METRO ® For Serial Nos. 850,000 & Higher Part No. 4500-534 Rev.
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: IMPORTANT The engine in this product is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code (CPRC) Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC 4126.
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.
Contents Brake and Wheel Drive Linkage Adjustment ............................................... 30 Shifter Lever Adjustment............................... 32 Shifter Detent Adjustment............................. 33 PTO Safety Switch Adjustment...................... 33 Handle Height Adjustment ............................ 33 Wheel Drive Spring Tension Adjustment ............................................... 33 Cleaning ...........................................................
Safety Safety • Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator. Safety Alert Symbol • 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.
Safety DANGER DANGER In certain conditions gasoline is extremely flammable and vapors are explosive. A fire or explosion from gasoline can burn you, others, and cause property damage. 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. • Fill the fuel tank outdoors on level ground, in an open area, when the engine is cold.
Safety Operation damage and make repairs before restarting and operating the mower). WARNING – Before clearing blockages. 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. – Whenever you leave the mower. • Stop engine, wait for all moving parts to stop, and engage parking brake: • Allow engine parts, especially the muffler, to cool before touching. – Before refueling.
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.
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease, dirt and debris from safety signs and instructional labels. • Replace all worn, damaged, or missing safety signs. • When replacement components are installed, be sure that current safety signs are affixed to the replaced components. • If an attachment or accessory has been installed, make sure current safety signs are visible.
Safety 1-403143 103–2076 98-5954 103-2244 ECS Units Only 103-1623 ECS Units Only 103-2245 ECS Units Only 103-1798 10
Safety 117–2718 103-5626 48 inch Deck Units Only 103-1967 Pistol Grip Units Only 11
Specifications Specifications Model Numbers Serial Nos: 850,000 and Higher M16KA322P M16KA362P M16KA362 M16KA483P M16KA483 M16KA322PCA M16KA362CA M16KA483CA Systems Transmission Engine • Peerless 700-070A, five speeds forward and one reverse. • Engine Specifications: See your Engine Owner’s Manual • Speed range: – 1st: 2.0 mph (3.22 km/hr) • RPM: Full Speed: 3600 (No Load) – 2nd: 2.7 mph (4.35 km/hr) Fuel System – 3rd: 3.5 mph (5.63 km/hr) • Capacity: 5.0 gal. (18.9 L) – 4th: 4.1 mph (6.
Specifications Cutting Deck Overall Length: • Cutting Width: 32 inch Deck 36 inch Deck 48 inch Deck Standard Pistol Grip Handles 78.0 inches (198.1 cm) 78.0 inches (198.1 cm) 73.0 inches (185.4 cm) ECS Handles 77.3 inches (196.3 cm) 77.3 inches (196.3 cm) 72.3 inches (183.6 cm) – 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 • Blade Size: – 32 inch Deck: 16.25 inches (41.
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.
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 ECS Handle 1. 2. 3. 4. The throttle is used to control engine speed.
Operation PTO Engagement 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. DANGER The rotating blades under the mower deck are dangerous. Blade contact can cause serious injury or kill you. 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.
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.
Operation Smoothly release both drive levers to engage drive wheels. 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. Pull the unit backward to “assist” with the movement of the unit.
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.
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.
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.
Maintenance Change Engine Oil 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. Service Interval: After the first 5 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. 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.
Maintenance Check Spark Plugs Lubrication Chart (cont'd.) Fitting Initial Locations Pumps Number of Places Service Interval: Every 160 hours Service Interval 6. Transmission Output Shaft Coupler 2 2 2 2 40 hours 7. Mower Deck Idler Pivots 2 1 1 1 40 hours Remove spark plugs, check condition and reset gaps, or replace with new plugs. See Engine Owner’s Manual. Change Fuel Filter Service Interval: As required A fuel filter is installed in the fuel line between the fuel tank and the engine.
Maintenance Dielectric Grease 9. Reinstall upper case half and fasten in place with six bolts previously removed. 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.
Maintenance Adjustments than adjusting axle position and number of spacers below caster support hub). 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.
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 Support Hub 1/2 inch (1.2 cm) 3/16 inch (.48 cm) Number of 1/4 inch (.64 cm) Blade Spacers Below Spindle 4 3 2 1 0 2 1/8– 3 1/8 inches (5.4–7.9 cm) C 2 0 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) 2 1/4– 3 1/4 inches (5.7–8.3 cm) C 2 1 2 1/4 inch (5.
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) spacers 2. Quick Pin 3. 3/16 inch (4.8 mm) spacer 4.
Maintenance Wheel Drive Belt Pulley Scrapers Height Adjustment Table and notes in the Adjusting the Cutting Height section. 9. Install unused spacers between top of spindle and spindle nut. 1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s). 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.
Maintenance Mower Deck Belt Routings: Check belt tension after the first hour of operation and at least twice during the first 24 hours of operation. Adjust as necessary. Figure 13 48 inch Deck Shown for Reference Only Figure 14 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.
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 1. Blade Brake Rod Brake and Wheel Drive Linkage Adjustment 3. 1/8 inch to 3/16 inch (3–5 mm) 2. Spring Mounting Bolts 1.
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.
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 2. Transmission Lever in neutral 3. 5/16–18 inch nyloc nut 4. Drive Levers in neutral 5. 5/16–18 x 1 3/4 inch hex capscrew 6. Drive Lever Linkage 7. Swivel 8.
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.
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 bolt moves down 2. Position A–Normal Conditions 3. Position B–More Severe 4. Position C–Most Severe 5.
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.
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.).
Troubleshooting Problem Mower pulls left or right (with levers fully forward). Possible Cause 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. 5. Drive linkage adjustment is not correct. 6. Tire pressure in drive tires not correct. Machine does not drive. Uneven cutting height. 1. Change the belt. 2.
Schematics Schematics KEY SWITCH OPC SWITCH N.O. TO SAFETY INTERLOCK MODULE GREEN BLACK DK BLUE ORANGE BROWN RED PTO SWITCH N.O. YELLOW TRANSMISSION N.C. AB C D E F ENGINE GROUND BLACK RED ENGINE KILL TERMINAL CONNECTORS ARE VIEWED FROM WIRE END N.C. = NORMALLY CLOSED N.O.
Exmark Commercial Turf Equipment 2 Year Limited Warranty If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at: Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice, NE 68310 402-223-6375 or service@exmark.com Conditions and Products Covered Exmark Mfg. Co. Inc.
Notes: 40
Notes: 41
Service Record Date: Description of Work Done: 42 Service Done By:
G011841 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.
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID-MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO-MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM OUT-FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL-TAIL WHEEL SN
