rises that change the operating angle,
as rough terrain could overturn the machine.
• Remove or mark obstacles such as rocks, t ree limbs, etc. from the m owing area.
Tall grass can hide obstacles.
• Use extreme care with grass catchers or attachment s. These can change the
stability of the machine and cause loss of contr ol.
1.4.5 Use EXTREME caution when backing up. LOOK BEHI ND 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 defective guards, 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 settings or over-speed the eng ine. Operating
an engine at excessive speed may increase the hazard of personal injury.
1.4.9 Place transmission in neutral, disengage PTO and engage park brake before
starting engine.
1.4.10 Start the engine carefully with feet well away from blades.
1.4.11 Keep hands, feet, and clothing away from r ot ating parts while the mower is being
operated.
1.4.12 Stop the engine, wait for all moving part s to stop, and remove spark plug wire(s) or
ignition key:
• Before checking, cleaning, or work ing on the mower.
• After striking a f or eign object (inspect the mower for damage and make
repairs before restart ing and operating the mower).
• Before clearing blockages.
• Whenever you leave the mower.
1.4.13 Stop the engine and wait for all moving parts to stop:
• Before removing the grass catcher.
• Before refueling.
• Before mak ing height adjustments.
1.4.14 Before stopping the engine, place t he throttle control 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-off valve. The fuel shut-off valve is used to
shut off the fuel when:
• The machine will not be used for a few days.
• During transport to and from the job.
• When parking inside a building.
1.4.16 This mower was designed for one operator only. Keep all others away from m ower
during operation.
- 5 -
1.4.17 Do Not mow with the grass deflector raised, rem oved or alt er ed unless t her e is a
grass collection system or mulch kit in place and working properly.
1.4.18 Be aware of the mower discharge and direct discharge away from others.
1.4.19 Do NOT operate the mower under the influence of alcohol or drugs.
1.4.20 Use care when approaching blind corners, shrubs, trees, or other objects that may
obscure vision.
1.5 MAINTENANCE AND STORAGE
1.5.1 For engine maintenance, follow the engine m anufacture’s recommendations
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 fuel in a container specif ically desig ned for this purpose in a cool, dry place.
1.5.4 Keep the mower and fuel container in locked stor age to prevent children from
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 tightness.
1.5.8 Keep all guards, shields, and all safety devices in place and in safe work ing condition.
1.5.9 Frequently check for worn or deterior ating components that could create 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
1.6.1 Use only Exmark riding attachments. T he 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 sur e t hat current safety signs are affixed to
the replaced components.
1.7.4 New safety signs may be obtained from your authorized Exmark equipment dealer
or distributor or from Exmar k 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 uct ion labels. They are
critical to the safe operation of your Exmark commercial mower.
- 6 -
(
PART NO. 1-303508
LOCATION: Front of Mower
Deck, Top Surface
PART NO. 1-303518
LOCATION: Transmission Shifter Plate
PART NO. 1-403143
LOCATION: RH Side of Rear Surface of Engine Deck
PART NO. 1-303517
LOCATION: LH Side of Rear Surface of Mower Deck
PART NO. 1-403005
LOCATION: RH & LH Corners
of Mower Deck
PART NO. 1-413206
LOCATION: Top of Cutter Deck, Under
Center Belt Shield (36”)
PART NO. 1-413327
LOCATION: Top of Cutter Deck, Under Belt
Shield
PART NO. 1-513746
LOCATION: On Engine Blower
Housing next to Muffler
& on Center Belt Cover
48” & 52” Decks)
PART NO. 1-413421
LOCATION: Left Rear on Top of
Engine Deck
- 7 -
PART NO. 1-553049
LOCATION: Front of Mower Deck Top Surface
PART NO. 103-1798
LOCATION: RH Side of
Console
PART NO. 103-1077
LOCATION: On Top LH Side of Mower Deck
PART NO. 103-2244
LOCATION: LH Side of Console
PART NO. 103-2245
LOCATION: RH Side of Console
PART NO. 103-1623
LOCATION: Console
- 8 -
PART NO. 98-5954
LOCATION: Under Mower Deck
Belt Shield(s)
2. SPECIFICATIONS
2.1 MODEL NUMBER: MHP3615KAC; MHP4815KAC
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 unleaded g asoline, 87 oct ane or higher. In countries using
the research method, it should be a 90 octane minimum.
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 PTO disengaged to start engine.
Release of OPC levers will cause the engine to stop if t r ansm ission is not in neutral
and/or PTO is engaged.
2.5 STEERING/BRAKE CONTROL:
Fingertip drive control levers provide independent speed control, br aking, and
neutral to each drive wheel for moving, stopping , and power turning. Parking
brakes are engaged by locking drive control levers in the “brake” position.
2.6 TRANSMISSION:
2.6.1 Peerless 700-070A, five speeds forward and one reverse.
st
2.6.2 Speed Range: 1
2
3
2.7 WHEEL DRIVE SYSTEM:
Banded double A-Section V-Belts, single topside idlers , and r eplaceable bolt-on
drive sheaves and brake drums.
2.8 TIRES:
2.9 DECK
Size 16 x 6.50-8 9 x 3.50-4
Quantity 2 2
Tread Turf Master Smooth
Ply Rating 4
Pressure 14 psi (97 kPa)
Pneumatic (Air-Filled) Semi-Pneumatic
2.9.1 Cutting Width: Model 36 in. .......35.25 in. (89.5 cm)
Model 48 in. .......47.25 in. (120.0 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
2.9.4 Type of Drive: Manual engagement of belt with over-cent er 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” ( 1.3 cm) increments from 1. 5” ( 3.8 cm) to 4 1/2” (11.4 cm).
2.0 mph (3.22 km/h) 4th 4.1 mph (6.60 km/h)
nd
2.7 mph (4.35 km/h) 5
rd
3.5 mph (5.63 km/h) Rev. 3. 1 m ph ( 4. 99 km/h)
Drive Front Caster
th
6.2 mph (9.98 km/h)
- 9 -
2.10 DIMENSIONS
2.10.1 Overall Width:
2.10.2 Overall Length:
2.10.3 Curb Weight:
∗ Weights will vary slightly depending on engine option.
2.10.4 Overall Height:
2.10.5 Tread Width (to outside of tires) :
Discharge chute down
Discharge chute up (Transport only)
36” 48”
77.0” (196 cm) 73.0” (185 cm)
36” 48”
517 lbs. (234 kg) 565 lbs. (256 kg)
36” 48”
46.25” (117.5 cm) 58.25” (148.0 cm)
36.1” (91.7 cm) 48.1” (122.2 cm)
36” 48”
44.1” (112 cm) 44.1” (112 cm)
36” 48”
35.2” (89.4 cm) 35.2” (89.4 cm)
2.11 TORQUE REQUIREMENTS
BOLT LOCATION TORQUE
Blade Mounting Bolt.................................................. 115-120 ft-lbs. (156-163 N-m)
Cutter Housing Spindle Nut ...................................... 140-145 ft-lbs. (190-197 N-m)
Mower Deck Support/Engine Deck Mount......................30-35 ft-lbs. (40-47 N-m)
Engine Mounting Bolts (15 HP
Transmission Shifter-lever Nut.......................................30-35 ft-lbs. (40-47 N-m)
Anti-Scalp Roller Bolts....................................................40-45 ft-lbs. (54-61 N-m)
Wheel Lug Nuts .............................................................90-95 ft-lbs. (122-129 N-m)
Kawasaki)......................15-20 ft-lbs. (20-27 N-m)
3. ASSEMBLY INSTRUCTIONS
3.1 Uncrate unit, and remove upper handle assembly, fuel tank, and linkages from top
of crate.
3.2 Remove and open the bolt bag.
3.3 Loosen the 5/16" hardware at the two (2) discharge deflector hinge points so that
the deflector is snug, but can be moved up and down freely.
3.4 Refer to Parts Manual to help you identify and locate parts and their proper posit ion.
3.5 Apply retaining adhesive “Fel-Pro Retaining I or Retaining II ” or “Loctite RC609 or
680” on the two threaded studs from t he bolt bag and install into the two left holes
underneath fuel tank. I nst all the fuel tank on top of t he fuel tank support with the
studs going through the slot s in t he support. Install two 5/16-18 x 3/4” screws with
a 5/16” SAE flat washer and 5/16” lock washer into the t hreaded holes in the right
side of the fuel tank . Do not over t ighten. Place a 5/16” SAE flat washer, then a
spring, over each of the studs and f ast en with a 5/16 nyloc nut. Tighten 5/16 nyloc
nut fully then back off a 1/2 turn. This is to allow for normal fuel tank expansion
with changes in temperature and fuel levels.
3.6 Attach the fuel tank hose to the tank fitt ing and secure with the clamp provided.
3.7 Position the lower end of the handle assembly on the outside of the upper rear
section of the fuel tank and handle support. Install four 3/8-16 x 1" bolts (with four
spring disk washers against the head of each bolt) from the outside in. Secure
using four 3/8" whizlock nuts on the inside of each handle support and tighten until
the spring disk washers are flat (See Fig ur e 1) .
- 10 -
FIGURE 1
UPPER HANDLE MOUNTING
3.8 Route the thrott le cable along the right side of the upper handle, t hrough the clip,
under the fuel tank support , and position the cable on the left side of the engine.
Attach throttle cable to engine:
a) Position the throttle control lever (located on console) ¼” (6mm ) from the upper
end of the slot.
b) Att ach inner wire of the throttle cable to the top hole in t he t hrottle control lever
as shown in Figure 2.
c) 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 2
SPEED CONTROL (THROTTLE CABLE HOOK-UP)
3.9 Connect the PTO eng agement linkages. Loosen jam nut and r emove turnbuckle
from lower linkage. Screw turnbuckle onto both upper and lower linkages
simultaneously. (See figure 3) Not e that the threads on upper linkage are left
hand. See 5.2.2 for linkage adjustment.
Note: ECS handles have the PTO linkage on the inside of the PT O engagement
lever tab and the hairpin on the outside.
FIGURE 3
PTO ENGAGEMENT LINKAGE
- 11 -
3.10 Install and adj ust shifter lever.
a) Remove the 3/8” nyloc nut and spring disc washer from the st ud on t op of the
transmission. Install the shif ter lever through slot in shift er lever plat e and
onto the stud on top of transm ission. Be sur e the square-hole washer
remains between the lever and transmission. Replace the spring disc washer
and nyloc nut (see figure 4). Tor que 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 bott o m of the slot (See
figure 5). If it is not, remove lever and bend it slightly to adjust. DO NOT bend
lever while it is attached to transmission. Reinstall lever and tighten hardware.
c) Shift to neutral position. Lever should not contact the left edged of the upper
slot. Push lever down. Lever should not contact the right edge of the bottom
slot (See Figure 6). Shifter plate can be adjusted side to side to adjust posit ion
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 5
THIS CLEARANCE SHOULD BE EQUAL
FIGURE 4
SHIFTER LEVER
TO TRANSMISSION
FIGURE 6
THIS CLEARANCE SHOULD BE EQUAL
3.11 Install and adjust wheel drive linkages.
a) Locate the (2) dr ive lever linka ges which have a balljoint and jam nut installed
on one end.
Locate the (2) 5/16-18x1-3/4 hex head cap screws and (2) 5/16-18 nyloc nuts
in the bolt bag.
NOTE: During set up at the factory, an “L” or “R” may have been marked on
the flats of the balljoints. If the balljoints are m arked, assemble accordingly.
If the balljoints are not m arked, they may be assembled on either side.
Thread the linkage into the swivel located on the wheel drive idler arm.
Thread in until the flat edge of the drive lever aligns with the bottom of the
roller notch in the neutral lock/par k brake latch when the cap screw is inserted
through the hole in the drive lever and the hole in the ball joint. Secure with a
nyloc nut. Tighten nyloc nut. Repeat for t he other side. See figures 7 and 8.
- 12 -
b) The bend in the drive lever linkages should be posit ioned downward and
slightly outward. If adjustm ent is needed, loosen jam nut below balljoint and
rotate linkage. Tighten jam nut.
Shift transmission lever to f ifth gear. Insure that bend in right hand linkage is
rotated outward enough that linkage clears shifter lever.
If linkage is rotated too far out, ball j o int m a y bind when drive lever is released
into the “drive” position. Insure that this does not happen.
FIGURE 7
DRIVE LEVER LINKAGE INSTALLATION
FIGURE 8
DRIVE LEVER SETTING
c) Adjust brakes by adjusting wingnut on the upper end of each brake rod.
Tighten the wingnut until the brakes engage when the drive levers are
squeezed enough allow the neutral lock/park br ake latches to be placed into
the “park brake” posit ion. See Figure 7.
d) Check for correct adjustment:
Place the drive levers in the “park brake” position. The mower should not
move forward or backward. If it does, tighten the wingnuts.
Place the drive levers in the “neutral lock” position. The mower should
move forward and backward freely. If it does not, loosen the wingnuts.
NOTE: The neutral lock/park brake latches must be easily moved into the
park brake position; if not the brake linkages must be adjusted again.
- 13 -
3.12 Route the long unattached wiring harness lead, up the left hand side of the handle
and connect the connector on the end of the shorter lead to the key switch.
Connect the two flag terminals that are on the longer lead (in any order) to the
operator presence control switch terminals underneath the control console.
Fasten the lead to the handle with two small wire ties from the bolt bag , one at the
upper end of the handle next to the console, and one at t he very lower end of the
handle where it attaches to the fuel tank suppor t. Fasten the lead to the small hole
in the channel under the console using another small tie from the bolt bag.
3.13 If machine is shipped without muffler installed, install muffler with hardware provided.
3.14 Service Engine: Refer to Eng ine O wner’s Manual.
3.15 GREASE UNIT: NOTE: UNIT IS NOT GREASED AT THE FACTORY.
Refer t o 5. 1. 13, for locations and grease amounts.
3.16 Follow pre-start inst r uctions as outlined in 4.2.
3.17 Perform any needed adjustments as outlined in the Adjustm ent Section.
4. OPERATION INSTRUCTIONS
4.1 Controls
4.1.1 Familiarize yourself with the controls and operation of the unit.
Carefully read the following information about the controls and their operation.
4.1.2 Operator Presence Control (OPC) Levers
: Located on the upper handle assembly
directly above the handle grips. See Figure 9. When these levers are
depressed, 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 positi on and will kill
the engine if either the t r ansmission shift lever is not in the neutral position or t he
PTO is engaged. See Figure 9.
4.1.3 Dr ive Levers
: Located on each side of the upper handle assembly directly below the
handle grips. See Figure 9. T hese levers individually control the clut ching action of
the wheel drive belts and the brakes. When the drive levers are all of the way out,
the brakes disengage and the wheel drive belts engage.
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 t ur n to the left or right r espect ively.
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/Parking Brake Latch
: Located at the end of the handles. The purpose
of these latches is to allow the operator t o 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 not engaged and the park brake is engaged.
See Figure 9.
Apply parking brakes whenever leavi ng the operators position.
- 14 -
FIGURE 9
NEUTRAL LOCK/PARK BRAKE LATCH
4.1.5 PTO Engagement
To engage the blades, push the lever forward, or away from the operator, until t he
linkage locks over-center.
To disengage the blades, pull the lever to t he r ear, or towards the operator.
4.1.6 Choke Control
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 st ar t ed m ove the
choke control to the “OFF” position. DO NOT run warm engine with the choke in
the “ON” position.
4.1.7 Throttle Control
control engine speed. Moving the throttle contr ol forward will increase engine
speed and moving it to the rear will decrease engine speed.
4.1.8 “Off-Run” Switch
the engine to be started. T ur n key to the “Off” posit ion to shut engine off.
4.1.9 Fuel Shut-Off Valve
engine. The fuel shut-off valve is used to shut off the flow of fuel when parking
inside a building, during transportation to and from the job sites, and when the
machine will not be used for a few days.
Rotate valve 1/4 turn clockwise to shut fuel off. Rotate valve 1/4 turn counter-
clockwise to turn fuel on.
4.1.10 Transmission Shif t Lever:
Located under the contr ol console and behind the fuel tank. It shifts the 5-speed
transmission into five forward gear s, neutral, and reverse. Shift tr ansm ission only
when drive levers are in the neutral position. Shifting without dr ive levers in neutral
may cause damage to the transmission.
: Located on the left side of t he upper handle.
: Choke is used to aid in starting a cold eng ine.
: Located on the control console’s right side. The throttle is used to
: Located on the console. Turn key to t he “ Run” posit ion to allow
: Installed in the fuel line midway between the tank and the
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.
4.2 PRE-START
4.2.1 Refer t o Maintenance and Adjust m ent Section 5 and perform all of t he necessary
inspection and maintenance steps.
4.2.2 Fill fuel tank. For best results use only clean fresh regular grade unleaded
gasoline with an octane rating of 87 or higher. Regular grade leaded ga soline m ay
also be used; however, combustion chamber and cylinder head will require more
frequent service. See Engine Owner's Manual.
- 15 -
Do not add oil to ga soline.
Do not overfill fuel tank. Never fill the fuel tank so that the fuel level rises above a
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.
4.2.3 Make sure you understand the controls, their locations, their functions and their
safety requirements.
4.3 OPERATING INSTRUCTIONS
4.3.1 Refer to Engine Owner’s Manual for detailed oper at ing instructions regarding t he engine.
4.3.2 Starting Engine
Open fuel shut-off valve.
NOTE: Always engage the left and right neutral lock/ park brake latches in the
“park brake” position when starti ng t he engi ne ( See Fi gure 10 ( d) ) .
Pull out the choke control. Place the t hr ottle control midway between the “Slow” and
“Fast” positions. Turn the key to “Run” position. Pull recoil rope to start engine.
After the engine warms up, gradually push in 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.
4.3.3 Stopping Engine
and position transmission in neutral. Place the throttle control midway between the
“slow” and “fast” positions. Allow the engine t o r un a m inim um of 15 seconds; then
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
To lock the drive levers in “neutral lock”, squeeze the drive levers to the “neutral”
position. See Figure 10 (b). Place thum bs on the inner thumb lobe of the neutral
lock /park brake lat c hes and r otate them to the “neutral” position. See Figure 10
(c). Release the drive levers.
To lock t he drive levers in “park brake”, squeeze the drive levers farther 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 10 ( d ) . Release
the drive levers.
: Operator must have PTO disengaged and transmi ssi on in neutral.
: Lock the drive levers in the “park br ake” position, disengage PTO,
:
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, slight ly squeeze the dr ive levers
while placing thumbs on the outer thumb lobe of t he neut ral lock/park brake lat c hes
(or the index finger on the front lobe) and rotate them from under the drive levers.
Slowly and carefully release the dr ive levers. See Figure 10 (a).
- 16 -
(a) (b)
(c)
(d)
FIGURE 10
DRIVE LEVER, NEUTRAL LOCK/PARK BRAKE LATCH OPERATION
4.3.5 Drive Wheel Engagement and T urning
: With dr ive levers in “neut r a l” or “park brake”
position, shift transmission int o desir ed gear. Squeeze both drive levers and move
both neutral lock/park br ake latches from the “neut ral” or “park brake” posit ion to
the “drive” position.
For straight ahead m ot ion: Smoothly release both drive levers to engage drive wheels.
For turning: Squeeze the right hand drive lever to turn right and the left hand dr ive
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 the drive levers. Shift
transmission to neutral.
4.3.7 PTO Engagement
:
DANGER
POTENTIAL HAZARD
♦ The rotating blades under the mower deck ar e
dangerous.
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
deck when the blades are engaged.
- 17 -
POTENTIAL HAZARD
♦ An uncovered discharge opening will allow objects to be
thrown in an operator’s or bystander’s direction. Also,
contact with the blade could occur.
WHAT CAN HAPPEN
♦ Thrown objects or blade contact can cause serious
injury or death.
HOW TO AVOID THE HAZARD
♦ Never operate the mower with the discharge deflector
raised, removed, or altered unless there is a g r ass
collection system or mulch kit in place and working
properly.
Be sure that all persons are clear of mow er deck and di scharge area bef ore
engaging the PTO. Set throttle to “ m idway” position. Push t he PTO engagement
arm forward and down to engage blades. Accelerat e to full throttle to beg in
mowing (See Section 4.1.4).
4.3.8 PT O Disengagement
arm to disengage the blades. (See Sect ion 4.1.4)
4.3.9 Changing Gears
When changing gears, always squeeze drive levers to the neut r al position. The shift
lever may be moved with a knee or by hand (engage the neutral lock lat ches if
shifting by hand).
: Pull upward and back completely on the PTO engagement
DANGER
NOTE: Reverse gear is reverse assist only, the operator must pull t he uni t
backwards.
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 truck 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 - o ff valve is closed.
Use a heavy duty trailer to transport the machine. Engage the park br akes 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 rel y sol el y on the parking brake to hold machine on trailer.
- 18 -
5. MAINTENANCE & ADJUSTMENTS
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
5.1 PERIODIC MAINTENANCE
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 cool.
c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinser t 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 t he Engine Owner’s Manual to
bring the oil level up to the “FULL” mark on the dipstick.
DO NOT OVERFILL.
IMPORTANT: DO NO T operate the engine with oil level below the “LOW” (or
“ADD”) mark 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 m oving par t s t o stop. Remove key or spark plug
wire(s).
b) Clean all debris from eng ine air intake screen and from ar ound engine
shrouding.
5.1.3 Clean grass build-up under deck and check mower blades
.
.
.
Service Interval: Daily
- 19 -
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 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.
a) Disengage PTO.
b) Stop engine and wait for all m oving par t s t o stop. Remove key or spark plug
wire(s).
c) Raise deck and block up using proper safet y precautions.
d) Clean out any grass build-up from underside of deck and in deck discharg e
chute.
e) Inspect blades and sharpen or replace as required.
f) If blade removal is necessary, be careful for t he shar p cut ting edges of the
blades.
g) Re-install the blades (if they were removed) and torque blade bolts to 115-120
ft. lbs. Be sure the spring disc washer cone is installed t oward the bolt head
(See Figure 11).
CAUTION
CAUTION
POTENTIAL HAZARD
♦ Operating a mower deck with loose or weakened
blade bolts can be dangerous.
WHAT CAN HAPPEN
♦ A loose or weakend blade bolt could allow a blade
rotating at a high speed to come out from under the
deck, causing serious injury or property damage.
HOW TO AVOID THE HAZARD
♦ Replace the blade bolt after striking a foreign object.
(Use only Exmark replacement parts PN 103-1026 -
blade bolt and PN 1-513208 – spring disc washer).
♦ DO NOT lubricate the threads of the bolt or spindle
before assembly.
♦ Torque the blade bolt to 115-120 ft. lbs.
h) Remove jack stands (or equivalent support) and lower deck t o ground.
- 20 -
FIGURE 11
BLADE BOLT INSTALLATION
5.1.4 Check saf et y interlock system
.
Service Interval: Daily
a) For your safety, your Exmark mower is equipped with Operator Presence
Controls (OPC). When either the PTO is engaged, or the transmission shift
lever is not in neutral and both hands are removed from the handles, the
mower engine MUST stop.
b) Check OPC cir c uit s . Clear the area. Run engine at one-third throttle, then
with drive levers and neutral lock/park brak e lat c hes in “park brake”
position, Shift the transmission into gear and release O PC levers – engine
MUST stop.
Again, run engine at one-thir d t h r ot tle, move the transmission shifter lever t o
neutral, engage PTO and release OPC levers - engine MUST stop.
c) If machine does not pass any of these tests, DO NOT operate. Cont act
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.
5.1.5 Check f or loose har dware
.
Service Interval: Daily
a) Stop engine and wait for all m oving parts to stop. Remove ignition k ey or
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 .
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
a) Stop engine and wait for all moving parts t o st op. Remove key or spark plug
wire(s).
b) See engine owners manual for cleaning instructions.
5.1.8 Change engine oil
.
Service Interval: See Engine Owner's Manual
NOTE: Change oil after first five (5) hours of operat i on. Follow engine
manufacturer’s recommendations for future oil changes.
- 21 -
a) Stop engine and wait for all m oving par t s t o stop. Remove key or spark plug
wire(s).
b) Drain oil while engine is warm from operation.
c) The oil drain valve is located on left hand side of engine.
Place pan under machine to catch oil and turn valve counter clockwise with a
10 mm wrench to open valve. Allow oil to drain, then turn valve clockwise to
close.
d) Replace the oil filter as per Engine Owner's Manual. Clean around oil filter and
unscrew filter to remove. Before reinstalling new filter, apply a thin coat ing of oil
on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts
the filter adapter then t ighten filter an additional 2/3 to 3/4 turn.
e) Clean around oil fill cap and remove cap. Fill t o the specified capacity and
replace cap. Use oil as specified in Engine Owners Manual. Do not overfill.
f) Start the engine and check for leak s. Stop engine and recheck oil levels.
5.1.9 Check grease level, input and output shaft bearing wear on Peerless Transmission
.
(Replace gearbox grease yearly)
Service Interval: 160 hrs.
a) Stop engine, wait for all moving parts to st op, and remove key or spark plug
wire(s).
b) Place drive levers and neutr al lock/park brake latches in the neutral lock
position.
c) Remove shift er lever from top of transm ission.
d) Remove shifter plate from top of transmission and t he t wo leads f r om the
neutral start switch.
e) Release the t ension on t he transmission belt.
f) Check for side play caused by bearing wear on the input and out put shafts of
the transmission. Replace bearings if necessary.
g) Remove the six bolts that fasten the upper case to the lower case and
carefully remove the upper case half.
h) Check t he 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 bott om . 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 5.2.5.
5.1.10 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 stop. Rem ove k ey or spar k plug
wire(s). Check air pressure in drive tires; recom m ended tire pressure 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.
5.1.11 Inspect Belt wear
.
Service Interval: 40 hrs.
a) Stop engine and wait for all m oving par t s t o stop. Remove key or spark plug
wire(s).
- 22 -
b) Remove deck support belt shield to check mower deck drive belt condition.
c) Look under engine deck to check the transm ission drive and clutching belt
condition.
d) Inspect wheel drive belt conditions
e) Check the wheel drive idler arms to be sure t hey pivot freely. Disassemble,
clean and grease pivot bushings if necessary.
5.1.12 I nspect PTO Clutching Belt Tension
.
Service Interval: Check every 2 hrs. for first 8 hrs. operation then check every
40 hrs. thereafter.
a) Stop engine and wait for all moving parts to stop.
b) Engage PTO lever.
c) Look through the round hole in the left rear corner of the engine deck to
inspect PTO clutching belt tension. Bolt on PTO engagement linkage
bellcrank and indicator arm should align within 1/16” ( See figure 14). Refer
to section 5.2.2 for adjust m ent .
5.1.13 Lubrication
Service Interval: Refer to Chart.
a) Stop engine, wait for all m oving par ts to stop, and remove key or spark plug
wire(s).
b) Lubricate fittings with one to two pumps of NGLI grade no. 2 mult i- purpose gun
grease. Refer to t he following chart for fitting locations and lubrication schedule.
GREASE LUBRICATION CHART
FITTING
LOCATIONS
1. Caster Wheel Bearings 12 2 2 8 hours
2. Caster Pivots 2 2 2 8 hours
3. Drive Wheel Id ler Ar m 2 2 2 8 hours
4. PTO Engagement Bellcr ank 1 1 1 40 hours
5. Clutch Arm Pivot 1 1 1 40 hours
6. Mower Deck Idler Pivots 2 1 1 Yearly
7. Trans. Output Shaft Coupler 2 2 2 40 hours
No. 5 (Clutch Arm Pivot)
Located Under Engine Deck
No. 7 (Trans. Coupler)
Located Below Fuel Tank Support
No. 3 (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.
INITIAL
PUMP
QUANTITY
36”
48”
SERVICE
INTERVAL
SPRAY LUBRICANT CHART
PIVOT POINT
1. PTO Engagement Lever 1 Weekly
NO. OF
PLACES
SERVICE
INTERVAL
- 23 -
d) Lubricate drive wheel hubs once a year. First remove wheel, then remove
hub cap. Lubricate the grease fit t ing on each wheel hub with an NGLI grade
no. 2 multipurpose gun grease, until grease appears through outer bearing.
Reinstall hub caps and wheels.
e) Replace 5-speed gearbox grease yearly. Use 18 oz. of Peerless grease
(Part No. 788067). See Section 5.1.9.
5.1.14 Check spark plugs
.
Service Interval: 160 hrs.
a) Remove spark plugs, check condit ion and adj ust 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, wait for all m oving par ts to stop, and remove key or spark plug
wire(s).
b) Remove cooling shrouds from engine and clean cooling fins. Also clean dust,
dirt and oil from external surfaces of engine which can cause improper cooling.
c) Make sure cooling shrouds are properly reinstalled. Operating the engine
without cooling shrouds will cause engine damage due to overheating.
5.1.16 Change fuel filter
.
Service Interval: As Required
a) A fuel filter is installed in the fuel line between the fuel tank and the engine.
Replace when necessary.
5.1.17 Refer to Engine Operators Manual for detailed maintenance regarding the engine.
5.1.18 Thread locking adhesives such as “Loctite 242” or “Fel- Pr o, Pr o- Lock Nut-Type” are
used on the following fasteners:
a) Transmission drive sheave setscrews.
b) W heel dr ive sheave setscrews on transmission output shafts.
c) OPC lever setscrews.
d) Sheave retaining bolt in end of engine crankshaft.
e) Lower Sheave retaining bolt on clutch arm.
f) Fuel tank bulkhead fitting threads ( S/ N 370, 000 & higher).
g) Cutt er housing spindle nut.
Adhesives such as “Loctit e RC/ 609 or RC/680”or“Fel-Pro Pro-Lock Retaining I or
Retaining II” are used on the following:
a) OPC lever hubs and cross-shaft
NOTE: Care must be used
not to bond the bearing, next to each OPC hub, t o the
cross shaft which could cause bindi ng of the OPC levers and erratic operation.
b) Fuel t ank studs, where studs are inserted into tank.
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 clut ch ar m assembly between bearings and shaft and between lower
sheave and shaft.
c) Between transmission input shaft and sheaves.
d) Between transmission output shafts and sheaves.
e) Between transmission output shaft s and bear ings.
- 24 -
5.1.20 Mobil HTS grease (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.
c) Under t op cutter housing bearing guard.
5.1.21 Dielectric grease
corrosion and loss of contact.
is used on all blade type electrical connections to prevent
5.2 ADJUSTMENTS
5.2.1 Cutting height and anti-scalp roller adjustment .
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 r ont
support rod hairpins are removed.
a) Stop engine, wait for all moving parts to st op, and remove key or spark plug
wire(s).
b) Install hairpin clips in the holes shown on sketch below for the desired cutting
height (See Figure 13).
IM PO RTANT: To maintain correct cutting height and rake, check the
following for proper adjustment .
1. The front and rear hair pins ar e in the same holes with the proper spacers
under the hair pins (See Figure 12).
2. The tire pressures are set as directed in Sect ion 5. 1. 10.
3. The length of the rear deck support link assemblies should average 6.89”
(approximately 6 7/8”) (17.5 cm) from the center of the balljoint to the
center of the furthest hole (See Figure 12).
NOTE: All (4) pins must equally support the weight of the deck. Adjustment
in the length of the rear deck support assemblies may be necessary. If one
side of the frame is long er than 6.89” (17.5 cm), than the opposit e side m ust
be shorter by the same amount.
WARNING
FIGURE 12
CUTTING HEIGHT ADJUSTMENT
- 25 -
FIGURE 13
ANTI-SCALP ROLLER BOLT INSTALLATION
ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT
c) Adjust anti-scalp rollers for Normal Operating Conditions. Stop eng ine and
wait for all moving parts to stop. Place rollers in one of the positions shown in
Figure 13. Rollers will maintain 3/4 in. (19 m m) clearance to the ground to
minimize gouging and roller wear or damag e. For Maximum Deck Flotation,
place rollers one hole position lower. Rollers should maintain 1/4 in. (6.4 mm)
minimum clearance to ground. Do Not adjust r oller s t o suppor t the deck. Be
sure the spring disc washer is installed with the cone towards the nut. Tighten
nuts properly.
d) W hen operating in extremely rough conditions it may be necessary to position
the anti-scalp rollers one or two holes higher than descr ibed in " b" to prevent
damage to the rollers and/or bolt failure (See Figure 13).
NOTE: When anti-scalp rollers are placed in these positions, reduced deck
flotation will result.
5.2.2 PTO engagement Linkage
: Located between the PTO engagement lever on t he
left handle and the left r ear cor ner of the engine deck.
a) Stop engine and wait for all m oving par ts to stop.
b) W it h PTO engaged, adjust t he linkage length by loosening the lock nut on t he
turnbuckle and adjusting the tur nbuckle so that the bolt on the bellcrank and
the indicator arm align with each other within 1/16” ( 1. 6 m m). See Figure 14.
Tighten locknut against t ur nbuckle.
FIGURE 14
PTO ENGAGEMENT LINKAGE
5.2.3 PTO Safety Switch
: Mounted to a tab on the inside left side of the fuel tank support.
a) Stop engine and wait for all m oving par t s t o stop. Remove key or spark plug
wire(s).
b) With PT O disengaged and the bellcrank touching the rear of the slot in the
engine deck, adjust the PT O safety switch (if needed) until the bellcrank arm
is 5/16” (8 mm) from the switch body.
c) Be sur e t he bellcr ank DOES NOT touch the switch body or damage to the
switch could occur.
d) Retighten PTO switch mounting har dware.
- 26 -
5.2.4 Engine to Cutt er Deck Belt
:
No adjustment necessary.
5.2.5 Transmission Belt Adjustment
:
a) Stop engine and wait for all moving parts to stop. Remove key or 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 oper ly adjust ed, the belt should have 1/2” (12 mm) of deflection with three
pounds (13.3 Nt) of pressure on the belt midway between the transmission and
engine pulley.
5.2.6 Wheel drive belts and scraper s
:
Be sure mud and grass scraper, on each side, is adjust ed pr oper ly 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.
NOTE: Wheel drive springs have three tension settings. See Section 5.2.11.
5.2.7 Brake Adjustment
:
See 3.11 steps c) and d)
5.2.8 Wheel drive linkage adjustment
:
See 3.11 steps a) and b)
5.2.9 Shifter lever adjustment
:
See 3.10
5.2.10 Shifter detent adjustment
:
Transmission shifter detent can be adj ust ed by adjust ing the setscrew on the
backside of transmission located just behind the neutral start switch. Turn setscr ew
in (clockwise) to hold the transmission shifter more positively in each gear and to
increase the force on the lever required to shift gears.
Turn setscrew out (counterclockwise) to decrease force on lever required to shift
gears. Factory setting is to 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.
5.2.11 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 eng ine, wait for all moving parts to stop, and r em o ve k ey or spark plug
wire(s).
b) Disengage neutral lock/park brake latches and release drive levers to lower
spring force.
c) Remove the 5/16-18 whizlock nut securing the adjustment bolt to the drive
wheel shield. Locate bolt assembly in the desired position as follows
Position A - Normal Conditions
Position B - More Severe
Position C - Most Severe
NOTE: Lever force is lowest with bolt assembly in Position A and will increase in
Positions B and C (See Figure 15).
- 27 -
FIGURE 15
DRIVE BELT TENSION
ADJUSTMENT POSITIONS
6. WASTE DISPOSAL
6.1 MOTOR OIL DISPOSAL
Eng ine oil is a pollut ant to the environment. Dispose of used oil at a cer tified
recycling center or according to your state and local regulations.
7. TROUBLE SHOOTING
7.1 MOWER PULLING LEFT OR RIGHT.
a) Check idler arm pulleys and drive sheaves for mud and/or g r ass 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 st eps a) and b)
e) Check for proper tire pressur e in dr ive tires. Recom mended tire pressure for
the drive tires is 12 to 16 psi. (82-110 kPa) Higher pressures may be used in
the tire on the side that it pulls to (up to 28 psi. (193 kPa)).
Note: Different pressures may make mower cut unevenly.
7.2 MOWER CUTS UNEVENLY.
a) Check the drive tire pressure and tire circumference. See 5.1.10. A more
uniform cutting heig ht may be obtained with higher tire pressure on rough
terrain. A lower tire pressure provides more flotation.
b) Check deck suppor t 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 t o t ip for straightness. (They should be within 3/16” (4.8
mm), or one blade width from being in line.)
7.3 ENGINE WILL NOT START.
a) Check that choke is in the “ON” position f or a cold engine.
NOTE: Kawasaki engines may need to be choked even when warm.
b) Make sure the k ey switch is in the “O N” position
c) Make sure transmission is in “true neutral” position. (See section 3.10c).
d) Check that the PTO is disengaged and the PTO switch is depressed.
e) Check that there is fuel in the tank and t hat the fuel valve is open.
- 28 -
f) Check that the spark plug wire(s) are properly connected.
g) Check for loose or faulty wiring connections. If it is necessary to disconnect
wire connectors, Do Not pull on the wires while disconnecting.
h) Check for corrosion at all wiring connections. Even minor corrosion may
cause a faulty connection. Clean connector terminals t hor oughly with
electrical contact cleaner, apply dielectric grease and r econnect.
IMPORTANT: It is essential that all operator safet y mechanisms be connected and in
proper operating condition prior to mow er use.
NOTE: After carefully checking the above steps, attempt to start the engine. If it
does not start, contact your authorized Exmark service dealer.
ENGINE TROUBLESHOOTING
When a problem occurs, do not overlook the simple causes. For example, starting
problems could be caused by an empty fuel tank. T he following table lists some of the
common causes of trouble. Do not at t em pt to service or replace major items or any items
that call for special timing or adjustment procedures (such as valves, governor, etc. ) . Have
this work done by your Engine Service Dealer.
ENGINE TROUBLESHOOTING TABLE
PROBLEM
Will not start
Hard starting
Stops suddenly
Lacks power
Operates
erratically
Knocks or pings
Skips or misfires
Backfires
Overheats
High fuel
consumption
NO
IMPROPER
FUEL
FUEL
X
X
X
X
X
X
X
X
DIRT IN
FUEL LINE
X
X
X
X
X
X
X
X
DIRTY AIR
FILTER
X
X
X
X
X
X
X
X
X
FAULTY
SPARK
PLUG
ENGINE
OVERLOADED
X X X
X X X
X X X X
X X X X X
X X X X
X X
X X
X X X
X X X
X X X
BLOCKED
FUEL
FILTER
INCORRECT
OIL
LEVEL
DIRTY
AIR
SCREEN
- 29 -
8. WIRING DIAGRAM –
15 HP KAWASAKI
- 30 -
9.
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
service@exmark.com
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 Warran 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.
- 31 -
NOTES
-32-
SERVICE RECORD
Date Description of Work Done Service Done By
-33-
ALIGN THIS EDGE WITH A VERTICAL SURFACE
(TREE, BUILDING, FENCE POST, POLE ETC.)
T
H
I
S
I
S
A
5
°
S
L
O
P
E
T
H
I
S
I
S
A
1
0
°
S
L
O
P
E
T
H
I
S
I
S
A
1
5
°
S
L
O
P
E
E
T
H
I
S
I
S
A
2
0
°
S
L
O
P
FOLD ALONG APPROPRIATE LINE
SLOPE WITH FOLDED
EDGE.
EXAMPLE: COMPARE
-34-
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 PART NO. 103-7195
EXMARK MFG. CO. INC. (402) 223-6300
INDUSTRIAL PARK BOX 808 FAX (402) 223-5489
BEATRICE, NE 68310
ALL RIGHTS RESERVED PRINTED IN U.S.A.
®
FG. CO. INC.
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