Exmark Lawn Mower MHP3614KA User Manual

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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.  
4.  
5.  
6.  
If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus order, he contacts Exmark by 3:00 p.m.,  
central time, with an Exmark Parts Plus order of six (6) line items or less.  
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.  
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.  
Who pays for the part and freight if it fails to arrive overnight in accordance to the program?  
A. Under any circumstance the customer does not pay.  
B. If the part does not arrive overnight due to:  
1. The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1:00 p.m., the dealer  
pays for the part and freight.  
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order  
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.  
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,  
Exmark pays for the part and freight.  
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark  
pays for the part.  
The following restrictions apply -- The Exmark Parts Plus Program is available only through participating Exmark  
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available  
only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental  
United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air  
charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no  
responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus orders must be received by Exmark by  
3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus Program are:  
Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and  
5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United  
Parcel Service size and weight restrictions.  
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day  
or Second Day Air.  
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be  
ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.  
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CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully  
designed and manufactured to give you a maximum amount of dependability and years of trouble-  
free operation.  
OPERATOR'S MANUAL  
This manual contains assembly, operating, maintenance, adjustment and safety instructions  
for your Exmark mower.  
BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
By following the operating, maintenance and safety instructions, you will prolong the life of  
your mower, maintain its maximum efficiency and promote safe operation.  
If additional information is needed, or should you require trained mechanic service, contact  
your authorized Exmark equipment dealer or distributor.  
All Exmark equipment dealers and distributors are kept informed of the latest methods of  
servicing and are equipped to provide prompt and efficient service in the field or at their service  
stations. They carry ample stock of service parts or can secure them promptly for you from the  
factory.  
All Exmark parts are thoroughly tested and inspected before leaving the factory, however,  
attention is required on your part if you are to obtain the fullest measure of satisfaction and  
performance.  
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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................................................................................... 32-33  
8. WARRANTY.............................................................................................. 34-35  
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1. SAFETY  
1.1 SAFETY ALERT SYMBOL  
THIS SAFETY ALERT SYMBOL  
IS USED BOTH IN THIS MANUAL AND ON  
THE MACHINE TO IDENTIFY IMPORTANT SAFETY 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 of unsafe actions  
or situations and will be followed by the word DANGER, WARNING, or CAUTION.  
When used with the word DANGER: IT DENOTES THAT AN EXTREME HAZARD  
EXISTS WHICH WOULD RESULT IN HIGH PROBABILITY OF DEATH OR  
IRREPARABLE INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.  
When used with the word WARNING: IT DENOTES THAT A HAZARD EXISTS  
WHICH CAN RESULT IN INJURY OR DEATH IF PROPER PRECAUTIONS ARE  
NOT TAKEN.  
When used with the word CAUTION: IT DENOTES A REMINDER OF SAFETY  
PRACTICES OR DIRECTS ATTENTION TO UNSAFE PRACTICES WHICH COULD  
RESULT IN PERSONAL INJURY IF PROPER PRECAUTIONS ARE NOT TAKEN.  
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. Familiarize yourself with the controls and the  
proper use of the equipment.  
1.2.3 Never allow children, teenagers, or people unfamiliar with these instructions to  
use the mower.  
1.2.4 Avoid mowing while people, especially children, or pets, are nearby. Keep in  
mind that the operator or user is  
responsible for accidents or hazards occurring to other people or their property.  
1.3 PREPARATION  
1.3.1 The use of personal protective equipment, such as (but not limited to)  
protection for the eyes, ears, feet and head is recommended.  
1.3.2 While mowing, always wear substantial footwear and long trousers. Do not  
operate equipment when barefoot or when wearing open sandals.  
1.3.3 Thoroughly inspect the area where the equipment is to be used and remove all  
stones, sticks, wires, bones and other foreign objects which may damage the  
equipment or cause personal injury to the operator or bystanders.  
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WARNING  
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 to 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.  
DANGER  
POTENTIAL HAZARD  
In certain conditions gasoline is extremely flammable  
and highly explosive.  
WHAT CAN HAPPEN  
A fire or explosion from gasoline can burn you, others,  
and cause property damage.  
HOW TO AVOID THE HAZARD  
DO NOT smoke while refueling, and stay away from  
an open flame or where gasoline fumes may 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 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 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, DO NOT attempt to start the engine.  
Move away from the area of the spill and avoid  
creating any source of ignition until fuel vapors have  
dissipated.  
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DANGER  
POTENTIAL HAZARD  
In certain conditions gasoline is extremely flammable  
and highly explosive.  
WHAT CAN HAPPEN  
A static charge can ignite gasoline 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 filling.  
Do not fill gasoline containers inside a vehicle or on a  
truck or trailer bed because interior carpets or plastic  
truck bed liners may insulate the container and slow  
the loss of any static charge.  
When practical, remove 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 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.  
1.4 OPERATION  
Although hazard control and accident prevention are partially dependent upon the  
design and configuration of the equipment, these factors are also dependent upon  
the awareness, concern, prudence and proper training of the personnel involved  
in the operation, transport, maintenance and storage of the equipment. It is  
essential that all Operator Safety Mechanisms be connected and in operating  
condition prior to use for mowing.  
1.4.1 Give complete, undivided attention to the job at hand.  
1.4.2 Mow only in daylight or good artificial light. Do Not operate the mower when  
children or others are in the area!  
1.4.3 When feasible, avoid operating the equipment in wet grass.  
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of  
traction and/or control could occur. Mow across slopes with walk behind  
mowers, never up and down. Loss of control and/or loss of operator’s footing  
could result in a fall with an arm or leg getting under the mower or engine deck  
and sustaining serious injury. Drive slower on slopes. DO NOT operate on  
slopes greater than 20 degrees. Watch for ditches, holes, rocks, dips, and  
rises which can cause erratic handlebar movement and loss of footing. Keep  
away from drop-offs and steep banks. Avoid sudden starts. Look down and  
behind you before and while moving backwards. DO NOT mow slopes when  
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.  
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1.4.5 Stop the blades when crossing surfaces other than grass; and when  
transporting the mower to and from 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 settings or over-speed the engine.  
Operating an engine at excessive speed may increase the hazard of personal  
injury.  
1.4.8 Place transmission in neutral, disengage blade drive before starting engine.  
1.4.9 Start the engine carefully with feet well away from blades.  
1.4.10 Keep hands, feet and clothing away from rotating parts while the mower is  
being operated.  
1.4.11 Stop the engine and remove spark plug wire(s) or ignition key:  
Before checking, cleaning or working on the mower.  
After striking a foreign object (inspect the mower for damage and make  
repairs before restarting and operating the mower).  
1.4.12 Stop the engine:  
Before clearing blockages.  
Whenever you leave the mower.  
Before removing the grass catcher.  
Before refueling.  
Before making height adjustments.  
1.4.13 Before stopping the engine, return the throttle control to the idle position for 30  
seconds to allow the engine to cool down.  
1.4.14 The fuel system is provided with a shut-off valve. The fuel shut-off valve is  
used to shut off the fuel when:  
The machine will not be used for a few days.  
During transport to and from the job.  
When parking inside a building.  
1.4.15 This mower was designed for one operator only. Keep all others away from  
mower during operation.  
1.4.16 Do Not 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 maintenance, follow the engine manufacture’s recommendations  
precisely as stated in the engine manual.  
1.5.2 When making adjustments while the engine is running, such as carburetor and  
motion control linkage adjustments, stand to one side and keep clear of  
moving/rotating components, such as engine screen, drive belts and sheaves.  
Do Not wear loose fitting clothing or jewelry that could get tangled in  
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 fuel in a container specifically designed for this purpose in a cool, dry  
place.  
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1.5.5 Keep the mower and fuel container in locked storage to prevent children from  
playing or tampering with them.  
1.5.6 Gasoline powered equipment or fuel containers should not be stored in a  
basement or any enclosed area, where open pilot lights or heat appliances are  
present.  
1.5.7 Maximum mowing results and safety can only be achieved if the mower is  
properly maintained and operated correctly.  
1.5.8. Check all bolts frequently to maintain proper tightness.  
1.5.9. Keep all guards, shields and all safety devices in place and in safe working  
condition.  
1.5.10 Frequently check for worn or deteriorating components that could create a  
hazard.  
1.5.11 All replacement parts must be the same as or equivalent to the parts supplied  
as original equipment.  
1.6 RIDING ATTACHMENTS  
1.6.1 Use only Exmark riding attachments. The use of other than Exmark riding  
attachments may create a hazardous condition resulting in injury.  
1.7 SAFETY SIGNS  
1.7.1 Keep all safety signs legible. Remove all grease, dirt and debris from safety  
signs.  
1.7.2 Safety signs must be replaced if they are missing or illegible.  
1.7.3 When new components are installed, be sure that current safety signs are  
affixed to the replaced components.  
1.7.4 New safety signs may be obtained from your authorized Exmark equipment  
dealer or distributor or from Exmark Mfg. Co. Inc.  
1.7.5 Safety signs may be affixed by peeling off the backing to expose the adhesive  
surface. Apply only to a clean, dry surface. Smooth to remove any air bubbles.  
1.7.6 Familiarize yourself with the following safety signs and instruction labels. They  
are critical to the safe operation of your Exmark commercial mower.  
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14 HP Kawasaki,Briggs & Stratton, & 15HP Kohler – All Serial Nos.  
(Serial Nos. 150,000-189,999: 17 HP Kawasaki  
PART NO. 323688  
14 HP Kawasaki & 15HP Kohler  
PART NO. 323689  
LOCATION: RH Side of  
Console  
LOCATION: Console  
Serial Nos. 190,000 & Higher 15 & 17 HP Kawasaki  
PART NO. 323699  
LOCATION: Console  
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  
PART NO. 403005  
LOCATION: RH & LH Corners  
of Mower Deck  
Fuel Tank Support  
PART NO. 303293  
LOCATION: On Top RH Side  
of Fuel Tank  
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PART NO. 403143  
PART NO. 303517  
LOCATION: RH Side of Rear  
Surface of Engine Deck  
LOCATION: LH Side of Rear  
Surface of Mower Deck  
PART NO. 553049  
LOCATION: Front of Mower Deck Top Surface  
16 HP Briggs & Stratton  
PART NO. 543631  
LOCATION: RH Side Console  
PART NO. 413421  
LOCATION: Left Rear on Top of  
Engine Deck  
PART NO. 323540  
LOCATION: Front of Mower Deck  
Top Surface  
PART NO. 323550  
LOCATION:Upper  
Handle  
PART NO. 513746  
LOCATION: On Engine Blower  
Housing next to  
PART NO. 303518  
LOCATION: Transmission Shifter Plate  
Muffler & on Center  
Belt Cover  
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PART NO. 413206  
PART NO. 413327  
LOCATION: Top of Cutter Deck, Under  
Center Belt Shield (36”)  
LOCATION: Top of Cutter Deck, Under  
Belt Shield (48” & 52” Decks)  
2. SPECIFICATIONS  
2.1 MODEL NUMBER:  
Serial Nos. 150,000 – 189,999: MHP4816BV; MHP5216BV  
Serial Nos. 150,000 – 219,999: MHP3614KA; MHP4814KA  
Serial Nos. 150,000 & Higher: MHP3615KC; MHP4815KC  
Serial Nos. 160,000 & Higher: MHP4817KA; MHP5217KA  
Serial Nos. 190,000 & Higher: MHP4815KA  
Serial Nos. 220,000 & Higher: MHP3615KA  
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 gasoline, 87 octane 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 blade clutch disengaged to  
start engine. Release of OPC levers will cause the engine to stop if  
not  
and/or  
engaged.  
blade clutch is  
transmission is  
in neutral  
2.5 STEERING/BRAKE CONTROL:  
Fingertip drive control levers provide independent speed control, braking and  
neutral to each drive wheel for moving, stopping and power turning. Parking  
brakes are engaged by locking drive control levers in the “brake” position.  
2.6 TRANSMISSION:  
2.6.1 Peerless 700-061, five speeds forward and one reverse.  
2.6.2 Speed Range:  
1st 2.0 mph (3.22 km/h) 4th 4.1 mph (6.60 km/h)  
2nd 2.7 mph (4.35 km/h) 5th 6.2 mph (9.98 km/h)  
3rd 3.5 mph (5.63 km/h) Rev. 3.1 mph (4.99 km/h)  
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2.7 WHEEL DRIVE SYSTEM:  
Banded double A-Section V-Belts, single top side idlers and replaceable bolt-  
on drive sheaves and brake drums.  
2.8 TIRES  
Drive  
Front Caster  
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 kPa).................. 22 psi(152 kPa)  
2.9 Deck  
2.9.1 Cutting Width:  
Model 36 in....................35.25 in. (89.5 cm)  
Model 48 in....................47.25 in. (120.0 cm)  
Model 52 in....................52.00 in. (132.1 cm)  
2.9.2 Discharge: Right Side  
2.9.3 Blade Size:  
Model 36 in....................18.00 in. (45.7 cm) ..............Qty. 2  
Model 48 in....................16.25 in. (41.3 cm) ..............Qty. 3  
Model 52 in....................18.00 in. (45.7 cm) ..............Qty. 3  
2.9.4 Type of Drive: Manual engagement of belt with over-center lock. Belt tension  
is adjustable via turnbuckle.  
2.9.5 Deck Mounting: Full floating deck is attached to out-front support frame,  
removable for service.  
2.9.6 Cutting Height: Adjusts in 1/2” (.63 cm) increments from 1.5” (3.8 cm) to 4 1/2”  
(11.4 cm).  
2.10 DIMENSIONS  
2.10.1 Overall Width:  
36”  
46.25”  
48”  
58.25”  
52”  
62.6”  
Discharge chute down  
(117.5 cm)  
(148.0 cm)  
(159.0 cm)  
Discharge chute up  
(Transport only)  
36.1”  
(91.7 cm)  
48.1”  
(122.2 cm)  
53.0”  
(134.62 cm)  
2.10.2 Overall Length:  
36”  
48”  
73.7”  
52”  
75.9”  
Overall Length  
77.7”  
(197 cm)  
(187 cm)  
(193 cm)  
2.10.3 Curb Weight:  
Curb Weight∗  
36”  
507 lbs.  
(230 kg)  
48”  
555 lbs.  
(252 kg)  
52”  
583 lbs.  
(264 kg)  
Weights will vary slightly depending on engine option.  
2.10.4 Overall Height: 42” (107 cm)(all units)  
2.10.5 Tread Width (to outside of tires):  
36” Model....................35.2” (89.4 cm)  
48” Model....................35.2” (89.4 cm  
52” Model....................35.2” (89.4 cm)  
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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 & Stratton & 15 & 17 HP Kawasaki.......... 15-20 ft-lbs.  
Kohler & 14 HP Kawasaki .................................. 25-30 ft-lbs.  
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) discharge deflector hinge points so  
that the deflector is snug, but can be moved up and down freely.  
3.4 Refer to Parts Manual to help you identify and locate parts and their proper  
position.  
3.5 Apply retaining adhesive “Fel-Pro Retaining I or Retaining II” or “Loctite RC609  
or 680” on the two threaded studs from the bolt bag and install into the two left  
holes underneath fuel tank. Install the fuel tank on top of the fuel tank support  
with the studs going through the slots in the support. Install two 5/16-18 x 3/4”  
screws with a 5/16” SAE flatwasher and 5/16” lockwasher into the threaded  
holes in the right side of the fuel tank. Do not over tighten. Place a 5/16” SAE  
flatwasher, then a spring, over each of the studs and fasten with a 5/16 nyloc  
nut. Tighten 3/16 nylock nut fully then cack off a 1/2 turn. This is to allow for  
normal fuel tank expansion with changes in temperature and fuel levels.  
3.6 Attach the fuel tank hose to the tank fitting and secure with the clamp provided.  
Make sure that fuel hose is not between engine and throttle plate on engine.  
3.7 Position the lower end of the handle assembly on the outside of the upper rear  
section of the fuel tank & handle support. Install four 3/8-16 x 1" bolts (with  
four spring disk washers against the head of each bolt) from the outside in.  
Secure using four 3/8" whizlock nuts on the inside of each handle support and  
tighten until the spring disk washers are flat (See Figure 1).  
FIG. 1  
UPPER HANDLE MOUNTING  
3.8 Route the throttle cable along the right side of the upper handle, under the fuel  
tank support, and position the cable on the left side of the engine (Kaw &  
Kohler) or to the right side of engine (B&S).  
Attach throttle cable to engine:  
For Kohler and Kawasaki engines with “positive” detents in throttle cable  
for the full throttle and idle positions.  
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a) Position the throttle control lever (on console) in the full throttle (but not  
choke) position. You will feel a detent when the throttle lever is  
approximately 3/4” from the upper end of the slot (this is full throttle  
position).  
b) Loosen clamp on engine control plate (See Figures 2, 3 & 4). Attach inner  
wire of the throttle cable to the control plate lever and position cable clamp,  
do not tighten clamp.  
FIG 2  
KOHLER SPEED CONTROL  
(THROTTLE CABLE HOOK-UP)  
FIG 3  
14 HP KAWASAKI SPEED CONTROL  
(THROTTLE CABLE HOOK-UP)  
Choke Link  
Control Plate Lever  
Control Alignment Holes  
Clamp  
Control Cable  
Choke Adjusting Screw  
FIG 4  
15 & 17 HP KAWASAKI SPEED CONTROL  
(THROTTLE CABLE HOOK-UP)  
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c)  
d)  
e)  
Pull cable upward (pull the cable to the right when facing the control plate  
on 15 & 17 HP Kawasaki units) until alignment holes in control plate lever  
and control plate line up. For Kawasaki 15/64” (6mm) drill bit can be  
inserted through these two holes to align them. For Kohler use a 19/64” drill  
bit. Once the holes are aligned, tighten clamp onto throttle cable.  
Be sure the choke adjusting screw just contacts the choke lever when  
the throttle control is in the full throttle position. Choke link should not move  
when throttle control is moved to the full throttle position. Choke must be  
completely closed when throttle lever is moved to the full forward “CHOKE”  
position.  
This step needs to be done after the unit has been assembled and the  
engine has been started. Refer to Section 4. (Operation Instructions).  
For Kohler and 14 HP Kawasaki engines:  
Check the engine “STOP” position by moving the throttle control fully to the  
rear. (Note: There is a detent toward the lower end of the slot in the  
console for “IDLE”; the “STOP” position is rearward from this detent).  
For Kohler engines:  
If the engine continues to run in the "STOP" position, turn the kill switch  
adjusting screw inward until engine stops, then give it an additional 1/2 to  
3/4 turn to assure it will always function properly.  
(The 14 HP Kawasaki kill switch is not adjustable).  
For 15 & 17 HP Kawasaki engines:  
There is not a “STOP” position. The engine will continue to run when the  
throttle control is moved past the rear detent.  
Turn the ignition switch to the “off” position to stop the engine.  
For B&S Vanguard Engines:  
a)  
Position the throttle control lever (on console) 1/8" from the upper end of  
the slot. Route the throttle cable along the right side of the upper handle,  
under the fuel tank support, and position the cable on the right side of the  
engine between the oil fill tube and engine.  
b)  
Attach the inner wire to the appropriate throttle control lever on the engine.  
Loosen the cable clamp on the engine, place the cable behind it and pullup  
on the cable to move the throttle linkage to the full throttle position.  
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 figure 5) Note that the threads on upper linkage  
are left hand. See 5.2.2 for linkage adjustment.  
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FIG 5  
BLADE ENGAGEMENT LINKAGE  
3.10 Install and adjust shifter lever.  
a)  
b)  
c)  
Remove the 3/8” nyloc nut and spring disc washer from the stud on top of  
the transmission. Install the shifter lever through slot in shifter lever plate  
and onto the stud on top of transmission. Be sure the square-hole washer  
remains between the lever and transmission. Replace the spring disc  
washer and nyloc nut(see figure 6). Torque the 3/8” nut to 35ft. lbs.  
(47N.M).  
Shift lever to second gear and check alignment of lever in slot of shifter  
plate. Clearance between top of lever and the top of the slot should be  
about equal to the clearance between bottom of the lever and the bottom  
of the slot (See figure 7). If it is not, remove lever and bend it slightly to  
adjust. DO NOT Bend lever while it is attached to transmission. Reinstall  
lever and tighten hardware.  
Shift to neutral position. Lever Should not contact the left edged of the  
upper slot. Push lever down. Lever should not contact the right edge of  
the bottom slot (See Figure 8). Shifter plate can be adjusted side to side  
to adjust position of lever relative to the slot in plate. Loosen the two  
bolts securing the shifter plate to the shifter lever legs. Adjust shifter  
plate and retighten bolts.  
FIG. 7  
THIS CLEARANCE SHOULD BE EQUAL  
FIG. 6  
SHIFTER LEVER  
TO TRANSMISSION  
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FIG. 8  
THIS CLEARANCE SHOULD BE EQUAL  
3.11 Install and adjust wheel drive linkages.  
a)  
b)  
Screw threaded end of drive linkages into swivels in wheel drive idler arms.  
Insert clevis pin from bolt bag through drive linkage, lever and slot in the  
neutral lock/park brake latches (See Figure 9). Make proper adjustments  
before adding hairpins.  
Neutral Lock/Park Brake Latch  
Clevis Pin  
Drive Linkage  
Drive Lever  
FIG. 9  
LEVER AND ROD ADJUSTMENT  
c)  
Adjust drive linkage length by threading into or out of the swivel until  
there is a 3/16” to 1/4” clearance between the linkage assembly and the  
bottom of the slot in the neutral lock/park brake latch. (See Figure 10)  
3/16” TO 1/4”  
Neutral Lock/ Park  
Brake Latch  
Drive Linkage  
1/4” Clearance  
FIG. 10  
NEUTRAL LOCK LEVER CLEARANCE  
Note: Neutral lock/park brake latch clearance should be checked when  
there is a slight upward force placed on the drive levers to remove any  
“slack” in the linkage.  
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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Drive Linkage  
Clevis Pin  
Left Side  
Shown  
Drive  
Lever  
Reference for  
Position Only  
Neutral  
Lock/Park  
Brake Latch  
Hairpin  
FIG. 11  
DRIVE LEVER HARDWARE LOCATION  
d)  
e)  
Adjust brakes by adjusting wingnut on upper end of each brake rod so  
that when brakes are engaged there is approximately 1/4” of clearance  
between ends of drive levers and handle grips (See Figure 10)  
Note: Adjustment should allow the brakes to be engaged, yet allow the  
neutral lock/park brake latches to be moved into the park brake position,  
if not the brake linkages must be adjusted again.  
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 presence  
control switch terminals underneath the control console.  
Fasten the lead to the handle with two small wire ties from the bolt bag, one at  
the upper end of the handle next to the console, and one at the very lower end  
of the handle where it attaches to the fuel tank support.  
3.13 If machine is shipped without muffler installed, install muffler with hardware  
provided.  
3.14 For Briggs and Stratton Engines install debris guard to top of engine.  
3.15 Service Engine: Refer to Engine Owner’s Manual.  
3.16 GREASE UNIT: NOTE: 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: Located on the upper handle  
assembly directly above the handle grips. 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 position and will kill the  
engine if either the transmission shift lever is not in the neutral position or the  
blade clutch is engaged.  
4.1.2 Drive Levers: Located on each side of the upper handle assembly directly  
below the handle grips. These levers individually control the clutching action of  
the wheel drive belts and brakes. When the drive levers are all of the way  
down, the wheel drive belts engage and the brakes disengage. Squeezing the  
left or right hand drive lever causes the left hand or right hand wheel to slow  
down or stop, which makes the machine turn to the left or right respectively.  
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The sharpness of the turn varies by how much the lever is squeezed. If both  
levers are squeezed all the way back, both brakes will engage and the machine  
will stop. For straight ahead motion, smoothly release both drive levers to  
engage both drive wheels simultaneously.  
4.1.3 Neutral Lock/Parking Brake Latch: Located directly above the drive levers. The  
purpose of these latches is to allow the operator to lock the drive levers in a  
"neutral" position where neither the wheel drive belts nor the brakes engage, or  
in a “park brake” position where the wheel drive belts are are not engaged and  
the park brake is engaged. To lock the drive levers in “neutral”, squeeze the  
drive levers back, place thumbs on the upper portion of the neutral lock/park  
brake latches and move them to the rear. Release drive levers. To lock the  
levers in “park brake”, squeeze the drive levers back, place thumb on the upper  
portion of the neutral lock/park brake latches and move them ahead. Release  
drive levers (See Figure 12).  
Apply parking brakes whenever leaving the operators position.  
ROTATE FORWARD FOR  
PARK BRAKE POSITION  
ROTATE BACK FOR  
NEUTRAL LOCK POSITION  
LATCH IS IN  
THE DRIVE  
POSTION  
PARK  
BRAKE  
FULL SPEED  
FORWARD  
NEUTRAL  
LOCK  
NEUTRAL - HOLD IN THIS POSITION  
FORWARD - RELEASE DRIVE LEVER  
REVERSE - SQUEEZE DRIVE LEVER  
FIG. 12  
DRIVE LEVER, NEUTRAL LOCK/PARK BRAKE LATCH OPERATION  
4.1.4 Blade Engagement: Located on the left side of the upper handle.  
To engage the blades, push the lever forward, or away from the operator, until  
the linkage locks over-center.  
To disengage the blades, pull the lever to the rear, or towards the operator.  
4.1.5 Choke Control: Choke is used to aid in starting a cold engine.  
On the B&S engine the choke control is located on the left hand, front corner of  
the engine and is activated by pulling the control outward. On Kawasaki and  
Kohler engines, the choke is part of the throttle control lever and is activated by  
moving the throttle control to the full forward position.  
Once the engine has started move the choke control to the off position and  
move the throttle to the medium or full throttle position.  
4.1.6 Throttle Control: Located on the control console’s right side. The throttle is  
used to control engine speed. Moving the throttle control forward will increase  
engine speed and moving it to the rear will decrease engine speed. All Kohler  
and 14 HP Kawasaki units are equipped with throttle kill as a standard feature.  
Moving the throttle to the full rear “Stop” position will shut off the engine (B&S  
and 15 & 17 HP Kawasaki units use a key switch to shut off engine).  
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4.1.7 “Off-Run” Switch (B&S and 15 & 17 HP Kawasaki only): Located on the  
console (Serial No.s 190,000 and higher) or front, left corner of the fuel tank  
support (Serial No.s 150,000-189,999). Turn key to the “Run” position to allow  
the engine to be started. Turn key to the “Off” position to shut engine off.  
4.1.8 Fuel Shut-Off Valve: Installed in the fuel line midway between the tank and the  
engine. The fuel shut-off valve is used to shut off the flow of fuel when parking  
inside a building, during transportation to and from the job sites, and when the  
machine will not be used for a few days. Rotate valve 1/4 turn clockwise to shut  
fuel off. Rotatevalve 1/4 turn counter-clockwise to turn fuel on.  
4.1.9 Transmission Shift Lever:  
Located under the control console and behind the fuel tank. It shifts the 5-  
speed transmission into five forward gears, neutral and reverse. Shift  
transmission only when drive levers are in the neutral position. Shifting  
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.  
4.2 Pre-Start  
DANGER  
POTENTIAL HAZARD  
In certain conditions gasoline is extremely flammable and  
highly explosive.  
WHAT CAN HAPPEN  
A fire or explosion from gasoline can burn you, others, and  
cause property damage.  
HOW TO AVOID THE HAZARD  
DO NOT smoke while refueling, and stay away from an open  
flame or where gasoline fumes may 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 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 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, DO NOT attempt to start the engine. Move  
away from the area of the spill and avoid creating any source  
of ignition until fuel vapors have dissipated.  
4.2.1 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 gasoline  
may also be used; however, combustion chamber and cylinder head will  
require more frequent service. See Engine Owner's Manual.  
Do not add oil to gasoline.  
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DANGER  
POTENTIAL HAZARD  
In certain conditions gasoline is extremely flammable  
and highly explosive.  
WHAT CAN HAPPEN  
A static charge can ignite gasoline 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 filling.  
Do not fill gasoline containers inside a vehicle or on a  
truck or trailer bed because interior carpets or plastic  
truck bed liners may insulate the container and slow  
the loss of any static charge.  
When practical, remove 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 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.  
4.2.2 Refer to Maintenance and Adjustment Section 5 and perform all of the  
necessary inspection and maintenance steps.  
4.2.3 Familiarize yourself with the controls and operation of unit.  
See Controls section 4.1 and Operating Instructions section 4.3.  
4.3 OPERATING INSTRUCTIONS  
4.3.1 Refer to Engine Owner’s Manual for detailed operating instructions regarding  
the engine.  
4.3.2 Starting Engine: Operator must have blade drive disengaged and  
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 starting the engine (See Section 4.1.3).  
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WARNING  
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 to 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 throttle in the 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 engine, gradually return choke to the full throttle position after the  
engine starts and warms up.  
On a warm engine, place the throttle control midway between the “Slow” and  
“Fast” positions.  
NOTE: Kawasaki engines generally need to be “choked” even when  
warm.  
For B&S engines:  
Turn key to the “Run” position.  
On a cold engine, place the throttle in the full forward position, and pull the  
choke control, on the engine, fully outward to the engaged position. Pull recoil  
rope to start engine. With a cold engine, gradually return choke to the full  
throttle position after the engine starts and warms up.  
On a warm engine, place the throttle control midway between the “Slow” and  
“Fast” positions. DO NOT choke B&S when warm.  
4.3.3 Stopping Engine: Disengage blade drive, position speed control lever in neutral  
and lock the drive levers in the “park brake” position. Move throttle to the  
“Slow” position. Allow engine to idle for 30 seconds to allow cool down.  
For 14 HP Kawasaki and Kohler engines; after cool down time, move throttle  
lever to the full rear (“Stop”) position. For B&S and 15 & 17 HP Kawasaki  
engines; After cool down time, move the throttle to the “midway” position. Turn  
key to the “Off” position and remove key.  
4.3.4 Drive Lever/Neutral Lock/Park Brake Latch Operation: To lock the drive levers  
in neutral, squeeze the drive levers back to the “neutral” position. Place thumbs  
on the upper portion of the neutral lock/park brake latches and move them to  
the rear. Release drive levers (See Figure 12).  
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)  
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CAUTION  
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 through the slots of each neutral  
lock latch are completely engaged in the rear slot of each  
latch.  
To place the drive levers in the drive position, firmly hold the drive levers, place  
thumbs on the upper portion of theneutral lock/park brake latches and move  
them out of either the “neutral” or “park brake” position to release drive levers.  
Carefully release the drive levers.  
4.3.5 Drive Wheel Engagement and Turning: With drive levers in “neutral” or “park  
brake” position, shift transmission into desired gear. Squeeze both drive levers  
and move both neutral lock/park brake latches from the “neutral” or “park  
brake” position.  
For straight ahead motion, smoothly release both drive levers to engage drive  
wheels.  
Squeeze the right hand drive lever to turn right and the left hand drive lever to  
turn left (See Section 4.1.2).  
4.3.6 To Stop: Squeeze drive levers back to engage brakes. Move neutral lock/park  
brake latches into the “park brake” position and release drive levers. Shift  
transmission to neutral.  
DANGER  
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 put hands or feet under the mower or mower  
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 “midway” position.  
Push the blade engagement arm forward and down to engage blades.  
Accelerate to full throttle to begin mowing (See Section 4.1.4).  
4.3.8 Blade Disengagement: Pull upward and back completely on the blade  
engagement arm to disengage the blades. (See Section 4.1.4)  
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4.3.9 Changing Gears  
When changing gears, always squeeze drive levers and/or engage neutral  
lock latches or park brakes. The shift lever may be moved with a knee or by  
hand.  
NOTE: Reverse gear is reverse assist only, the operator must pull the unit  
backwards.  
4.3 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 from under the unit when  
loading and unloading.  
If necessary, use assistance when loading.  
Use a heavy duty trailer to transport the machine. Engage park brakes and  
block wheels. Securely fasten the machine to the trailer with straps, chains,  
cables or ropes.  
Do not rely solely on parking brake to hold machine on trailer.  
Use a safety chain and be sure that the trailer has all necessary lighting and  
marking as required by law.  
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 ignition 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).  
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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 engine area.  
5.1.1 Check engine oil level.  
Service Interval: See Engine Owner's Manual  
a) Make sure engine is stopped and on a level surface.  
b) Check with engine cool.  
c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert  
the dipstick (DO NOT screw into place for Kohler and Kawasaki engines;  
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: DO NOT operate the engine with oil level below the “L”  
mark or over the “F” mark.  
5.1.2 Clean engine air cooling system.  
Service Interval: See Engine Owner's Manual  
a) Stop engine and remove spark plug wire(s).  
b) Clean all debris from engine air intake screen and from around engine  
shrouding.  
5.1.3 Clean grass build-up under deck and check mower blades.  
Service Interval: Daily  
CAUTION  
POTENTIAL HAZARD  
Raising the mower deck for service or maintenance  
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.  
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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 the sharp cutting edges of  
the blades.  
g) Re-install the blades (if they were removed) and torque blade bolts to 75-  
80 ft. lbs. Be sure the spring disc washer cone is installed toward the bolt  
head (See Figure 13).  
h) Remove jack stands (or equivalent support) and lower deck to ground.  
FIG. 13  
BLADE BOLT INSTALLATION  
5.1.4 Check safety interlock system.  
Service Interval: Daily  
a)  
For your safety, your Exmark mower is equipped with Operator Presence  
Controls (OPC). When either the mower blades are engaged, or the  
transmission shift lever is not in neutral and both hands are removed from  
the handles, the mower engine MUST stop.  
b)  
Check OPC circuits. Clear the area. Run engine at one-third throttle, then  
with drive levers and neutral lock/park brake latches in “park brake”  
position, Shift the transmission into gear and release OPC levers –  
engine MUST stop.  
Again, run engine at one-third throttle, move the transmission shifter lever to  
neutral, engage blade clutch and release OPC levers - engine MUST stop.  
c)  
If machine does not pass any of these tests, DO NOT operate. Contact  
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 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.  
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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 operation. Follow engine  
manufacturers recommendations for future oil changes.  
a) Disengage blade clutch.  
b) Stop engine and remove spark plug wire(s).  
c) Drain oil while engine is warm from operation.  
d) Remove the oil drain plug from the right hand side of the engine. Allow oil  
to drain, then replace drain plug.  
e) Replace the oil filter as per Engine Owner's Manual. Clean around oil filter  
and unscrew filter to remove. Before reinstalling new filter, apply a thin  
coating of oil on the surface of the rubber seal. Turn filter clockwise until  
rubber seal contacts the filter adapter then tighten filter an additional 2/3 to  
3/4 turn.  
f) Clean around oil fill cap and remove cap. Fill to the specified capacity and  
replace cap. Use oil as specified in Engine Owners Manual. 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 shaft 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 from top of transmission.  
d) Remove shifter plate from top of transmission and the two leads from the  
neutral start switch.  
e) Release the tension on the transmission belt.  
f) Check for side play caused by bearing wear on the input and out put  
shafts of the transmission. Replace bearings if necessary.  
g) Remove the six bolts that fasten the upper case to the lower case and  
carefully remove the upper case half.  
h) Check the grease level in the lower case. The grease level should be  
approximately 1-1/2” to 1-3/4” from the gearbox bottom. If necessary, fill  
to proper level with Peerless grease (Part No. 788067)  
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.  
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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 stated above. Measure circumference of each  
drive tire. Adjust tire pressures within the above range to try to make tire  
circumferences match as closely as possible.  
NOTE: Front caster tires have permanent tire sealant installed.  
5.1.11 Inspect Belt wear.  
Service Interval: 40 hrs.  
a) Stop engine and remove spark plug wire(s).  
b) Remove deck support belt shield to check mower deck drive belt  
condition.  
c) Look under engine deck to check the transmission drive and clutching  
belt condition.  
d) Inspect wheel drive belt conditions  
e) Check all idler arms to be sure they pivot freely. Disassemble, clean and  
grease pivot bushings if necessary.  
5.1.12 Inspect Blade Clutching Belt Tension.  
Service Interval: 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 round hole in the left rear corner of the engine deck to  
inspect blade clutching belt tension. Bolt on blade engagement linkage  
bellcrank and indicator arm should align within 1/16” (See fig. 15). Refer  
to section 5.2.2 for adjustment.  
5.1.13 Lubrication  
Service Interval: 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 the following chart for fitting locations and lubrication  
schedule.  
GREASE LUBRICATION CHART  
FITTING  
INITIAL  
QUANTITY  
SERVICE  
LOCATIONS  
PUMP  
36” 48” 52” INTERVAL  
1. Caster Wheel Bearings  
2. Caster Pivots  
3. Blade Engagement Bellcrank  
4. Drive Wheel Idler Arm  
5. Clutch Arm Pivot  
6. Cutter Deck Idler Pivots  
7. Trans. Output Shaft Coupler  
8. Cutter Spindles  
12  
2
1
2
1
2
2
10  
2
2
1
2
1
1
2
2
2
2
1
2
1
1
2
3
2
3
1
2
1
1
2
3
Daily  
Daily  
Weekly  
Weekly  
Weekly  
Weekly  
Weekly  
† Weekly  
(S/N’s 150,000 to 159,999)  
Under severe cutting conditions, two pumps of  
grease twice weekly may be more beneficial.  
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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  
NO. OF  
PLACES  
SERVICE  
INTERVAL  
Weekly  
PIVOT POINT  
1. Blade Engagement Lever  
1
d) Lubricate drive wheel hubs once a year. First remove wheel, then remove  
hub cap. Lubricate the grease fitting on each wheel hub with an SAE No.  
2 multipurpose gun grease, until grease appears through outer bearing.  
Reinstall hub caps and wheels.  
e) Replace 5-speed gearbox grease yearly. Use 18 oz. Of Peerless grease  
(Part No. 788067). See Section 5.1.9.  
5.1.14 Check spark plugs.  
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 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-Pro, Pro-Lock Nut-  
Type” are used on the following fasteners:  
a) Transmission drive sheave setscrew.  
b) Wheel drive sheave setscrews on transmission output shafts.  
c) OPC lever setscrews.  
d) Sheave retaining bolt in end of engine crankshaft.  
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e) Lower Sheave retaining bolt on clutch arm.  
Adhesives such as “Loctite RC/609 or RC/680”or“Fel-Pro Pro-Lock Retaining I  
or Retaining II” are used on the following:  
a) OPC lever hubs and cross-shaft  
NOTE: Care must be used not to bond the bearing, next to each OPC  
hub, to the cross shaft which could cause binding of the OPC levers and  
erratic operation.  
5.1.19 An anti-seize compound is used on the following locations:  
a) Between engine crankshaft and transmission and blade drive sheaves.  
b) On clutch arm assembly between bearings and shaft and between lower  
sheave and shaft.  
c) Between transmission shaft and sheaves.  
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 height and anti-scalp roller adjustment.  
WARNING  
POTENTIAL HAZARD  
When the two front 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 front  
support rod hairpins are removed.  
a) Install hairpin clips in the holes shown on sketch below for the desired  
cutting height (See Figure 14).  
FIG 14  
ANTI-SCALP ROLLER BOLT INSTALLATION  
ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT  
b) Adjust anti-scalp rollers for Normal Operating Conditions. Stop engine.  
Place rollers in one of the positions shown in Fig 14. Rollers will maintain  
3/4 in. (19 mm) clearance to the ground to minimize gouging and roller  
wear or damage. For Maximum Deck Flotation, place rollers one hole  
position lower. Rollers should maintain 1/4 in. (6.4 mm) minimum  
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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. Torque to 40-45 ft-lbs., or loss of  
roller may result.  
c) When operating in extremely rough conditions it may be necessary to  
position the anti-scalp rollers one or two holes higher than described in  
"b" to prevent damage to the rollers and/or bolt failure(See Figure 14).  
NOTE: 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 rear corner of the engine deck.  
a) Stop engine and remove spark plug wire(s).  
b) With blade drive engaged, adjust the linkage length by loosening the  
locknut on the turnbuckle and adjusting the turnbuckle so that the bolt on  
the bellcrank and the indicator arm align with each other within 1/16”.  
See Figure 15. Tighten locknut against turnbuckle.  
FIG. 15  
BLADE ENGAGEMENT LINKAGE  
5.2.3 Blade Safety Switch:  
a) Stop engine and remove spark plug wire(s).  
b) With blades disengaged and the bellcrank touching the rear of the slot in  
the engine deck, adjust the blade safety switch (if needed) until the  
bellcrank arm is 5/16” from the switch body.  
c) Be sure the bellcrank 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 properly adjusted, the belt should have 1/2” of deflection with three  
pounds of pressure on the belt midway between the transmission and  
engine pulley.  
5.2.6 Wheel drive belts and scrapers:  
a) If wheel traction appears to be slipping, drive lever rods may be touching  
bottom of neutral lock/park brake latch slot. To adjust, refer to directions  
in Section 3.11  
NOTE: Wheel drive springs have three tension settings. Refer to Section  
5.2.11.  
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b) Be sure mud and grass scraper, on each side, is adjusted properly and  
centered in the pulley grooves. The pointed part of the scraper should be  
centered and as deep in the pulley groove as possible without rubbing at  
any point.  
5.2.7 Brake Adjustment:  
See 3.11  
5.2.8 Wheel drive linkage adjustment:  
See 3.11  
5.2.9 Shifter lever adjustment:  
See 3.10  
5.2.10 Shifter detent adjustment:  
Transmission shifter detent can be adjusted by adjusting the setscrew on the  
backside of transmission located just behind the neutral start switch. Turn  
setscrew in (clockwise) to hold the transmission shifter more positively in each  
gear and to increase the force on the lever required to shift gears.  
Turn setscrew out (counterclockwise) to decrease force on lever required to shift  
gears. Factory setting is to turn setscrew all the way in then back out 1-1/2 turns.  
IMPORTANT: Screwing setscrew in too far will prevent the transmission  
from shifting.  
5.2.11 Wheel drive spring tension adjustment:  
It may be necessary to increase wheel drive belt tension under certain  
conditions such as, wet grass, hilly terrain, or while pulling a sulky.  
a) Stop engine and remove spark plug wire(s).  
b) Disengage neutral lock/park brake latches and release drive levers to  
lower spring force.  
c) Remove the 5/16-18 whizlock nut securing the adjustment bolt to the  
drive wheel shield. Locate bolt assembly in the desired position as follows  
Position A - Normal Conditions  
Position B - More Severe  
Position C - Most Severe  
NOTE: Lever force is lowest with bolt assembly in Position A and will increase  
in Positions B and C (See Figure 16).  
FIG. 16  
DRIVE BELT TENSION  
ADJUSTMENT POSITIONS  
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5.2.12 Adjust Throttle Lever Tension (B&S Engines only):  
a)  
b)  
Stop engine and remove spark plug.  
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.  
Check to be sure idler arms pivot freely, if not lubricate idler pivots.  
Check for worn drive belts.  
b)  
c)  
NOTE: Wheel drive belts should be replaced as a set. A new belt should  
not be mixed with a worn belt.  
d)  
e)  
Check drive linkage adjustment - See 3.11  
Check for proper tire pressure in drive tires. Recommended tire pressure  
for the drive tires is 12 to 16 psi. Higher pressures may be used in the tire  
on the side that it pulls to (up to 28 psi).  
Note: Different pressures may make mower cut unevenly.  
6.2 MOWER CUTS UNEVENLY.  
a)  
Check the drive tire pressure and tire circumference. See 5.1.10. A  
more uniform cutting height may be obtained with higher tire pressure on  
rough terrain. A lower tire pressure provides more flotation.  
b)  
c)  
d)  
Check deck support pins. Hairpin clips must be in the same hole position  
on each support pin.  
Check deck support alignment and check mounting brackets to be sure  
all bolts are tight.  
Check blades tip to tip for straightness. (They should be within 3/16”, or  
one blade width from being in line.)  
6.3 ENGINE WILL NOT START.  
a) Check that choke is in the “ON” position for a cold engine or in the “OFF”  
position for a warm engine. See 4.3.2.  
NOTE: Kawasaki engines may need to be choked even when warm.  
b)  
Make sure the key switch is in the “ON” position (B&S and 15 & 17 HP  
Kawasaki engines only).  
c)  
d)  
e)  
f)  
Make sure transmission is in “true neutral” position. (See section 3.10c).  
Check that the blades are disengaged and the blade switch is depressed.  
Check that there is fuel in the tank and that the fuel valve is open.  
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 thoroughly with  
electrical contact cleaner, apply dielectric grease and reconnect.  
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, contact your authorized Exmark service  
dealer.  
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ENGINE TROUBLESHOOTING  
When a problem occurs, do not overlook the simple causes. For example,  
starting problems could be caused by an empty fuel tank.  
The following table lists some of the common causes of trouble.  
Do not attempt to service or replace major items or any items that call for  
special timing or adjustment procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
ENGINE TROUBLESHOOTING TABLE  
FAULTY  
SPARK  
PLUG  
BLOCKED INCORRECT  
DIRTY  
AIR  
SCREEN  
NO  
FUEL  
IMPROPER  
FUEL  
DIRT IN  
DIRTY AIR  
FILTER  
ENGINE  
FUEL  
OIL  
PROBLEM  
FUEL LINE  
OVERLOADED  
FILTER  
LEVEL  
Will not start  
Hard starting  
Stops suddenly  
Lacks power  
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
Operates  
erratically  
X
X
X
X
X
X
Knocks or pings  
Skips or misfires  
Backfires  
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Overheats  
X
High fuel  
consumption  
X
X
X
X
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7. WIRING DIAGRAM  
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8. WARRANTY  
Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg. Co. Inc. ("Exmark") warrants on  
the terms and conditions herein, that it will repair, replace or adjust any part manufactured by  
Exmark and found by Exmark(in the exercise of its reasonable discretion)to be defective in factory  
material or workmanship.  
This warranty is limited to one year from the date of original retail purchase (90 days for rental use)  
for any Exmark mower that is used for commercial or any other income producing purpose. The  
Blade Spindle assemblies will be warranted for three years, one year parts and labor with an  
additional two years parts only, from date of original retail purchase against defects in materials or  
workmanship. The hydrostatic traction drive system, excluding hoses, will be warranted for two full  
years from date of original retail purchase against defects in materials or workmanship. Exmark  
Mfg. will extend the Peerless 5-speed transmission manufacturer's warranty from 90 days to one  
year. Belts and tires are warranted for 90 days against defects in materials or workmanship.  
The engine warranty is covered by its respective engine manufacturer. Please refer to the engine  
manufacturers warranty statement that is included in the literature packet. Exmark is not authorized  
to handle warranty adjustments on engines. Engine warranties should be referred to the nearest  
authorized service outlet of the engine manufacturer.  
This warranty extends only to the original retail purchaser of the equipment. The warranty may not  
be assigned or transferred without the prior express written consent of Exmark. The warranty  
commences upon the date of the original retail purchase.  
The Exmark turf equipment, including any defective part, must be returned to an authorized Exmark  
service dealer within the warranty period. The warranty shall extend to cost to repair or replace(as  
determined by Exmark) the defective part, including labor. The expense of delivering the mower to  
the dealer for warranty work and the expense of returning it back to the owner after repair or  
replacement will be paid for by the owner. Exmark's responsibility in respect to claims is limited to  
making the required repairs or replacements, and no claim of breach of warranty shall be cause for  
cancellation or rescission of the contract of sale of any Exmark mower. Proof of purchase may be  
required by the dealer to substantiate any warranty claim. All warranty work must be performed by  
an authorized Exmark service dealer.  
This warranty extends only to turf equipment operated under normal conditions and properly  
serviced and maintained. The warranty expressly does not cover: (i) any defects, damage or  
deterioration due to normal use, wear and tear, or exposure; (ii) normal maintenance services, such  
as oil change, cleaning, lubrication, adjustment; (iii) replacement of service items, such as oil,  
lubricants, spark plugs, belts, rubber hoses or other items subject to normal service replacement; (iv)  
damage or defects arising out of or relating to misuse, neglect, alteration, negligence or accident; (v)  
repair or replacement arising from operation of or use of the turf equipment which is not in  
accordance with operating instructions as specified in the operator's manual or other operational  
instructions provided by Exmark; (vi) repair or replacement arising as a result of any operation from  
turf equipment that has been altered or modified so as to, in the determination of Exmark, adversely  
affect the operation, performance or durability of the equipment or that has altered, modified or  
affected the turf equipment so as to change the intended use of the product; (vii) repair or  
replacement necessitated by use of parts, accessories or supplies, including gasoline, oil or  
lubricants, incompatible with the turf equipment or other than as recommended in the operator's  
manual or other operational instructions provided by Exmark; (viii) repairs or replacements resulting  
from parts or accessories which have adversely affected the operation, performance or durability of  
the turf equipment; or (ix) damage or defects due to or arising out of repair of turf equipment by  
person or persons other than an authorized Exmark service dealer or the installation of parts other  
than genuine Exmark or Exmark recommended parts.  
As a condition to this warranty, customer shall have read the operator's manual and shall have  
returned to Exmark, within the prescribed time, the enclosed warranty registration card.  
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The sole liability of Exmark with respect to this warranty shall be repair and replacement as set forth  
herein. Exmark shall have no liability for any other cost, loss or damage, including but not limited to,  
any incidental or consequential loss or damage. In particular, Exmark shall have no liability or  
responsibility for: (i) expenses relating to gasoline, oil or lubricants; (ii) loss, cost or expense  
relating to transportation or delivery of turf equipment from the location of owner or location where  
used by owner to or from any authorized Exmark service dealer; (iii) travel time, overtime, after  
hours time or other extraordinary repair charges or charge relating to repairs or replacements  
outside of normal business hours at the place of business of the authorized Exmark service dealer;  
(iv) rental of like or similar replacement equipment during the period of any warranty, repair or  
replacement work; (v) any telephone or telegram charges or travel charges; (vi) loss or damage to  
person or property other than that covered by the terms of this warranty; (vii) any claims for lost  
revenue, lost profit or additional cost as a result of a claim of breach of warranty; or (viii) attorney's  
fees.  
There are no representations or warranties which have been authorized and provided to the buyer of  
the turf equipment, other than as set forth in this warranty. Any and all statements or  
representations made by any seller of this equipment, including those set forth in any sales literature  
or made orally by any sales representative, are superseded by the terms of this warranty. Any  
affirmation of fact or promise made by Exmark or any of its representatives to the buyer which  
relates to the goods that are the subject of this warranty shall not be regarded as part of the basis of  
the bargain and shall not be deemed to create any express warranty that such goods shall conform  
to the affirmation or promise.  
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR  
WARRANTIES, EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED TO ANY REGARDING  
THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), NOT SPECIFIED  
HEREIN, RESPECTING THE EQUIPMENT WHICH IS THE SUBJECT OF THIS WARRANTY.  
This warranty applies to all Exmark turf equipment sold in the United States and Canada and  
intended to be used for commercial purposes.  
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SERVICE RECORD  
Date  
Description of Work Done  
Service Done By  
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NOTES  
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ALIGN THIS EDGE WITH A VERTICAL SURFACE  
(TREE, BUILDING, FENCE POST, POLE ETC.)  
T
H
I
S
I
S
A
1
5
°
S
L
O
P
E
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SEE EXMARK’S COMPLETE  
LINE OF PRODUCTS FOR TURF CARE  
LAZER Z™  
LAZER ZHP  
TURF RANGER®  
TURF TRACER®  
TURF TRACER® HP  
VIKING HYDRO  
METRO™  
METROHP  
SELF STEERING SULKY  
GRASS CATCHER  
MICRO-MULCH ACCESSORY  
©1997,1998, 1999  
EXMARK MFG. CO. INC.  
PART NO. 850662  
(402) 223-6300  
INDUSTRIAL PARK BOX 808  
BEATRICE, NE 68310  
FAX (402) 223-5489  
ALL RIGHTS RESERVED  
PRINTED IN U.S.A.  
®
M FG .CO .IN C .  
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