Exmark Lawn Mower 4500 689 User Guide

METRO®  
For Serial Nos.  
920,000 & Higher  
Part No. 4500-689 Rev. A  
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Introduction  
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.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
Figure 1  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
1. Model and serial number location  
Model No.  
Serial No.  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
Exmark parts manuals are available online at  
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.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Belt Guide Adjustment.................................. 30  
Contents  
Torque Requirements .................................... 13  
Periodic Maintenance ....................................... 20  
Replace Emissions Air Intake Filter................ 23  
Shaft Bearing Wear on Peerless  
4
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Safety  
not read English it is the owner’s responsibility to  
explain this material to them.  
Safety  
Safety Alert Symbol  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
This lawn mower meets or exceeds the B71.4  
specifications of the American National Standards  
Institute in effect at the time of production.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
• Never let children or untrained people operate  
or service the equipment. Local regulations may  
restrict the age of the operator.  
Exmark designed and tested this lawn mower to offer  
reasonably safe service; however, failure to comply  
with the following instructions may result in personal  
injury.  
• Only adults and mature teenagers should operate  
a mower, and even mature teenagers should have  
adult supervision. Be sure a teenager:  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents.  
1. has read and understands the Operator’s  
Manual and recognizes the risks involved;  
2. is sufficiently mature to use caution; and  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
3. is of sufficient size and weight to operate  
the controls comfortably and to manage the  
mower without taking risks.  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
Figure 2  
1. Safety alert symbol  
Preparation  
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.  
• 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.  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
CAUTION  
This machine produces sound levels in excess  
of 85 dBA at the operator’s ear and can cause  
hearing loss through extended periods of  
exposure.  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
Wear hearing protection when operating this  
machine.  
Safe Operating Practices  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
Training  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
5
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Safety  
DANGER  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
In certain conditions during fueling, static  
electricity can be released causing a spark  
which can ignite gasoline vapors. A fire or  
explosion from gasoline can burn you and  
others and cause property damage.  
A fire or explosion from gasoline can burn  
you, others, and cause property damage.  
• Fill the fuel tank outdoors on level ground,  
in an open area, when the engine is cold.  
Wipe up any gasoline that spills.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• 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.  
• Do Not fill the fuel tank completely full.  
Fill the fuel tank to the bottom of the filler  
neck. The empty space in the tank allows  
gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine  
or emission system.  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Never smoke when handling gasoline, and  
stay away from an open flame or where  
gasoline fumes may be ignited by spark.  
• 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.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
• 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.  
• 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.  
• 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.  
WARNING  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• 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.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
6
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Safety  
damage and make repairs before restarting  
Operation  
WARNING  
Operating engine parts, especially the muffler,  
become extremely hot. Severe burns can occur  
on contact and debris, such as leaves, grass,  
brush, etc. can catch fire.  
and operating the mower).  
– Before clearing blockages.  
– Whenever you leave the mower.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
– Before refueling.  
• Allow engine parts, especially the muffler, to  
cool before touching.  
– Before dumping the grass catcher.  
– Before making height adjustments.  
• Remove accumulated debris from muffler  
and engine area.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
WARNING  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can kill  
you.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
Do Not run engine indoors or in a small confined  
area where dangerous carbon monoxide fumes  
can collect.  
DO NOT operate the mower when people,  
especially children, or pets are in the area.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Never raise deck with blades running.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
• Park machine on level ground. Stop engine, wait  
for all moving parts to stop, remove key and  
engage parking brake:  
Slope Operation  
– Before checking, cleaning or working on the  
mower.  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
occur. The operator is responsible for safe operation  
on slopes.  
– After striking a foreign object or abnormal  
vibration occurs (inspect the mower for  
7
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Safety  
• 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.  
DANGER  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. 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, death or drowning.  
• Let engine cool before storing and Do Not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• 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.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
• Use jack stands to support components when  
required.  
• Reduce speed and use extreme caution on  
slopes.  
• Carefully release pressure from components with  
stored energy.  
• Avoid sudden turns or rapid speed changes.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Keep hands and feet away from moving parts.  
If possible, Do Not make adjustments with the  
engine running.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
• Check all bolts frequently to maintain proper  
tightness.  
• Be aware that operating on wet grass, across steep  
slopes or downhill may cause the mower to lose  
traction. Loss of traction to the drive wheels may  
result in sliding and a loss of braking and steering.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
WARNING  
Removing standard original equipment parts,  
or using non-Exmark replacement parts and  
accessories may alter the warranty, traction, and  
safety of the machine. Failure to use original  
Exmark parts could cause serious injury or  
death.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
Replace all parts including, but not limited to,  
tires, belts, and blades with original Exmark  
parts.  
Maintenance and Storage  
• Disengage drives, lower implement, set parking  
brake, stop engine and remove key or disconnect  
spark plug wire. Wait for all movement to stop  
before adjusting, cleaning or repairing.  
8
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• 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.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
1-303508  
1-323427  
32 inch and 36 inch Units Only  
1-303517  
1-303518  
1-323550  
Pistol Grip Handle Units Only  
1-403005  
9
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Safety  
1-403143  
98-5954  
103-2076  
103-2244  
ECS Units Only  
103-1623  
ECS Units Only  
103-2245  
ECS Units Only  
103-1798  
10  
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Safety  
117–2718  
103-5626  
48 inch Deck Units Only  
103-1967  
Pistol Grip Units Only  
11  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 920,000 and Higher  
MG16KA322P; MG16KA322PCA; MG16KA362; MG16KA362CA; MG16KA362P; MG16KA483;  
MG16KA483CA; MG16KA483P  
Systems  
Transmission  
• Peerless 700-070A, five speeds forward and one  
reverse.  
Engine  
• Engine Specifications: See your Engine Owner’s  
Manual  
• Speed range:  
– 1st: 2.0 mph (3.22 km/hr)  
– 2nd: 2.7 mph (4.35 km/hr)  
– 3rd: 3.5 mph (5.63 km/hr)  
– 4th: 4.1 mph (6.60 km/hr)  
– 5th: 6.2 mph (9.98 km/hr)  
– Reverse: 3.1 mph (4.99 km/hr)  
• Engine Oil Type: Exmark 4–Cycle Premium  
Engine Oil  
• RPM: Full Speed: 3600 (No Load)  
Idle: 1550 RPM  
Fuel System  
• Capacity: 5.0 gal. (18.9 L)  
Wheel Drive System  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher; containing no more than 10%  
methanol or ethanol.  
Banded double A-Section V-belts, single top-side  
idlers and replaceable bolt-on drive sheaves and brake  
drums. (Single B-Section V-belts for the 32 inch  
Model)  
• Fuel Filter: Replaceable In-line  
• Fuel Shut-Off Valve: 1/4 turn increments  
Tires & Wheels  
Safety Interlock System  
Front  
Caster  
Drive  
Operator must have the transmission in neutral and  
PTO disengaged to start engine. Release of Operator  
Presence Control (OPC) levers will cause engine to  
stop if transmission is not in neutral and/or PTO  
is engaged.  
Semi-  
Pneumatic  
Pneumatic (Air-Filled)  
32  
2
36 & 48  
2
All Decks  
2
Quantity  
Tread  
Turf Saver  
Turf Master Smooth  
Steering/Brake Controls  
Size  
13 x 5.00-6 13 x 6.50-6 9 x 3.50-4  
Fingertip drive control levers provide independent  
control of traction, 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.  
Ply Rating  
Pressure  
4
4
14 psi  
(97 kPa)  
14 psi  
(97 kPa)  
Bearings  
Replaceable Replaceable Replaceable  
Ball Ball Roller  
12  
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Specifications  
Cutting Deck  
Overall Length:  
• Cutting Width:  
32 inch  
Deck  
36 inch  
Deck  
48 inch  
Deck  
– 32 inch Deck: 31.75 inches (80.7 cm)  
– 36 inch Deck: 35.38 inches (89.9 cm)  
– 48 inch Deck: 47.25 inches (120.0 cm)  
• Discharge: Side  
Standard  
78.0 inches 78.0 inches 73.0 inches  
Pistol Grip (198.1 cm) (198.1 cm) (185.4 cm)  
Handles  
ECS  
Handles  
77.3 inches 77.3 inches 72.3 inches  
(196.3 cm) (196.3 cm) (183.6 cm)  
• Blade Size:  
– 32 inch Deck: 16.25 inches (41.3 cm) —  
Quantity: 2  
Overall Height:  
Standard Pistol Grip  
Handles  
40.0 inches (101.6 cm)  
42.1 inches (106.9 cm)  
– 36 inch Deck: 18.00 inches (45.7 cm)—  
Quantity: 2  
ECS Handles  
– 48 inch Deck: 16.25 inches (41.3 cm)—  
Quantity: 3  
Tread Width: (Outside to Outside of  
Tires, Widthwise)  
• Deck Drive: Manual engagement of belt with  
over-center lock. Blade belt tension is adjustable  
via turnbuckle.  
32 inch  
Deck  
36 inch  
Deck  
48 inch  
Deck  
• Blade Brake: When the blade engagement control  
is moved to the disengaged position a friction  
brake pad stops the rotation of the blades.  
Standard  
32.1 inches 35.6 inches 35.6 inches  
Pistol Grip (81.4 cm)  
& ECS  
(90.4 cm)  
(90.4 cm)  
• Deck Mounting: Bolted directly to engine deck.  
• Deck Depth:  
Handles  
– 32 inch Deck: 5.0 inches (12.7 cm)  
– 36 inch Deck: 5.0 inches (12.7 cm)  
– 48 inch Deck: 5.0 inches (12.7 cm)  
• Cutting Height Adjustment:  
Curb Weight:  
32 inch  
Deck  
36 inch  
Deck  
48 inch  
Deck  
Standard  
477 lb  
495 lb  
(223 kg)  
536 lb  
(241 kg)  
Pistol Grip (215 kg)  
Handles  
Adjusts from 1 inch (2.5 cm) to 4 1/4 inches (10.8  
cm) in 1/4 inch (6.4 mm) or smaller increments  
by various adjustments of caster spacers, blade  
spacers, and axle height.  
ECS  
Handles  
507 lb  
(228 kg)  
507 lb  
(228 kg)  
554 lb  
(249 kg)  
Torque Requirements  
Dimensions  
Bolt Location  
Torque  
75-80 ft-lb (102-109 N-m)  
Overall Width:  
Blade/Cutter Housing  
Spindle Bolt  
32 inch  
Deck  
36 inch  
Deck  
48 inch  
Deck  
Caster Bracket Mounts  
30-35 ft-lb (41-48 N-m)  
30-35 ft-lb (41-48 N-m)  
Mower Deck/Engine  
Deck Mount  
Deflector  
Up  
32.7 inches 36.4 inches 48.1 inches  
(83.1 cm) (92.5 cm) (122.2 cm)  
Engine Mounting Bolts  
17-23 ft-lb (23-31 N-m)  
Deflector  
Down  
43.3 inches 47.0 inches 57.9 inches  
(110.0 cm) (119.4 cm) (147.1 cm)  
Transmission Shifter Lever 30-35 ft-lb (41-48 N-m)  
Nut  
13  
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Operation  
Product Overview  
Operation  
Note: Determine the left and right sides of the  
machine from the normal operating position.  
Controls  
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 PTO is engaged (see Figure 4 and  
Figure 5).  
Figure 3  
1. Controls  
2. Fuel Cap  
3. Pistol Grip Handles  
4. ECS Handles  
5. Blade Spacers  
Figure 4  
Pistol Grip Handle  
1. Neutral Lock/Park Brake Latch  
2. Rotate latch forward for park brake position  
3. Rotate latch back for neutral lock position  
4. OPC Lever  
5. Drive Lever  
14  
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Operation  
Choke Control  
Located on the front left corner of the fuel tank  
support.  
Choke is used to aid in starting a cold engine. The  
choke control is pulled out to be in the “ON” position  
and pushed in to be in the “OFF” position. Do Not  
run a warm engine with choke in the “ON” position.  
Throttle Control  
Located on the on the control console right side.  
Figure 5  
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. Moving the throttle forward into the detent  
is full position.  
ECS Handle  
1. OPC Lever  
2. Rotate latch for neutral lock and park brake positions  
3. Neutral Lock Latch/Park Brake Latch  
4. Drive Lever  
Transmission Shift Lever  
Drive Levers  
Located under the control console and behind the  
fuel tank.  
Located on each side of the upper handle assembly  
ahead of and below the handle grips (see Figure 4  
and Figure 5).  
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 drive levers in neutral may cause damage to  
the transmission.  
These levers individually control clutching action of  
the wheel drive belts and brakes. When the drive  
levers are all the way down, the brakes disengage and  
the wheel drive belts engage  
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.  
Gradually squeezing the left or right hand drive lever  
disengages the wheel drive belts, causing the left hand  
or right hand wheel to slow down until they reach  
neutral or stop. This makes the machine turn to the  
left or right respectively. Squeezing further engages  
the park brakes. The sharpness 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.  
“Off-Run” Switch  
Located on the control console.  
Turn the key to the “Run” position to allow the  
engine to be started. Turn the key to the “Off ”  
position to shut engine off.  
Neutral Lock/Park Brake Latches  
For Pistol Grip Handles: Located on handles  
Fuel Shut-Off Valve  
Located in the fuel line midway between the tank  
and engine.  
ahead of the grips.  
For ECS Handles: Located on the upper handle  
assembly on the ends of the handle grips.  
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.  
The latches 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 not engaged  
and the park brake is engaged (see Figure 4 and  
Figure 5).  
Rotate valve 1/4 turn clockwise to shut fuel off.  
Rotate valve 1/4 turn counterclockwise to turn fuel  
on.  
15  
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Operation  
PTO Engagement  
DANGER  
The rotating blades under the mower deck are  
dangerous. Blade contact can cause serious  
injury or kill you.  
Pre-Start  
Fill fuel tank on level ground. For best results use  
only clean, fresh regular grade unleaded gasoline with  
an octane rating of 87 or higher.  
Important: Never use methanol, gasoline  
containing methanol, gasohol containing more  
than 10% ethanol, premium gasoline, or white  
gas because the fuel system could be damaged.  
Do Not put hands or feet under the mower or  
mower deck when the blades are engaged.  
Do Not add oil to gasoline.  
DANGER  
Do Not overfill fuel tank. Fill the fuel tank to the  
bottom of the filler neck. The empty space in the  
tank allows gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine or emission  
system.  
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. Thrown objects or blade  
contact can cause serious injury or death.  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Never operate the mower with the discharge  
deflector raised, removed, or altered unless there  
is a grass collection system or mulch kit in place  
and working properly.  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
The PTO switch engages the cutting blades. Be sure  
that all persons are clear of mower deck and discharge  
area before engaging the PTO.  
Operating Instructions  
1. Set throttle to “MIDWAY” position.  
Open the Fuel Shut-Off Valve  
2. Push the PTO lever forward to engage blades.  
Rotate the valve 1/4 turn counterclockwise to turn  
fuel on.  
3. Place the throttle in the “FAST” position to begin  
mowing.  
Starting the Engine  
Disengaging the PTO  
1. Set throttle to “MIDWAY” position.  
Note: Always engage the left and right neutral  
lock/park brake latches in the “park brake” position  
when starting the engine  
2. Pull the blade engagement lever to the full  
rearward position to disengage the blades  
1. On a cold engine, place the throttle midway  
between the “Slow” and “Fast” positions and  
place the choke in the “On” position. On a warm  
engine, place the throttle lever midway between  
“Slow” and “Fast” positions and leave the choke  
in the “Off ” position.  
Stopping the Engine  
1. Bring the unit to a full stop.  
2. Lock drive levers in “park brake” position.  
3. Disengage the PTO.  
2. Turn ignition switch to “Run” position. Pull the  
recoil rope to start engine.  
4. Move transmission shift lever to “neutral”.  
3. On a cold engine, gradually return choke to the  
“Off ” position after engine starts and warms up.  
5. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
6. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
Note: Kawasaki engines generally need to be  
“choked” even when warm.  
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Operation  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
Driving the Machine  
Drive Lever/Neutral Lock/Park Brake Latch  
Operation  
For Pistol Grip Handles  
To lock the drive levers in “neutral”, squeeze the  
drive levers back to the neutral position. Place  
thumbs on the upper portion of the neutral  
lock/park brake latches and move them to the  
rear. Release the drive levers.  
Figure 6  
6. Neutral lock  
1. Latch is in the drive  
position  
2. Rotate forward for park  
brake position  
7. Forward — release drive  
lever  
To lock the levers in “park brake”, squeeze the  
drive levers back to the brake position. Place  
thumbs on the upper portion of the neutral  
lock/park brake latches and move them to the  
front. Release the drive levers (see Figure 6)  
3. Rotate back for neutral  
lock position  
4. Park brake  
8. Neutral —hold in this  
position  
9. Reverse—squeeze drive  
lever  
5. Full speed forward  
For ECS Handles  
CAUTION  
To lock the drive levers in “neutral lock”, squeeze  
the drive levers to the “neutral” position. See  
Figure 7 position 2. Place thumbs on the inner  
thumb lobe of the neutral lock /park brake latches  
and rotate them to the “neutral” position. See  
Figure 7 position 3. Release the drive levers.  
If the neutral lock/park brake latches are not  
completely engaged the drive levers could  
unexpectedly slip into the forward drive  
position. If the drive levers slip into the drive  
position, the unit could lurch forward and  
cause injury or property damage.  
To lock the 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  
to the “park” position. See Figure 7 position 4.  
Release drive levers.  
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 the neutral lock/park brake  
latches and move them out of the “neutral” or  
the “park brake” position. Slowly and smoothly  
release the drive levers.  
CAUTION  
If the neutral lock/park brake latches are not  
completely engaged the drive levers could  
unexpectedly slip into the forward drive  
position. If the drive levers slip into the drive  
position, the unit could lurch forward and  
cause injury or property damage.  
Be sure the drive levers are securely seated at  
the bottom of the “neutral” or “park” areas of  
the neutral lock latches.  
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Operation  
To place the drive levers in the “drive” position,  
slightly squeeze the drive levers while placing  
thumbs on the outer thumb lobe of the neutral  
lock/park brake latches (or the index finger on  
the front lobe) and rotate them from under the  
drive levers. Slowly and carefully release the drive  
levers. See Figure 7 position 1.  
Smoothly release both drive levers to engage drive  
wheels.  
Pull the unit backward to “assist” with the movement  
of the unit.  
To stop, squeeze drive levers all the way back to  
engage the brakes. Move the neutral lock latches into  
the “park brake” position and release drive levers.  
Move the speed control lever to the neutral position.  
Changing Gears  
When changing gears, always squeeze drive levers to  
the neutral position. The shift lever may be moved  
with a knee or by hand (engage the neutral lock  
latches if shifting by hand).  
Note: Reverse gear is “reverse assist” only, the  
operator must pull the unit backwards.  
Transporting  
Figure 7  
1. Drive Lever in drive  
position  
2. Drive Lever in neutral  
position  
3. Drive Lever locked in  
neutral position  
4. Drive Lever locked in  
park position  
Transporting a Unit  
WARNING  
Loading the mower onto a trailer without strong  
enough or properly supported ramps could be  
dangerous. The ramps could collapse causing  
the unit to fall, which could cause injury.  
Driving Forward  
1. With drive levers in the “neutral” or “park brake”  
position, shift transmission into desired gear.  
• Use proper ramps that are secured to the  
truck or trailer.  
2. Squeeze both drive levers and move both neutral  
lock/park brake latches from the “neutral” or  
“park brake” position to the “drive” position.  
• Keep feet and legs out from under the unit  
when loading and unloading.  
3. To move forward in a straight line, smoothly  
release both drive levers to engage drive wheels.  
• If necessary, use assistance when loading.  
To turn left or right, squeeze the right hand drive  
lever to turn right and the left hand drive lever  
to turn left.  
Be sure the fuel shut-off valve is closed.  
Use a heavy duty trailer to transport the machine.  
Engage neutral lock latches and park brake, then  
block wheels.  
Squeeze drive levers all the way back to engage  
brakes. Move neutral lock/park brake latches into  
the “park brake” position and release drive levers.  
Shift transmission into neutral.  
Securely fasten the machine to the trailer with straps,  
chains, cables, or ropes.  
Driving in Reverse  
Do Not rely solely on the parking brake to hold the  
machine on the trailer.  
Note: Reverse gear is reverse assist only, the operator  
must pull the unit backwards.  
Be sure that the trailer has all necessary lighting and  
marking as required by law and use a safety chain.  
To move rearward, squeeze the drive levers to neutral  
position and move the shifter to the “R”.  
18  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could seriously  
injure you or other bystanders.  
The engine can become very hot. Touching a hot  
engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine area.  
Remove the key from the ignition switch, engage  
parking brake, 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).  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check for loose hardware.  
• Grease the front caster wheel bearings.  
• Grease front caster pivots.  
• Grease the drive wheels.  
Before each use or daily  
• Grease the drive wheel idler arm.  
• Clean the engine and exhaust system area.  
• Clean the grass and debris build-up from the machine and cutting deck.  
• Clean the grass build-up from under the deck.  
• Service the foam element. (May need more often under severe conditions. See the Engine  
Owner’s manual for additional information.)  
Every 25 hours  
Every 40 hours  
• Check the tire pressures.  
• Check the condition of the belts.  
• Grease the brake arm.  
• Grease the transmission output shaft coupler  
• Grease the mower deck idler pivots  
• Service the paper element. (May need more often under severe conditions. See the Engine  
Owner’s manual for additional information.)  
• Change the engine oil. (May need more often under severe conditions.)  
• Remove engine shrouds and clean cooling fins.  
Every 100 hours  
Every 160 hours  
• Check the spark plugs.  
• Check grease level, input and output shaft bearing wear on Peerless Transmission.  
• Replace the paper element.  
• Replace the emissions air intake filter.  
• Replace gearbox grease.  
Every 200 hours  
Every 500 hours  
Yearly  
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Maintenance  
Periodic Maintenance  
Check Engine Oil Level  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
2. Check with engine cold.  
3. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Do Not screw into  
place. Remove the dipstick and read the oil level.  
4. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Exmark 4-Cycle Premium  
Engine Oil is recommended; refer to the Engine  
Owner’s manual for an acceptable alternative. Do  
Not overfill.  
Figure 8  
1. Spring disc washer (cone towards bolt head)  
2. Blade bolt torque to 75-80 ft-lb (102-109 N-m).  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
Replacing the Discharge  
Deflector  
Service Interval: As required  
Check Mower Blades  
Service Interval: Before each use or daily  
DANGER  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
An uncovered discharge opening could allow the  
lawn mower to throw objects in the operator’s or  
bystander’s direction and result in serious injury.  
Also, contact with the blade could occur.  
2. Lift deck and secure in raised position as stated  
in the Clean Grass Build-Up Under Deck  
procedure.  
Never operate the lawn mower unless you install  
a mulch plate, discharge deflector, or grass  
collection system.  
3. Inspect blades and sharpen or replace as required.  
4. Re-install the blades (if they were removed) and  
torque blade bolts to 75-80 ft-lb (102-109 N-m).  
Be sure the spring disc washer cone is installed  
toward the bolt head (see Figure 8).  
1. To remove a damaged or worn discharge  
deflector, lift the leg of the spring with the loop  
out of the notch in the discharge deflector and  
slide the rod out of the discharge deflector  
brackets, and discharge deflector.  
2. To install new discharge deflector, orient the  
spring on the rod as shown in Figure 9. Slide the  
rod through the front discharge deflector bracket,  
discharge deflector, and rear deflector bracket.  
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Maintenance  
shift the transmission into gear and release the  
OPC levers–the engine must stop.  
3. Again, run the engine at on-third throttle, move  
the transmission shifter lever to neutral, engage  
the PTO and release the OPC levers–the engine  
must stop.  
Note: If machine does not pass any of these tests,  
do not operate. Contact your authorized EXMARK  
SERVICE DEALER.  
Important: It is essential that operator safety  
mechanisms be connected and in proper  
operating condition prior to use for mowing.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Figure 9  
4. Mower deck  
1. Rod  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
2. Spring  
5. Discharge deflector  
bracket  
6. Assembled view  
3. Discharge deflector  
3. Hook the bent end of the rod around the front  
discharge deflector bracket to retain it from  
sliding out. Place the leg of the spring with the  
loop in the notch in the discharge deflector to  
hold the discharge deflector in the down position  
(see Figure 9).  
Service Air Cleaner  
Service Interval: Every 25 hours—Service  
the foam element. (May  
need more often under  
severe conditions. See  
the Engine Owner’s  
Important: The discharge deflector must be  
spring loaded in the down position. Lift the  
deflector up to test that it snaps to the full  
down position.  
manual for additional  
information.)  
Every 100 hours—Service  
the paper element. (May  
need more often under  
severe conditions. See the  
Engine Owner’s manual  
for additional information.)  
Check Safety Interlock  
System  
Service Interval: Before each use or daily  
1. For your safety, your Exmark mower is equipped  
with Operator Presence Controls, referred to as  
(OPC). When either the PTO is engaged, or the  
transmission shifter lever is not in neutral and the  
operator removes both hands from the handles,  
the mower engine must stop.  
Every 200 hours/Yearly  
(whichever comes  
first)—Replace the paper  
element.  
1. Stop engine, wait for all moving parts to stop, and  
remove key or spark plug wire(s). Engage parking  
brake.  
2. To determine if the OPC is in operating condition,  
clear area of bystanders. Run the engine at  
2. See the Engine Owner’s Manual for maintenance  
instructions.  
one-third throttle, then with the drive levers and  
neutral lock latches in the “park brake” position,  
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Maintenance  
Change Engine Oil  
Check Condition Of Belts  
Service Interval: After the first 5 hours  
Service Interval: Every 40 hours  
Every 100 hours (May  
need more often under  
severe conditions.)  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Remove the mower deck belt shield to check  
mower blade drive belt condition.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Look under engine deck to check the transmission  
drive belt condition.  
2. Drain oil while engine is warm from operation.  
3. Remove the oil drain plug from the right hand  
side of the engine. Allow oil to drain, replace  
drain plug.  
4. Inspect wheel drive belt conditions.  
5. Check all idler arms to be sure they pivot freely.  
Disassemble, clean and grease pivot bushings if  
necessary.  
4. Replace the oil filter per the engine owner’s  
manual. Clean around oil filter and unscrew filter  
to remove. Before the new filter is installed,  
apply a thin coating of Exmark 4–Cycle Premium  
Engine 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.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Lubricate fittings with NGLI grade #2  
multi-purpose gun grease.  
5. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
6. Use oil recommended in the Check Engine Oil  
Level section. Do Not overfill. Start the engine  
and check for leaks. Stop engine and recheck oil  
level.  
Lubrication Chart  
Fitting  
Locations Pumps  
Initial  
Number of Places  
Service  
Interval  
7. Wipe up any spilled oil from engine deck  
mounting surfaces.  
32 inch 36 inch 48 inch  
Deck  
Deck  
Deck  
Check Tire Pressures  
Service Interval: Every 40 hours  
1. Front  
Caster  
Wheel  
12  
2
2
2
2
Daily  
Daily  
Bearings  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Front  
Caster  
Pivots  
2
2
2
2. Check tire pressure in drive tires.  
3. Drive  
Wheels  
18  
2
2
2
2
2
2
2
Daily  
Daily  
3. Inflate drive tires to 12–16 psi (83–110 kPa).  
4. Inflate tires to pressures stated above. Measure  
the circumference of each drive tire. Adjust tire  
pressures within the above range to try to make  
tire circumferences match as closely as possible.  
4. Drive  
Wheel  
Idler Arm  
2
2
2
2
40  
hours  
5. Brake  
Arm  
5. Semi-pneumatic caster tires Do Not need to be  
inflated.  
Note: A more uniform cutting height may be  
obtained with higher tire pressure on rough terrain.  
A lower tire pressure provides more flotation.  
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Maintenance  
Lubrication Chart (cont'd.)  
Check Spark Plugs  
Service Interval: Every 160 hours  
Fitting  
Locations Pumps  
Initial  
Number of Places  
Service  
Interval  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner’s  
Manual.  
2
2
2
2
2
40  
hours  
6. Trans-  
mission  
Output  
Shaft  
Coupler  
Change Fuel Filter  
Service Interval: As required  
7. Mower  
Deck  
Idler  
1
1
1
40  
hours  
Pivots  
A fuel filter is installed in the fuel line between the  
fuel tank and the engine. Replace when necessary.  
Replace Emissions Air Intake  
Filter  
Service Interval: Every 500 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key or spark plug wire(s). Engage parking  
brake.  
2. Remove the filter from the vent hose.  
3. Insert a new filter into the end of the vent hose.  
Check Grease Level,  
Input and Output Shaft  
Bearing Wear on Peerless  
Transmission  
Service Interval: Every 160 hours—Check  
grease level, input and  
output shaft bearing  
48 inch Deck Shown for Reference Only  
Number 4 and 7 (Idler Arm Pivots) Disassemble and  
grease once a month under a “No Load” condition  
Number 6 (Transmission Coupler) Located  
below fuel tank support  
3. Replace 5-speed gearbox grease yearly. Use 18 oz.  
of Peerless grease (Part No. 788067). See Check  
Grease Level, Input and Output Shaft Bearing  
Wear on Peerless Transmission section for  
special lubrication instructions.  
wear on Peerless  
Transmission.  
Yearly—Replace gearbox  
grease.  
4. Lubricate pivot points with a spray penetrating  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake. Remove key  
or spark plug wire(s).  
lubricant as shown in the Spray Lubricant Chart.  
Spray Lubricant Chart  
2. Place drive levers and neutral lock/park brake  
latches in neutral lock position  
Number of Places  
Pivot Points 32 inch  
Deck  
36 inch  
Deck  
48 inch  
Deck  
Service  
Interval  
3. Remove shifter lever from top of transmission.  
4. Remove shifter plate from top of transmission  
and the two leads from the neutral start switch.  
1
1
1
1. Blade  
Engagement  
Bellcrank  
40 hours  
5. Release the tension on the transmission belt.  
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Maintenance  
6. Check for side play caused by bearing wear on  
the input and output shafts of the transmission.  
Replace bearings if necessary.  
Copper-Based Anti-seize  
Copper-based anti-seize is used in the following  
locations:  
7. Remove the six bolts that fasten the upper case  
to the lower case and carefully remove the upper  
case half  
• Between the blade drive and transmission drive  
pulleys and engine crankshaft.  
• Between the transmission drive pulley and  
transmission drive shaft.  
8. Check the grease level in the lower case. The  
grease level should be approximately 1 1/2 inch  
to 1 3/4 inch (3.8 to 4.4 cm) from the gearbox  
bottom. If necessary, fill to proper level with  
Peerless grease (Part No. 788067).  
• Between the bearings and sheaves and  
transmission output shafts.  
9. Reinstall upper case half and fasten in place with  
six bolts previously removed.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
10. Reinstall all parts removed in steps 3 and 4. Install  
drive belt and adjust tension as stated in the  
Transmission Belt Adjustment section.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
• All belt drive pulley setscrews.  
• OPC lever setscrews.  
• Pulley retaining bolt in end of engine crankshaft.  
• Fuel tank bulkhead fitting threads  
Adhesives such as “Loctite RC/609 or RC/680” or  
“Fel-Pro Pro-Lock Retaining I or Retaining II” are  
used on the following:  
• 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.  
• Fuel tank studs, where studs are inserted into tank.  
Mobil HTS Grease (Or  
Food-Grade Anti-seize)  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
• Between the cutter housing spindle and bearings.  
• Between the cutter housing spindle and sheave.  
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Maintenance  
than adjusting axle position and number of spacers  
below caster support hub).  
Adjustments  
Note: Disengage PTO, shut off engine, wait for  
all moving parts to stop, engage parking brake, and  
remove key before servicing, cleaning, or making any  
adjustments to the unit.  
Note that:  
• For the best cut and discharge, place a minimum  
of two spacers between the blade and the spindle.  
• For highest quality cut, place all four spacers  
between the blade and the spindle.  
Adjusting the Cutting Height  
• If mulching kit is installed, the highest quality cut  
can be obtained with 3 spacers between the blade  
and the spindle (minimum is 1 for a good cut).  
The cutting height of the mower deck is adjusted  
from 1 inch to 4 1/4 inches (2.54 cm to 11.4 cm) in  
1/4 inch (.64 cm) increments by adjusting the axle  
position, number of spacers below the caster hub,  
and number of spacers between blade and spindle.  
• When mulching leaves it is best to have fewer  
spacers between blade and spindle.  
Refer to the Cutting Height Adjustment table and  
select a cutting height range in the left hand column  
which corresponds to the range of cutting heights  
you will most often be using. Adjustments within this  
range can then be made by adjusting the number of  
blade spacers between the blade and the bottom of  
the spindle (this is a much easier adjustment to make  
Refer to the table and select desired cutting height  
range. Refer to Adjusting the Axle Position,  
Adjusting the Number of Spacers below Caster  
Support Hub, and Adjusting the Cutting  
Height with Blade Spacers and sections to make  
adjustments make adjustment to obtain specific  
cutting height.  
Cutting Height Adjustment Table (1 inch to 4 1/4 inches (2.5 cm-10.8 cm))  
Cutting  
Height  
Range  
Axle  
Position  
(Figure 10)  
Number Of Spacers  
Below Caster  
Number of 1/4 inch (.64 cm) Blade Spacers Below Spindle  
Support Hub  
4
3
2
1
0
1/2  
inch  
3/16  
inch  
(1.2 cm)  
(.48 cm)  
1–2 inches  
(2.5–5.0 cm)  
1 inch  
(2.5 cm)  
1 1/4 inch  
(3.2 cm)  
1 1/2 inch  
(3.5 cm)  
1 3/4 inch  
(4.4 cm)  
2 inch  
(5.0 cm)  
A
A
A
B
B
0
0
1
0
1
0
1
0
1
0
1 1/8–  
2 1/8 inches  
(2.9–5.4 cm)  
1 1/8 inch  
(2.9 cm)  
1 3/8 inch  
(3.5 cm)  
1 5/8 inch  
(4.1 cm)  
1 7/8 inch  
(4.8 cm)  
2 1/8 inch  
(5.4 cm)  
1 3/8–  
2 3/8 inches  
(3.5–6.0 cm)  
1 3/8 inch  
(3.5 cm)  
1 5/8 inch  
(4.1 cm)  
1 7/8 inch  
(4.8 cm)  
2 1/8 inch  
(5.4 cm)  
2 3/8 inch  
(6.0 cm)  
1 3/8–  
2 3/8 inches  
(3.5–6.0 cm)  
1 3/8 inch  
(3.5 cm)  
1 5/8 inch  
(4.1 cm)  
1 7/8 inch  
(4.8 cm)  
2 1/8 inch  
(5.4 cm)  
2 3/8 inch  
(6.0 cm)  
1 5/8–  
2 5/8 inches  
(4.1–6.7 cm)  
1 5/8 inch  
(4.1 cm)  
1 7/8 inch  
(4.8 cm)  
2 1/8 inch  
(5.4 cm)  
2 3/8 inch  
(6.0 cm)  
2 5/8 inch  
(6.7 cm)  
1 3/4–  
2 3/4 inches  
(4.4–7.0 cm)  
1 3/4 inch  
(4.4 cm)  
2 inch  
(5.0 cm)  
2 1/4 inch  
(5.7 cm)  
2 1/2 inch  
(6.4 cm)  
2 3/4 inch  
(7.0 cm)  
B
B
1
2
1
0
2–3 inches  
(5.0–7.6 cm)  
2 inch  
(5.0 cm)  
2 1/4 inch  
(5.7 cm)  
2 1/2 inch  
(6.4 cm)  
2 3/4 inch  
(7.0 cm)  
3 inch  
(7.6 cm)  
1 7/8–  
2 7/8 inches  
(4.8–7.3 cm)  
1 7/8 inch  
(4.8 cm)  
2 1/8 inch  
(5.4 cm)  
2 3/8 inch  
(6.0 cm)  
2 5/8 inch  
(6.7 cm)  
2 7/8 inch  
(7.3 cm)  
C
1
1
25  
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Maintenance  
Cutting Height Adjustment Table (1 inch to 4 1/4 inches (2.5 cm-10.8 cm)) (cont'd.)  
Cutting  
Height  
Range  
Axle  
Position  
(Figure 10)  
Number Of Spacers  
Below Caster  
Number of 1/4 inch (.64 cm) Blade Spacers Below Spindle  
Support Hub  
4
3
2
1
0
1/2  
inch  
3/16  
inch  
(1.2 cm)  
(.48 cm)  
2 1/8–  
3 1/8 inches  
(5.4–7.9 cm)  
2 1/8 inch  
(5.4 cm)  
2 3/8 inch  
(6.0 cm)  
2 5/8 inch  
(6.7 cm)  
2 7/8 inch  
(7.3 cm)  
3 1/8 inch  
(7.9 cm)  
C
C
2
2
3
2
3
0
1
0
1
0
2 1/4–  
3 1/4 inches  
(5.7–8.3 cm)  
2 1/4 inch  
(5.7 cm)  
2 1/2 inch  
(6.4 cm)  
2 3/4 inch  
(7.0 cm)  
3 inch  
(7.6 cm)  
3 1/4 inch  
(8.3 cm)  
2 1/2–  
3 1/2 inches  
(6.4–8.9 cm)  
2 1/2 inch  
(6.4 cm)  
2 3/4 inch  
(7.0 cm)  
3 inch  
(7.6 cm)  
3 1/4 inch  
(8.3 cm)  
3 1/2 inch  
(8.9 cm)  
C
2 3/8–  
3 3/8 inches  
(6.0–8.6 cm)  
2 3/8 inch  
(6.0 cm)  
2 5/8 inch  
(6.7 cm)  
2 7/8 inch  
(7.3 cm)  
3 1/8 inch  
(7.9 cm)  
3 3/8 inch  
(8.6 cm)  
D
D
2 1/2–  
3 1/2 inches  
(6.4–8.9 cm)  
2 1/2 inch  
(6.4 cm)  
2 3/4 inch  
(7.0 cm)  
3 inch  
(7.6 cm)  
3 1/4 inch  
(8.3 cm)  
3 1/2 inch  
(8.9 cm)  
2 3/4–  
3 3/4 inches  
(7.0–9.5 cm)  
2 3/4 inch  
(7.0 cm)  
3 inch  
(7.6 cm)  
3 1/4 inch  
(8.3 cm)  
3 1/2 inch  
(8.9 cm)  
3 3/4 inch  
(9.5 cm)  
D
D
3
4
1
0
3–4 inches  
(7.6–10.1 cm)  
3 inch  
(7.6 cm)  
3 1/4 inch  
(8.3 cm)  
3 1/2 inch  
(8.9 cm)  
3 3/4 inch  
(9.5 cm)  
4 inch  
(10.1 cm)  
2 7/8–  
3 7/8 inches  
(7.3–9.8 cm)  
2 7/8 inch  
(7.3 cm)  
3 1/8 inch  
(7.9 cm)  
3 3/8 inch  
(8.6 cm)  
3 5/8 inch  
(9.2 cm)  
3 7/8 inch  
(9.8 cm)  
E
E
E
3
4
4
1
0
1
3 1/8–  
4 1/8 inches  
(7.9–10.5 cm)  
3 1/8 inch  
(7.9 cm)  
3 3/8 inch  
(8.6 cm)  
3 5/8 inch  
(9.2 cm)  
3 7/8 inch  
(9.8 cm)  
4 1/8 inch  
(10.5 cm)  
3 1/4–  
4 1/4 inches  
(8.3–10.8 cm)  
3 1/4 inch  
(8.3 cm)  
3 1/2 inch  
(8.9 cm)  
3 3/4 inch  
(9.5 cm)  
4 inch  
(10.1 cm)  
4 1/4 inch  
(10.8 cm)  
Important: Always adjust the Number of Spacers below Caster Hub to correspond to the Axle  
Position as shown in table to obtain proper “rake” (blades should always be level to the ground  
or tipped slightly down at the front).  
Adjusting the Axle Position  
3. Place the drive levers in the neutral lock position.  
4. Remove mower deck belt shield for access to axle  
adjustment bolts.  
Desired cutting height range can be obtained by  
adjusting the rear axle and placing caster spacers  
above or below the caster arm (See Figure 10 and  
Figure 11 along with the Cutting Height Adjustment  
Chart). It may be necessary to readjust wheel drive  
and brake linkages.  
5. Loosen but do not remove the two axle pivot  
bolts and the two axle adjustment bolts (see  
Figure 10).  
6. Place a jack under the rear center of the engine  
deck.  
To adjust rear axle:  
1. Stop the machine and move the drive levers to  
the neutral lock position.  
7. Raise the back end of the engine deck up enough  
to remove the two axle adjustment bolts.  
2. Disengage the PTO.  
26  
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Maintenance  
8. With the jack, raise or lower the back end of the  
engine deck so that two axle adjustment bolts can  
be reinstalled in desired hole location. A tapered  
punch can be used to help align the holes.  
9. Retighten all four bolts, lower unit and remove  
jack.  
10. Install mower deck belt shield.  
11. Adjust wheel drive and brake linkages as  
required (see Brake and Wheel Drive Linkage  
Adjustment section).  
Figure 11  
1. Four 1/2 inch (127 mm) 3. 3/16 inch (4.8 mm)  
spacers  
spacer  
2. Quick Pin  
4. Caster support  
7. Adjust the number of 1/2 inch spacers between  
bottom of hub and caster yoke to obtain the  
desired cutting height from the Cutting Height  
Adjustment Table in the Adjusting the Cutting  
Height section.  
8. Install remaining spacers on top of hub.  
9. Install “quick pin”.  
Figure 10  
1. Axle Pivot Bolt  
5. Position C  
6. Position D  
10. Repeat for other caster.  
2. Axle Adjustment Holes  
(Located in the side of  
the rear deck.)  
Adjusting the Cutting Height  
with Blade Spacers  
3. Position A  
4. Position B  
7. Position E  
8. Place jack here  
1. Stop the machine and move the drive levers to the  
neutral locked position.  
Note: The axle positions are in 1/2 inch (1.3 cm)  
increments and the large caster spacers are 1/2  
inch (1.3 cm) thick. Therefore, by adjusting the  
same number of 1/2 inch (1.3 cm) caster spacers as  
axle hole positions the blades will retain the same  
front-to-back tip (rake).  
2. Disengage the PTO.  
3. Engage the park brake.  
4. Stop the engine, remove the key and wait for all  
moving parts to stop.  
5. Blades may be adjusted for cutting height by using  
the four 1/4 inch (.64 cm) spacers found on the  
blade spindle bolts (factory setting is two above  
and two below). This allows a 1 inch (2.5 cm)  
range in 1/4 inch (.64 cm) increments of cutting  
height in any axle position. The same number  
of blade spacers must be used on all blades to  
achieve a level cut (two above and two below, one  
above and three below, etc.).  
Adjusting the Number  
of Spacers below Caster  
Support Hub  
1. Stop the machine and move the drive levers to  
the neutral lock position.  
2. Disengage the PTO.  
3. Place the drive levers in the “park brake” position.  
6. Raise front of deck and support with jack stands.  
4. Push down on handles to lift front casters off the  
ground.  
5. Support with jackstands.  
7. Hold blade bolt on bottom and loosen spindle  
nut on top.  
6. Remove “quick pin” from one caster and remove  
caster from hub (see Figure 11).  
8. Adjust number of spacers between bottom of  
spindle and blade as indicated in the Cutting  
27  
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Maintenance  
Height Adjustment Table and notes in the  
Adjusting the Cutting Height section.  
Wheel Drive Belt Pulley  
Scrapers  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove key or spark plug  
wire(s).  
9. Install unused spacers between top of spindle and  
spindle nut.  
10. Torque bolt to 75–80 ft-lb (102–109 N-m) (see  
Figure 12).  
2. 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.  
Engine to Mower Deck Belt  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove key or spark plug  
wire(s).  
2. Check the adjustment of the lower blade drive  
linkage located between the bellcrank on the  
engine deck and assist arm on the mower deck.  
Lengthen or shorten the linkage. When properly  
adjusted, there should be 1/16 inch to 1/8 inch  
(2–3 mm) of clearance between bell-crank and  
transmission output shaft when belt is engaged.  
Make sure the assist arm is against the rear assist  
arm stop on the deck (see Figure 13). Push the  
lever down to the disengaged position. The assist  
arm should contact the front assist arm stop on  
the deck. If it does not contact, readjust so that  
the bellcrank is closer to the transmission output  
shaft.  
Figure 12  
1. Spring disc washer  
(cone towards bolt head)  
2. Blade bolt torque to  
75–80 ft-lb (102–109  
N-m)  
Transmission Belt  
Adjustment  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove key or spark plug  
wire(s).  
3. Belt must be tight enough to not slip during heavy  
loads while cutting grass. Over-tensioning will  
reduce belt and spindle bearing life. To adjust  
belt tension, loosen the 5/16 inch whizlock nut  
on turnbuckle and rotate the turnbuckle; rotate  
turnbuckle toward rear of mower to tighten, and  
toward front of mower to loosen belt tension (see  
Figure 13). Leave a minimum of 5/16 inch (.79  
cm) of the eyebolt threads engaged on both ends  
of the turnbuckle.  
2. To tighten transmission belt, loosen the 3/8 inch  
nyloc nut on transmission belt idler pulley. Slide  
bolt inward in slot and retighten nyloc nut.  
3. When properly adjusted, the belt should have 1/2  
inch (1.3 cm) of deflection with three pounds  
of pressure on the belt midway between the  
transmission and engine pulley.  
For 48” Decks: If there is no adjustment left in  
the turnbuckle and the belt is still loose, the rear  
idler pulley can be repositioned in the front hole  
(See Figure 12). The belt guide located next to  
the pulley must also be repositioned in the front  
hole when the pulley is moved. The turnbuckle  
will need to be readjusted.  
28  
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Maintenance  
Check belt tension after the first hour of operation  
and at least twice during the first 24 hours of  
operation. Adjust as necessary.  
Mower Deck Belt Routings:  
Figure 13  
Figure 14  
48 inch Deck Shown for Reference Only  
32 inch and 36 inch Mower Deck  
1. Pulley location for Metro  
2. Pulley can be moved to the front position to tighten the  
belt when there is no adjustment left in the turnbuckle  
(48 inch deck only)  
3. Belt guide must be moved to the front position if the  
pulley is moved. (48 inch deck only)  
4. Turnbuckle  
5. 5/16 inch (.79 cm) minimum engagement  
6. 5/16 inch whizlock nut  
7. Rear Assist Arm Stop  
8. Assist Arm  
9. Front Assist Arm Stop  
10. Point “A”  
4. Proper belt tension will require about 10 lb (4.5  
kg) side pull on belt, halfway between pulleys (see  
Figure 13, item 10–Point A) to deflect belt 1/2  
inch (12 mm).  
Figure 15  
48 inch Mower Deck  
5. Check belt guide under the engine deck to see that  
it is properly set (see Belt Guide Adjustment  
section). Also check the blade brake adjustment  
(see Blade Brake Adjustment section).  
Blade Brake Adjustment  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove key or spark plug  
wire(s).  
2. Disengage blades.  
3. Make sure the blade brake pad rests against  
the sheave. Adjust the spring mounting bolts  
to properly align the pad on the sheave (see  
Figure 16).  
4. Check the distance between the spacer and the  
nut at the end of the blade brake rod. The  
29  
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Maintenance  
distance should be between 1/8 inch and 3/16  
inch (3–5 mm) (see Figure 16).  
5. Engage the blade control and check to make sure  
the blade brake pad clears the sheave.  
Figure 18  
48 inch Belt Guide Location  
(Viewed from underneath the deck)  
1. 1 3/8 inch (3.5 cm)  
Figure 16  
Shown with Blades Disengaged  
Brake and Wheel Drive  
Linkage Adjustment  
1. Check for correct brake adjustment:  
1. Blade Brake Rod  
3. 1/8 inch to 3/16 inch (3–5  
mm)  
2. Spring Mounting Bolts  
Place the drive levers in the “park brake”  
position. The mower should not move forward  
or backward. If it does, tighten the wingnuts.  
Belt Guide Adjustment  
Place the drive levers in the “neutral lock”  
position. The mower should move forward and  
backward freely. If it does not, brake adjustment  
is necessary  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove key or spark plug  
wire(s).  
2. Engage the blade drive belt.  
2. 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 to allow the neutral lock/park  
brake latches to be placed into the “park brake”  
position.  
3. Check belt guide under the engine deck for proper  
adjustment (See Figure 17 and Figure 18). Adjust  
as necessary.  
The disengaged belt should not drag or fall off  
pulley when guides are properly adjusted.  
See Figure 6 for Standard Pistol Grip handles and  
Figure 7 for ECS handles.  
Note: The neutral lock/park brake latches must  
be able to be moved into the park brake position,  
if not, the brake linkages must be adjusted again.  
3. Check for correct wheel drive linkage adjustment.  
For Pistol Grip Handles  
Allow drive levers to drop into the full forward  
position: The clevis pin should rest in the  
neutral lock latch with approximately 3/16  
inch to 1/4 inch (4.7–6.4 mm) clearance from  
the bottom of the slot (see Figure 19). Adjust  
if necessary.  
Figure 17  
32 inch and 36 inch Belt Guide Location  
(Viewed from underneath the deck)  
1. 1 1/4 inch (3.1 cm)  
To adjust the wheel drive linkage:  
30  
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Maintenance  
A. For wheel drive linkage adjustment,  
remove the hairpin between the neutral  
lock latch and drive lever (Figure 19).  
a slight upward force placed on the drive  
levers to remove any "slack" in the linkage.  
C. Re-install hairpin into hole on the clevis  
pin between the neutral lock/park brake  
latch and drive lever (See Figure 19).  
Repeat procedure on opposite side of unit.  
For ECS Handles:  
Allow drive levers to drop into the full forward  
position: the flat edge of the drive lever  
should align with the bottom roller notch (See  
Figure 21). Adjust if necessary  
Figure 19  
Left Side Shown  
1. Drive Lever  
4. Neutral Lock/Park Brake  
Latch  
2. Clevis Pin  
5. Hairpin  
3. Drive Linkage  
B. Adjust drive linkage length by threading  
into or out of the swivel until there is  
a 3/16 inch to 1/4 inch (.47-.64 cm)  
clearance between the linkage assembly  
and the bottom of the slot in the neutral  
lock/park brake latch (see Figure 20).  
Figure 21  
1. Notch in Neutral  
Lock/Park Brake Latch  
2. Drive Lever  
To adjust the wheel drive linkage:  
A. Locate a drive lever linkage on one side  
of the unit and remove the 5/16-18 x 1  
3/4 inch hex cap screw and 5/16-18 inch  
nyloc nut (see Figure 22).  
B. Thread drive lever linkage into or out of  
the swivel located on the wheel drive idler  
arm until the flat edge of the drive lever  
aligns with bottom of the roller notch  
in the neutral lock/park brake latch (see  
Figure 22).  
C. Re-install the 5/16-18 x 1 3/4 inch hex  
cap screw and secure with the 5/16-18  
inch nyloc nut. Repeat for the other side  
(see Figure 22).  
Figure 20  
1. 3/16 inch to 1/4 inch (.47 cm-.64 cm)  
2. Neutral Lock/Park Brake Latch  
3. Drive Linkage  
Note: Neutral lock/park brake latch  
clearance should be checked when there is  
31  
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Maintenance  
Figure 24  
3. Adjustment slot  
1. Shifter Lever  
2. Equal distance  
• To adjust the shifter lever:  
1. Remove the 3/8 inch nyloc nut and spring  
disc washer from the stud on top of the  
transmission (See Figure 25).  
Figure 22  
Right Side of Unit Shown  
1. Wingnut  
5. 5/16–18 x 1 3/4 inch hex  
capscrew  
2. Transmission Lever in  
neutral  
3. 5/16–18 inch nyloc nut  
6. Drive Lever Linkage  
7. Swivel  
4. Drive Levers in neutral  
8. Brake Rod  
Shifter Lever Adjustment  
The shifter lever in neutral should not contact the  
upper or lower edge of the slot or the left edge of  
the upper slot or the right edge of the bottom slot  
(See Figure 23 and Figure 24). The clearance should  
be equal. Adjust the shifter lever and shifter plate  
if necessary.  
Figure 25  
1. Shifter Lever  
3. Transmission  
2. Square Holed Washer  
2. Remove the shifter lever and bend it slightly.  
Do Not bend the lever while it is attached to  
the transmission.  
3. Re-install lever and torque the 3/8 inch nyloc  
nut to 35 ft-lb (47 N-m).  
• To adjust shifter plate:  
Figure 23  
Note: The square-hole washer must be between the  
lever and the transmission.  
1. Equal distance  
2. Shifter Lever  
3. Shifter Plate  
Place shifter lever in the neutral position. Loosen the  
two bolts securing the shifter plate to the shifter lever  
legs. Adjust shifter plate and retighten bolts.  
32  
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Maintenance  
Shifter Detent Adjustment  
Transmission shifter detent can be adjusted  
by adjusting the setscrew on the back side 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.  
Figure 26  
1. Upper Handle  
2. Upper Hole  
3. Adjustment Holes  
4. Fuel Tank Support  
Important: Screwing setscrew in too far will  
prevent the transmission from shifting.  
Note: Adjustment Holes are actually in the side  
of the fuel tank support.  
PTO Safety Switch  
Adjustment  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove key or spark plug  
wire(s).  
Wheel Drive Spring Tension  
Adjustment  
It may be necessary to increase wheel drive belt  
tension under certain operating conditions such as,  
wet grass, hilly terrain, or while pulling a sulky.  
2. With the blades disengaged and the bellcrank  
touching the engine deck, adjust the blade safety  
switch (if needed) until the bellcrank depresses  
the plunger by 1/4 inch (.64 cm).  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove key or spark plug  
wire(s).  
3. Be sure the bellcrank does not contact the switch  
body to prevent damage to the switch.  
2. Disengage neutral lock/park brake latches and  
release drive levers to lower spring force.  
4. Retighten switch mounting hardware.  
3. Remove the 5/16-18 inch whizlock nut securing  
the adjustment bolt to the drive wheel shield.  
Locate bolt assembly in the desired position as  
follows:  
Handle Height Adjustment  
The handle can be pivoted to allow positioning in  
one of the three holes allowing various adjustments  
for operator comfort (see Figure 26).  
• Position A-Normal Conditions  
• Position B-More Severe  
• Position C-Most Severe  
To adjust the handle height:  
1. Remove the bottom mounting hardware on each  
side of the handle.  
Note: Lever force is lowest with bolt assembly  
in Position A and will increase in Positions B and  
C (see Figure 27).  
2. Pivot the handle to one of the three positions.  
3. Re-install hardware and tighten.  
Important: If the handle height position is  
changed, it will be necessary to readjust the  
drive and brake linkage (see Check Brake and  
Wheel Drive Linkage Adjustment section in  
Operation.)  
33  
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Maintenance  
Cleaning  
Clean Engine and Exhaust  
System Area  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
conditions.)  
CAUTION  
Excessive debris around engine cooling air  
intake and exhaust system area can cause engine  
and exhaust system area to overheat which can  
create a fire hazard.  
Figure 27  
1. More traction applied as 4. Position C–Most Severe  
bolt moves down  
2. Position A–Normal  
Conditions  
3. Position B–More Severe  
5. Front of Unit  
Clean all debris from engine and exhaust system  
area.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean all debris from rotating engine air intake  
screen, around engine shrouding, and exhaust  
system area.  
3. Wipe up any excessive grease or oil around the  
engine and exhaust system area  
Remove Engine Shrouds and  
Clean Cooling Fins  
Service Interval: Every 100 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. 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.  
3. Make sure cooling shrouds are properly  
reinstalled. Operating the engine without  
cooling shrouds will cause engine damage due to  
overheating.  
34  
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Maintenance  
Clean Debris From Machine  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean off any oil, debris, or grass build-up on the  
machine and cutting deck, especially under deck  
belt shields, around the fuel tank, around engine  
and exhaust area.  
Clean Grass Build-Up Under  
Deck  
Service Interval: Before each use or daily  
1. Disengage PTO.  
2. Stop engine and wait for all moving parts to stop.  
Engage parking brake. Remove key or spark plug  
wire(s).  
3. Raise deck and support unit using jack stands or  
equivalent support.  
CAUTION  
Raising the mower for service or maintenance  
relying solely on mechanical or hydraulic  
jacks could be dangerous. The mechanical or  
hydraulic jacks may not be enough support  
or may malfunction allowing the unit to fall,  
which could cause injury.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
4. Clean out any grass build-up from underside of  
deck and in discharge chute.  
Waste Disposal  
Motor Oil Disposal  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
recycling center or according to your state and local  
regulations.  
35  
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Troubleshooting  
Troubleshooting  
Important: It is essential that all operator safety mechanisms be connected and in proper operating  
condition prior to mower use.  
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 of adjustments procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.  
Problem  
Possible Cause  
1. Fuel tank is empty.  
Corrective Action  
1. Fill the fuel tank.  
Engine will not start, starts hard, or fails to  
keep running.  
2. Fuel shutoff valve is closed.  
2. Open the fuel shutoff valve.  
3. The throttle and choke are not in the  
correct position.  
3. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions, and the choke is in the “ON”  
position for a cold engine or the “OFF”  
position for a warm engine.  
4. Dirt in fuel filter.  
4. Replace the fuel filter.  
5. Dirt, water, or stale fuel is in the fuel  
system.  
5. Contact an Authorized Service Dealer.  
6. Air cleaner is dirty.  
6. Clean or replace the air cleaner element.  
7. Electrical connections are corroded, loose 7. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
8. Relay or switch is defective.  
9. Faulty spark plug.  
10. Spark plug wire is not connected.  
11. PTO is engaged.  
8. Contact an Authorized Service Dealer.  
9. Clean, adjust or replace spark plug.  
10. Check the spark plug wire connection.  
11. Disengage the PTO.  
12. Transmission is not in true neutral  
position.  
12. Ensure the shifter lever is in the neutral  
position.  
13. OPC levers are released.  
13. Depress OPC levers.  
Engine loses power  
1. Engine load is excessive  
1. Reduce the ground speed.  
2. Air cleaner is dirty.  
3. Oil level in the crankcase is low.  
2. Clean or replace the air cleaner element.  
3. Add oil to the crankcase.  
4. Cooling fins and air passages for the  
engine are plugged.  
4. Remove the obstructions from the cooling  
fins and air passages.  
5. Vent hole in the fuel cap is plugged.  
6. Dirt in fuel filter.  
5. Clean or replace the fuel cap.  
6. Replace the fuel filter.  
7. Dirt, water, or stale fuel is in the fuel  
system.  
7. Contact an Authorized Service Dealer.  
Engine overheats  
1. Engine load is excessive  
1. Reduce the ground speed.  
2. Add oil to the crankcase.  
2. Oil level in the crankcase is low.  
3. Cooling fins and air passages for the  
engine are plugged.  
3. Remove the obstructions from the cooling  
fins and air passages.  
36  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Mower pulls left or right (with levers fully  
forward).  
1. Idler arm pulleys and drive sheaves are  
dirty.  
1. Remove mud and/or grass buildup.  
2. Wheel drive belt pulley scrapers  
adjustment is not correct  
3. Idler pivot arms cannot pivot freely  
4. Drive belts are worn.  
2. Correct adjustment.  
3. Lubricate ilder pivots.  
4. Replace drive belts as a set. (Do Not mix  
a new belt with a worn drive belt.)  
5. Drive linkage adjustment is not correct.  
6. Tire pressure in drive tires not correct.  
5. Correct adjustment.  
6. Adjust tire pressure in the drive tires.  
Machine does not drive.  
Uneven cutting height.  
1. Transmission drive belt is worn, loose or  
broken.  
1. Change the belt.  
2. Change the belt.  
2. Transmission drive belt is off a pulley.  
1. Blade(s) not sharp.  
1. Sharpen the blade(s).  
2. Install new cutting blade(s).  
3. Level mower deck from side-to-side and  
front-to-rear.  
2. Cutting blade(s) is/are bent.  
3. Mower deck is not level.  
4. Underside of mower is dirty.  
5. Tire pressure in drive tires not correct.  
6. Blade spindle bent.  
4. Clean the underside of the mower.  
5. Adjust tire pressure in the drive tires.  
6. Contact an Authorized Service Dealer.  
7. Tips of adjacent blades are at an uneven  
cutting height. Blades tips should be even  
within 3/16 inch which is approximately  
one blade thickness.  
7. Replace blades, spindles and (or) check  
for damage to mower deck.  
8. Caster mounting brackets are loose.  
8. Tighten hardware.  
Abnormal vibration  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Engine mounting bolts are loose.  
4. Loose engine pulley, idler pulley, or blade  
pulley.  
2. Tighten the blade mounting bolt.  
3. Tighten the engine mounting bolts.  
4. Tighten the appropriate pulley.  
5. Engine pulley is damaged.  
6. Blade spindle is bent.  
7. Belt is damaged.  
5. Contact an Authorized Service Dealer.  
6. Contact an Authorized Service Dealer.  
7. Install new belt.  
Blades do not rotate.  
1. Deck belt is worn, loose or broken.  
2. Deck belt is off pulley.  
1. Install new deck belt.  
2. Install deck pulley and check the idler  
pulley, idler arm and spring for correct  
position and function.  
Blades do not stop when disengaged.  
1. Blade brake is not adjusted properly.  
1. Adjust blade brake.  
2. Belt guide is not properly set  
3. PTO engagement is not properly set.  
2. Adjust belt guide to proper position.  
3. Check the PTO engagement position.  
37  
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Schematics  
Schematics  
KEY  
OPC  
SWITCH SWITCH  
N.O.  
TRANSMISSION  
N.C.  
PTO  
SWITCH  
N.O.  
TO SAFETY  
INTERLOCK  
MODULE  
ENGINE GROUND  
BLACK  
RED  
ENGINE KILL  
TERMINAL  
CONNECTORS ARE VIEWED FROM WIRE END  
N.C. = NORMALLY CLOSED  
N.O. = NORMALLY OPEN  
G006816  
38  
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Exmark Commercial Turf Equipment  
2Year Limited Warranty  
If for any reason you are dissatisfied with the Service Dealer’s  
analysis or with the assistance provided, contact us at:  
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 on these products 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.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
402-223-6375 or  
This warranty applies to Exmark commercial turf equipment  
sold in the U.S. 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.  
Owner’s Responsibilities  
If your product requires warranty service it 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 read the operator’s  
manual. You must also 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.  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
*
• Engine  
* The Engine warranty is covered by the engine manufacturer.  
Please refer to the engine manufacturer’s warranty statement  
that is included in the literature packet.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company  
with respect to this warranty shall be repair or replacement of  
defective components as set forth herein. Neither Exmark  
nor Exmark Warranty Company shall be liable for any  
incidental or consequential loss or damage.  
This warranty only includes the cost of parts and labor.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Pickup and delivery charges to and from any authorized  
Exmark Service Dealer.  
Such damages include but are not limited to:  
• Expenses related to gasoline, oil or lubricants.  
• Travel time, overtime, after hours time or other  
extraordinary repair charges or charges 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 damage or deterioration due to normal use, wear and  
tear, or exposure.  
• Cost of regular maintenance service or parts, such as filters,  
fuel, lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or  
required replacement or repair due to normal wear,  
accidents, or lack of proper maintenance.  
• Any repairs necessary due to 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.  
• Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
• Attorney's fees.  
There are no other express warranties except for engine and  
special emission system coverage.  
No Claim of breach of warranty shall be cause for cancellation  
or rescission of the contract of sale of any Exmark mower.  
All warranty work must be performed by an authorized  
Exmark Service Dealer using Exmark approved replacement  
parts.  
All implied warranties of merchantability (that the  
product is fit for ordinary use) and fitness for use (that the  
product is fit for a particular purpose) are limited to the  
duration of the express warranty.  
Instructions for Obtaining Warranty Service  
The product must be registered with original proof of purchase  
by an Exmark Service Dealer before obtaining any warranty  
service.  
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.  
Contact any Exmark Service Dealer to arrange service at their  
dealership. To locate a dealer convenient to you, access our  
also call 402-223-6375.  
This warranty gives you specific legal rights, and you may  
also have other rights which vary from state to state.  
G4500-589_C  
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Notes:  
40  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
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Figure 28  
This page may be copied for personal use.  
1. The maximum slope you can safely operate the machine on is 20 degrees. Use the slope indicator to determine the  
degree of slope of hills before operating. Do Not operate this machine on a slope greater than 20 degrees. Fold  
along the appropriate line to match the recommended slope.  
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.  
3. Example of how to compare slope with folded edge.  
43  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
©2010 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-689 Rev. A  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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