METRO®
ForSerialNos.
850,000&Higher
PartNo.4500-534Rev.B
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:IMPORTANTTheengineinthis
productisnotequippedwithasparkarrester
mufer.ItisaviolationofCaliforniaPublic
ResourceCode(CPRC)Section4442touse
oroperatethisengineonanyforest-covered,
brush-covered,orgrass-coveredlandasdened
inCPRC4126.Otherstatesorfederalareasmay
havesimilarlaws.
Toacquireasparkarresterforyourunit,seeyour
EngineServiceDealer.
ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada
TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.
KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2010ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
2
Contactusatwww.Exmark.com.
PrintedintheUSA
AllRightsReserved
Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
Exmarkpartsmanualsareavailableonlineat
http://www.exmark.com/manuals.htm
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3
Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.......................9
Specications.......................................................12
ModelNumbers............................................12
Systems.........................................................12
Dimensions...................................................13
TorqueRequirements....................................13
ProductOverview................................................14
Operation.............................................................14
Controls........................................................14
Pre-Start........................................................16
OperatingInstructions..................................16
Transporting.................................................18
Maintenance.........................................................19
RecommendedMaintenanceSchedule(s)...........19
PeriodicMaintenance.......................................20
CheckEngineOilLevel.................................20
CheckMowerBlades.....................................20
CheckSafetyInterlockSystem.......................21
CheckforLooseHardware............................21
ServiceAirCleaner........................................21
ChangeEngineOil........................................22
CheckTirePressures.....................................22
CheckConditionOfBelts..............................22
LubricateGreaseFittings...............................22
CheckSparkPlugs.........................................23
CheckGreaseLevel,InputandOutput
ShaftBearingWearonPeerless
Transmission.............................................23
ThreadLockingAdhesives.............................24
MobilHTSGrease(OrFood-Grade
Anti-seize).................................................24
Copper-BasedAnti-seize..............................24
DielectricGrease...........................................24
Adjustments.....................................................25
AdjustingtheCuttingHeight.........................25
AdjustingtheAxlePosition............................26
AdjustingtheNumberofSpacersbelow
CasterSupportHub...................................27
AdjustingtheCuttingHeightwithBlade
Spacers......................................................27
TransmissionBeltAdjustment.......................28
WheelDriveBeltPulleyScrapers...................28
EnginetoMowerDeckBelt...........................28
BladeBrakeAdjustment................................29
BeltGuideAdjustment..................................30
BrakeandWheelDriveLinkage
Adjustment...............................................30
ShifterLeverAdjustment...............................32
ShifterDetentAdjustment.............................33
PTOSafetySwitchAdjustment......................33
HandleHeightAdjustment............................33
WheelDriveSpringTension
Adjustment...............................................33
Cleaning...........................................................34
CleanEngineandExhaustSystem
Area..........................................................34
RemoveEngineShroudsandCleanCooling
Fins...........................................................34
CleanDebrisFromMachine..........................35
CleanGrassBuild-UpUnderDeck................35
WasteDisposal..............................................35
Troubleshooting...................................................36
Schematics...........................................................38
4
Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
•Onlyadultsandmatureteenagersshouldoperate
amower,andevenmatureteenagersshouldhave
adultsupervision.Besureateenager:
1.hasreadandunderstandstheOperator’s
Manualandrecognizestherisksinvolved;
2.issufcientlymaturetousecaution;and
3.isofsufcientsizeandweighttooperate
thecontrolscomfortablyandtomanagethe
mowerwithouttakingrisks.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.
CAUTION
Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.
Wearhearingprotectionwhenoperatingthis
machine.
•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
5
Safety
DANGER
Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.
•Fillthefueltankoutdoorsonlevelground,
inanopenarea,whentheengineiscold.
Wipeupanygasolinethatspills.
•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.
•DoNotllthefueltankcompletelyfull.
Fillthefueltanktothebottomoftheller
neck.Theemptyspaceinthetankallows
gasolinetoexpand.Overllingmayresult
infuelleakageordamagetotheengineor
emissionsystem(ifequipped).
•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyspark.
•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.
•Addfuelbeforestartingtheengine.Never
removethecapofthefueltankoradd
fuelwhenengineisrunningorwhenthe
engineishot.
•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
DANGER
Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.
•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.
•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.
•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.
•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.
•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.
WARNING
Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgas
tank/containeropening.
•Keepawayfromeyesandskin.
•Neversiphonbymouth.
•Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
6
Safety
Operation
WARNING
Operatingengineparts,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,to
coolbeforetouching.
•Removeaccumulateddebrisfrommufer
andenginearea.
•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcankill
you.
DoNotrunengineindoorsorinasmallconned
areawheredangerouscarbonmonoxidefumes
cancollect.
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.
•Neverraisedeckwithbladesrunning.
•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.
•DoNotchangetheenginegovernorsettingor
overspeedtheengine.
•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:
–Beforerefueling.
–Beforedumpingthegrasscatcher.
–Beforemakingheightadjustments.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.
•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
•DONOToperatethemowerwhenpeople,
especiallychildren,orpetsareinthearea.
•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.
•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
7
Safety
DANGER
Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Lossofcontrol
and/orlossofoperator’sfootingcouldresultina
fallwithanarmorleggettingunderthemower
orenginedeckwhichmayresultinserious
injury,deathordrowning.
•Mowacrossslopes,neverupanddown.
•DoNotmowslopeswhengrassiswet.
•DoNotmowneardrop-offsornearwater.
•DoNotmowslopesgreaterthan20degrees.
•Reducespeedanduseextremecautionon
slopes.
•Avoidsuddenturnsorrapidspeedchanges.
•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.
•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.
•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.
MaintenanceandStorage
•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.
•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.
•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.
•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.
•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
WARNING
Removingstandardoriginalequipmentparts,
orusingnon-Exmarkreplacementpartsand
accessoriesmayalterthewarranty,traction,and
safetyofthemachine.Failuretouseoriginal
Exmarkpartscouldcauseseriousinjuryor
death.
Replaceallpartsincluding,butnotlimitedto
tires,belts,andbladeswithoriginalExmark
parts.
8
Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
1-303508
1-303517
1-303518
1-323427
32inchand36inchUnitsOnly
1-323550
PistolGripHandleUnitsOnly
1-403005
9
Safety
1-403143
98-5954
103-1623
ECSUnitsOnly
103-1798
103–2076
103-2244
ECSUnitsOnly
103-2245
ECSUnitsOnly
10
Safety
103-5626
48inchDeckUnitsOnly
117–2718
103-1967
PistolGripUnitsOnly
11
Specications
Specications
ModelNumbers
SerialNos:850,000andHigher
M16KA322PM16KA362PM16KA362M16KA483PM16KA483M16KA322PCAM16KA362CAM16KA483CA
Systems
Engine
•EngineSpecications:SeeyourEngineOwner’s
Manual
•RPM:FullSpeed:3600(NoLoad)
FuelSystem
•Capacity:5.0gal.(18.9L)
•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher;containingnomorethan10%
methanolorethanol.
•FuelFilter:ReplaceableIn-line
•FuelShut-OffValve:1/4turnincrements
SafetyInterlockSystem
Operatormusthavethetransmissioninneutraland
PTOdisengagedtostartengine.ReleaseofOperator
PresenceControl(OPC)leverswillcauseengineto
stopiftransmissionisnotinneutraland/orPTO
isengaged.
Steering/BrakeControls
Fingertipdrivecontrolleversprovideindependent
controloftraction,braking,andneutraltoeachdrive
wheelformoving,stopping,andpowerturning.
Parkingbrakesareengagedbylockingdrivecontrol
leversinthe“brake”position.
Transmission
•Peerless700-070A,vespeedsforwardandone
reverse.
•Speedrange:
–1st:2.0mph(3.22km/hr)
–2nd:2.7mph(4.35km/hr)
–3rd:3.5mph(5.63km/hr)
–4th:4.1mph(6.60km/hr)
–5th:6.2mph(9.98km/hr)
–Reverse:3.1mph(4.99km/hr)
WheelDriveSystem
BandeddoubleA-SectionV-belts,singletop-side
idlersandreplaceablebolt-ondrivesheavesandbrake
drums.(SingleB-SectionV-beltsforthe32inch
Model)
Tires&Wheels
Drive
Front
Caster
Pneumatic(Air-Filled)
Semi-
Pneumatic
3236&48
AllDecks
Quantity
222
Tread
TurfSaverTurfMasterSmooth
Size13x5.00-613x6.50-69x3.50-4
PlyRating
44
Pressure
14psi
(97kPa)
14psi
(97kPa)
Bearings
Replaceable
Ball
Replaceable
Ball
Replaceable
Roller
12
Specications
CuttingDeck
•CuttingWidth:
–32inchDeck:31.75inches(80.7cm)
–36inchDeck:35.38inches(89.9cm)
–48inchDeck:47.25inches(120.0cm)
•Discharge:Side
•BladeSize:
–32inchDeck:16.25inches(41.3cm)—
Quantity:2
–36inchDeck:18.00inches(45.7cm)—
Quantity:2
–48inchDeck:16.25inches(41.3cm)—
Quantity:3
•DeckDrive:Manualengagementofbeltwith
over-centerlock.Bladebelttensionisadjustable
viaturnbuckle.
•BladeBrake:Whenthebladeengagementcontrol
ismovedtothedisengagedpositionafriction
brakepadstopstherotationoftheblades.
•DeckMounting:Bolteddirectlytoenginedeck.
•DeckDepth:
–32inchDeck:5.0inches(12.7cm)
–36inchDeck:5.0inches(12.7cm)
–48inchDeck:5.0inches(12.7cm)
•CuttingHeightAdjustment:
Adjustsfrom1inch(2.5cm)to41/4inches(10.8
cm)in1/4inch(6.4mm)orsmallerincrements
byvariousadjustmentsofcasterspacers,blade
spacers,andaxleheight.
Dimensions
OverallWidth:
32inch
Deck
36inch
Deck
48inch
Deck
Deector
Up
32.7inches
(83.1cm)
36.4inches
(92.5cm)
48.1inches
(122.2cm)
Deector
Down
43.3inches
(110.0cm)
47.0inches
(119.4cm)
57.9inches
(147.1cm)
OverallLength:
32inch
Deck
36inch
Deck
48inch
Deck
Standard
PistolGrip
Handles
78.0inches
(198.1cm)
78.0inches
(198.1cm)
73.0inches
(185.4cm)
ECS
Handles
77.3inches
(196.3cm)
77.3inches
(196.3cm)
72.3inches
(183.6cm)
OverallHeight:
StandardPistolGrip
Handles
40.0inches(101.6cm)
ECSHandles
42.1inches(106.9cm)
TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)
32inch
Deck
36inch
Deck
48inch
Deck
Standard
PistolGrip
&ECS
Handles
32.1inches
(81.4cm)
35.6inches
(90.4cm)
35.6inches
(90.4cm)
CurbWeight:
32inch
Deck
36inch
Deck
48inch
Deck
Standard
PistolGrip
Handles
420lb
(191kg)
430lb
(195kg)
475lb
(215kg)
ECS
Handles
435lb
(197kg)
446lb
(202kg)
490lb
(222kg)
TorqueRequirements
BoltLocation
Torque
Blade/CutterHousing
SpindleBolt
75-80ft-lb(102-109N-m)
CasterBracketMounts
30-35ft-lb(41-48N-m)
MowerDeck/Engine
DeckMount
30-35ft-lb(41-48N-m)
EngineMountingBolts
17-23ft-lb(23-31N-m)
TransmissionShifterLever
Nut
30-35ft-lb(41-48N-m)
13
Operation
ProductOverview
Figure3
1.Controls4.ECSHandles
2.FuelCap5.BladeSpacers
3.PistolGripHandles
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
OperatorPresenceControl(OPC)
Levers
Locatedontheupperhandleassemblydirectlyabove
thehandlegrips.
Whentheseleversaredepressed,theOPCsystem
sensesthattheoperatorisinthenormaloperator’s
position.Whentheleversarereleased,theOPC
systemsensesthattheoperatorhasmovedfromthe
normaloperatingpositionandwillkilltheengineif
eitherthetransmissionshiftleverisnotintheneutral
positionorthePTOisengaged(see
Figure4and
Figure5).
Figure4
PistolGripHandle
1.NeutralLock/ParkBrakeLatch
2.Rotatelatchforwardforparkbrakeposition
3.Rotatelatchbackforneutrallockposition
4.OPCLever
5.DriveLever
14
Operation
Figure5
ECSHandle
1.OPCLever
2.Rotatelatchforneutrallockandparkbrakepositions
3.NeutralLockLatch/ParkBrakeLatch
4.DriveLever
DriveLevers
Locatedoneachsideoftheupperhandleassembly
aheadofandbelowthehandlegrips(seeFigure4
andFigure5).
Theseleversindividuallycontrolclutchingactionof
thewheeldrivebeltsandbrakes.Whenthedrive
leversareallthewaydown,thebrakesdisengageand
thewheeldrivebeltsengage
Graduallysqueezingtheleftorrighthanddrivelever
disengagesthewheeldrivebelts,causingthelefthand
orrighthandwheeltoslowdownuntiltheyreach
neutralorstop.Thismakesthemachineturntothe
leftorrightrespectively.Squeezingfurtherengages
theparkbrakes.Thesharpnessoftheturnvariesby
howmuchtheleverissqueezed.Forstraightahead
motion,smoothlyreleasebothdriveleverstoengage
bothdrivewheelssimultaneously.
NeutralLock/ParkBrakeLatches
•ForPistolGripHandles:Locatedonhandles
aheadofthegrips.
•ForECSHandles:Locatedontheupperhandle
assemblyontheendsofthehandlegrips.
Thelatchesallowtheoperatortolockthedrivelevers
ina“neutral”positionwhereneitherthewheeldrive
beltsnorthebrakesengageorina“parkbrake”
positionwherethewheeldrivebeltsarenotengaged
andtheparkbrakeisengaged(seeFigure4and
Figure5).
ChokeControl
Locatedonthefrontleftcornerofthefueltank
support.
Chokeisusedtoaidinstartingacoldengine.The
chokecontrolispulledouttobeinthe“ON”position
andpushedintobeinthe“OFF”position.DoNot
runawarmenginewithchokeinthe“ON”position.
ThrottleControl
Locatedontheonthecontrolconsolerightside.
Thethrottleisusedtocontrolenginespeed.Moving
thethrottlecontrolforwardwillincreaseengine
speedandmovingittotherearwilldecreaseengine
speed.Movingthethrottleforwardintothedetent
isfullposition.
TransmissionShiftLever
Locatedunderthecontrolconsoleandbehindthe
fueltank.
Itshiftsthe5-speedtransmissionintoveforward
gears,neutralandreverse.Shifttransmissiononly
whendriveleversareintheneutralposition.Shifting
withoutdriveleversinneutralmaycausedamageto
thetransmission.
Note:Reverseis“reverseassist”only,meaningwhen
thetransmissionisinreverse,theoperatorhastopull
theunitbackwardto“assist”withthemovementof
theunit.
“Off-Run”Switch
Locatedonthecontrolconsole.
Turnthekeytothe“Run”positiontoallowthe
enginetobestarted.Turnthekeytothe“Off”
positiontoshutengineoff.
FuelShut-OffValve
Locatedinthefuellinemidwaybetweenthetank
andengine.
Thefuelshut-offvalveisusedtoshutoffthe
owoffuelwhenparkinginsideabuilding,during
transportationtoandfromthejobsites,andwhen
themachinewillnotbeusedforafewdays.
Rotatevalve1/4turnclockwisetoshutfueloff.
Rotatevalve1/4turncounterclockwisetoturnfuel
on.
15
Operation
Pre-Start
Fillfueltankonlevelground.Forbestresultsuse
onlyclean,freshregulargradeunleadedgasolinewith
anoctaneratingof87orhigher.
Important:Neverusemethanol,gasoline
containingmethanol,gasoholcontainingmore
than10%ethanol,premiumgasoline,orwhite
gasbecausethefuelsystemcouldbedamaged.
DoNotaddoiltogasoline.
DoNotoverllfueltank.Fillthefueltanktothe
bottomofthellerneck.Theemptyspaceinthe
tankallowsgasolinetoexpand.Overllingmayresult
infuelleakageordamagetotheengineoremission
system(ifequipped).
Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.
RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.
OperatingInstructions
OpentheFuelShut-OffValve
Rotatethevalve1/4turncounterclockwisetoturn
fuelon.
StartingtheEngine
Note:Alwaysengagetheleftandrightneutral
lock/parkbrakelatchesinthe“parkbrake”position
whenstartingtheengine
1.Onacoldengine,placethethrottlemidway
betweenthe“Slow”and“Fast”positionsand
placethechokeinthe“On”position.Onawarm
engine,placethethrottlelevermidwaybetween
“Slow”and“Fast”positionsandleavethechoke
inthe“Off”position.
2.Turnignitionswitchto“Run”position.Pullthe
recoilropetostartengine.
3.Onacoldengine,graduallyreturnchoketothe
“Off”positionafterenginestartsandwarmsup.
Note:Kawasakienginesgenerallyneedtobe
“choked”evenwhenwarm.
PTOEngagement
DANGER
Therotatingbladesunderthemowerdeckare
dangerous.Bladecontactcancauseserious
injuryorkillyou.
DoNotputhandsorfeetunderthemoweror
mowerdeckwhenthebladesareengaged.
DANGER
Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.
Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunlessthere
isagrasscollectionsystemormulchkitinplace
andworkingproperly.
ThePTOswitchengagesthecuttingblades.Besure
thatallpersonsareclearofmowerdeckanddischarge
areabeforeengagingthePTO.
1.Setthrottleto“MIDWAY”position.
2.PushthePTOleverforwardtoengageblades.
3.Placethethrottleinthe“FAST”positiontobegin
mowing.
DisengagingthePTO
1.Setthrottleto“MIDWAY”position.
2.Pullthebladeengagementlevertothefull
rearwardpositiontodisengagetheblades
StoppingtheEngine
1.Bringtheunittoafullstop.
2.Lockdriveleversin“parkbrake”position.
3.DisengagethePTO.
4.Movetransmissionshiftleverto“neutral”.
5.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.
6.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.
16
Operation
7.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.
8.Closethefuelshut-offvalvewhenthemachine
willnotbeinuseforafewdays,when
transporting,orwhentheunitisparkedinside
abuilding.
DrivingtheMachine
DriveLever/NeutralLock/ParkBrakeLatch
Operation
•ForPistolGripHandles
Tolockthedriveleversin“neutral”,squeezethe
driveleversbacktotheneutralposition.Place
thumbsontheupperportionoftheneutral
lock/parkbrakelatchesandmovethemtothe
rear.Releasethedrivelevers.
Tolocktheleversin“parkbrake”,squeezethe
driveleversbacktothebrakeposition.Place
thumbsontheupperportionoftheneutral
lock/parkbrakelatchesandmovethemtothe
front.Releasethedrivelevers(see
Figure6)
CAUTION
Iftheneutrallock/parkbrakelatchesarenot
completelyengagedthedriveleverscould
unexpectedlyslipintotheforwarddrive
position.Ifthedriveleversslipintothedrive
position,theunitcouldlurchforwardand
causeinjuryorpropertydamage.
Besurethepinsprotrudingthroughtheslots
ofeachneutrallocklatcharecompletely
engagedintherearslotofeachlatch.
Toplacethedriveleversinthedriveposition,
rmlyholdthedrivelevers,placethumbsonthe
upperportionoftheneutrallock/parkbrake
latchesandmovethemoutofthe“neutral”or
the“parkbrake”position.Slowlyandsmoothly
releasethedrivelevers.
Figure6
1.Latchisinthedrive
position
6.Neutrallock
2.Rotateforwardforpark
brakeposition
7.Forward—releasedrive
lever
3.Rotatebackforneutral
lockposition
8.Neutral—holdinthis
position
4.Parkbrake9.Reverse—squeezedrive
lever
5.Fullspeedforward
•ForECSHandles
Tolockthedriveleversin“neutrallock”,squeeze
thedriveleverstothe“neutral”position.See
Figure7position2.Placethumbsontheinner
thumblobeoftheneutrallock/parkbrakelatches
androtatethemtothe“neutral”position.See
Figure7position3.Releasethedrivelevers.
Tolockthedriveleversin“parkbrake”,squeeze
thedriveleversfarthertothe“brake”position.
Placethumbsontheinnerthumblobeofthe
neutrallock/parkbrakelatchesandrotatethem
tothe“park”position.See
Figure7position4.
Releasedrivelevers.
CAUTION
Iftheneutrallock/parkbrakelatchesarenot
completelyengagedthedriveleverscould
unexpectedlyslipintotheforwarddrive
position.Ifthedriveleversslipintothedrive
position,theunitcouldlurchforwardand
causeinjuryorpropertydamage.
Besurethedriveleversaresecurelyseatedat
thebottomofthe“neutral”or“park”areasof
theneutrallocklatches.
17
Operation
Toplacethedriveleversinthe“drive”position,
slightlysqueezethedriveleverswhileplacing
thumbsontheouterthumblobeoftheneutral
lock/parkbrakelatches(ortheindexngeron
thefrontlobe)androtatethemfromunderthe
drivelevers.Slowlyandcarefullyreleasethedrive
levers.See
Figure7position1.
Figure7
1.DriveLeverindrive
position
3.DriveLeverlockedin
neutralposition
2.DriveLeverinneutral
position
4.DriveLeverlockedin
parkposition
DrivingForward
1.Withdriveleversinthe“neutral”or“parkbrake”
position,shifttransmissionintodesiredgear.
2.Squeezebothdriveleversandmovebothneutral
lock/parkbrakelatchesfromthe“neutral”or
“parkbrake”positiontothe“drive”position.
3.Tomoveforwardinastraightline,smoothly
releasebothdriveleverstoengagedrivewheels.
Toturnleftorright,squeezetherighthanddrive
levertoturnrightandthelefthanddrivelever
toturnleft.
Squeezedriveleversallthewaybacktoengage
brakes.Moveneutrallock/parkbrakelatchesinto
the“parkbrake”positionandreleasedrivelevers.
Shifttransmissionintoneutral.
DrivinginReverse
Note:Reversegearisreverseassistonly,theoperator
mustpulltheunitbackwards.
Tomoverearward,squeezethedriveleverstoneutral
positionandmovetheshiftertothe“R”.
Smoothlyreleasebothdriveleverstoengagedrive
wheels.
Pulltheunitbackwardto“assist”withthemovement
oftheunit.
Tostop,squeezedriveleversallthewaybackto
engagethebrakes.Movetheneutrallocklatchesinto
the“parkbrake”positionandreleasedrivelevers.
Movethespeedcontrollevertotheneutralposition.
ChangingGears
Whenchanginggears,alwayssqueezedriveleversto
theneutralposition.Theshiftlevermaybemoved
withakneeorbyhand(engagetheneutrallock
latchesifshiftingbyhand).
Note:Reversegearis“reverseassist”only,the
operatormustpulltheunitbackwards.
Transporting
TransportingaUnit
WARNING
Loadingthemowerontoatrailerwithoutstrong
enoughorproperlysupportedrampscouldbe
dangerous.Therampscouldcollapsecausing
theunittofall,whichcouldcauseinjury.
•Useproperrampsthataresecuredtothe
truckortrailer.
•Keepfeetandlegsoutfromundertheunit
whenloadingandunloading.
•Ifnecessary,useassistancewhenloading.
Besurethefuelshut-offvalveisclosed.
Useaheavydutytrailertotransportthemachine.
Engageneutrallocklatchesandparkbrake,then
blockwheels.
Securelyfastenthemachinetothetrailerwithstraps,
chains,cables,orropes.
DoNotrelysolelyontheparkingbraketoholdthe
machineonthetrailer.
Besurethatthetrailerhasallnecessarylightingand
markingasrequiredbylawanduseasafetychain.
18
Maintenance
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
WARNING
Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecouldseriously
injureyouorotherbystanders.
Removethekeyfromtheignitionswitch,engage
parkingbrake,andpullthewire(s)offthespark
plug(s)beforeyoudoanymaintenance.Also
pushthewire(s)asidesoitdoesnotaccidentally
contactthesparkplug(s).
WARNING
Theenginecanbecomeveryhot.Touchingahot
enginecancausesevereburns.
Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheenginearea.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
MaintenanceProcedure
Aftertherst5hours
•Changetheengineoil.
Beforeeachuseordaily
•Checktheengineoillevel.
•Checkthemowerblades.
•Checkthesafetyinterlocksystem.
•Checkforloosehardware.
•Greasethefrontcasterwheelbearings.
•Greasefrontcasterpivots.
•Greasethedrivewheels.
•Greasethedrivewheelidlerarm.
•Cleantheengineandexhaustsystemarea.
•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.
•Cleanthegrassbuild-upfromunderthedeck.
Every25hours
•Servicethefoamelement.(Mayneedmoreoftenundersevereconditions.SeetheEngine
Owner’smanualforadditionalinformation.)
Every40hours
•Checkthetirepressures.
•Checktheconditionofthebelts.
•Greasethebrakearm.
•Greasethetransmissionoutputshaftcoupler
•Greasethemowerdeckidlerpivots
Every100hours
•Servicethepaperelement.(Mayneedmoreoftenundersevereconditions.SeetheEngine
Owner’smanualforadditionalinformation.)
•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)
•Removeengineshroudsandcleancoolingns.
Every160hours
•Checkthesparkplugs.
•Checkgreaselevel,inputandoutputshaftbearingwearonPeerlessTransmission.
Every200hours
•Replacethepaperelement.
Yearly
•Replacegearboxgrease.
19
Maintenance
PeriodicMaintenance
CheckEngineOilLevel
ServiceInterval:Beforeeachuseordaily
1.Stopengineandwaitforallmovingpartstostop.
Makesureunitisonalevelsurface.
2.Checkwithenginecold.
3.Cleanareaarounddipstick.Removedipstickand
wipeoiloff.Reinsertthedipstickandpushitall
thewaydownintothetube.DoNotscrewinto
place.Removethedipstickandreadtheoillevel.
4.Iftheoillevelislow,wipeofftheareaaroundthe
oilllcap,removecapandlltothe“FULL”
markonthedipstick.Useoilasspeciedin
EngineOwner’sManual.DoNotoverll.
Important:DoNotoperatetheenginewiththe
oillevelbelowthe“LOW”(or“ADD”)markon
thedipstick,oroverthe“FULL”mark.
CheckMowerBlades
ServiceInterval:Beforeeachuseordaily
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Liftdeckandsecureinraisedpositionasstated
intheCleanGrassBuild-UpUnderDeck
procedure.
3.Inspectbladesandsharpenorreplaceasrequired.
4.Re-installtheblades(iftheywereremoved)and
torquebladeboltsto75-80ft-lb(102-109N-m).
Besurethespringdiscwasherconeisinstalled
towardthebolthead(see
Figure8).
Figure8
1.Springdiscwasher(conetowardsbolthead)
2.Bladebolttorqueto75-80ft-lb(102-109N-m).
ReplacingtheDischarge
Deector
ServiceInterval:Asrequired
DANGER
Anuncovereddischargeopeningcouldallowthe
lawnmowertothrowobjectsintheoperator’sor
bystander’sdirectionandresultinseriousinjury.
Also,contactwiththebladecouldoccur.
Neveroperatethelawnmowerunlessyouinstall
amulchplate,dischargedeector,orgrass
collectionsystem.
1.Toremoveadamagedorworndischarge
deector,liftthelegofthespringwiththeloop
outofthenotchinthedischargedeectorand
slidetherodoutofthedischargedeector
brackets,anddischargedeector.
2.Toinstallnewdischargedeector,orientthe
springontherodasshowninFigure9.Slidethe
rodthroughthefrontdischargedeectorbracket,
dischargedeector,andreardeectorbracket.
20
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