Exmark 4500-689 manual

METRO ® For Serial Nos. 920,000 & Higher Part No. 4500-689 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer , bir th defects, or other reproductiv e har m. Important: The engine in this product is not equipped with a spark ar rester mufer . It is a violation of Califor nia Public Resource Code (CPRC) Se[...]

Introduction CONGRATULATIONS on the purc hase of your Exmark Mo w er . T his product has been carefully designed and man ufactured to gi ve you a maxim um amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for your Exmark mow er . BEFORE OPERATING Y OUR MO W[...]

Contents Introduction . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . 3 Safety .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. 5 Safety Aler t Symbol . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. [...]

Safety Safety Safety Alert Symbol This lawn mow er meets or ex ceeds the B71.4 specications of the American National Standards Institute in effect at the time of production. Exmark designed and tested this lawn mo wer to offer reasonably safe ser vice; howev er , failure to comply with the following instr uctions may result in personal injur y .[...]

Safety DANGER In cer tain conditions gasoline is extremely ammable and v apors are explosiv e. A re or explosion fr om gasoline can bur n y ou, others, and cause proper ty damage. • Fill the fuel tank outdoors on lev el ground, in an open ar ea, when the engine is cold. Wipe up any gasoline that spills. • Never rell the fuel tank or dr[...]

Safety Operation W ARNING Operating engine par ts, especially the muf er , become extremely hot. Severe bur ns can occur on contact and de bris, such as leav es, grass, br ush, etc. can catch re. • Allow engine par ts, especially the mufer , to cool befor e touching . • Remo ve accumulated de bris from mufer and engine area. • Ins[...]

Safety DANGER Operating on wet g rass 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 ar m or leg getting under the mo wer or engine deck which may r esult in serious injur y , death or drowning . • Mow acr oss slopes, nev er up and down. • Do Not mow slop[...]

Safety Safety and Instructional Decals • Keep all safety signs legible. R emo v e all g rease , dirt and debris from safety signs and instructional labels . • R eplace all w orn, damaged, or missing safety signs . • When replacement components are installed, be sure that current safety signs are afxed to the replaced components . • If an[...]

Safety 1-403143 98-5954 103-1623 ECS Units Only 103-1798 103-2076 103-2244 ECS Units Only 103-2245 ECS Units Only 10[...]

Safety 103-5626 48 inch Deck Units Only 1 17–2718 103-1967 Pistol Grip Units Only 1 1[...]

Specications Specications Model Numbers Serial Nos: 920,000 and Higher MG16KA322P; MG16KA322PCA; MG16KA362; MG16KA362CA; MG16KA362P; MG16KA483; MG16KA483CA; MG16KA483P Systems Engine • Engine Specications: See your Engine Owner’ s Manual • Engine Oil T ype: Exmark 4–Cycle Premium Engine Oil • RPM: Full Speed: 3600 (No Load) Idle:[...]

Specications Cutting Deck • Cutting Width: – 32 inc h Dec k: 31.75 inches (80.7 cm) – 36 inc h Dec k: 35.38 inches (89.9 cm) – 48 inc h Dec k: 47.25 inches (120.0 cm) • Discharge: Side • Blade Size: – 32 inch Deck: 16.25 inches (41.3 cm) — Quantity: 2 – 36 inch Dec k: 18.00 inc hes (45.7 cm)— Quantity: 2 – 48 inch Dec k: 16[...]

Operation Product Overview Figure 3 1. Controls 4. ECS Handles 2. Fuel Cap 5. Blade Spacers 3. Pistol Grip Handles Operation Note: Deter mine the left and right sides of the machine from the nor mal operating position. Controls Operator Presence Control (OPC) Levers Located on the upper handle assembly directly abo v e the handle g rips . When thes[...]

Operation Figure 5 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 Drive Levers Located on each side of the upper handle assembly ahead of and belo w the handle grips (see Figure 4 and Figure 5). These levers indi vidually control clutc hing action of the wheel [...]

Operation Pre-Start Fill fuel tank on lev el g round. F or best results use only clean, fresh regular grade unleaded g asoline with an octane rating of 87 or higher . Important: Nev er use methanol, gasoline containing methanol, gasohol containing more than 10% ethanol, premium gasoline, or white gas because the fuel system could be dama ged. Do No[...]

Operation 7. R emov e the key to prev ent children or other unauthorized persons from starting engine. 8. Close the fuel shut-off valv e 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 Driv e Lever/Neutral Lock/P ark Brak e Latch Operation • F or Pistol Gri[...]

Operation T o place the drive levers in the “drive” position, slightly squeeze the dri ve levers while placing thumbs on the outer thumb lobe of the neutral lock/park brake latc hes (or the index ng er on the front lobe) and rotate them from under the driv e levers . Slowly and carefully release the drive levers . See Figure 7 position 1. Fi[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the mac hine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental starting of the engine could seriousl y injure you or other bystanders. Remo ve the key fr om the ignition s witch, enga ge parki[...]

Maintenance Periodic Maintenance Check Engine Oil Level Service Interval: Before each use or daily 1. Stop engine and w ait for all moving parts to stop . Make sure unit is on a lev el surface . 2. Check with engine cold. 3. Clean area around dipstick. Remo ve dipstick and wipe oil off . R einser t the dipstick and push it all the wa y do wn into t[...]

Maintenance Figure 9 1. Rod 4. Mower deck 2. Spring 5. Discharge deector bracket 3. Discharge deector 6. Assembled view 3. Hook the bent end of the rod around the front discharge deector brack et to retain it from sliding out. Place the leg of the spring with the loop in the notch in the disc harge deector to hold the discharge deect[...]

Maintenance Change Engine Oil Service Interval: After the rst 5 hours Every 100 hours (May need more often under severe conditions.) 1. Stop engine, wait for all moving parts to stop , and remov e k ey . Engag e parking brak e . 2. Drain oil while engine is w ar m from operation. 3. R emov e the oil drain plug from the right hand side of the eng[...]

Maintenance Lubrication Chart (cont'd.) Fitting Locations Initial Pumps Number of Places Ser vice Inter v al 6. T rans- mission Output Shaft Coupler 2 2 2 2 40 hours 7. Mo wer Deck Idler Piv ots 2 1 1 1 40 hours 48 inch Deck Shown for R eference Only Number 4 and 7 (Idler Ar m Pivots) Disassemble and g rease once a month under a “No Load” [...]

Maintenance 6. Check for side play caused b y bearing wear on the input and output shafts of the transmission. R eplace bearings if necessar y . 7. R emov e the six bolts that fasten the upper case to the lower case and carefully remo v e the upper case half 8. Check the grease lev el in the lower case. The g rease lev el should be approximately 1 [...]

Maintenance Adjustments Note: Disengag e PTO , shut off engine , w ait for all moving parts to stop , engage parking brake, and remov e key before ser vicing, cleaning, or making any adjustments to the unit. Adjusting the Cutting Height The cutting height of the mower deck is adjusted from 1 inc h to 4 1/4 inches (2.54 cm to 11.4 cm) in 1/4 inch (.[...]

Maintenance Cutting Height Adjustment T able (1 inch to 4 1/4 inches (2.5 cm-10.8 cm)) (cont'd.) Number Of Spacers Below Caster Suppor t Hub Number of 1/4 inch (.64 cm) Blade Spacers Below Spindle Cutting Height Range Axle Position (Figure 10) 1/2 inch (1.2 cm) 3/16 inch (.48 cm) 4 3 2 1 0 2 1/8– 3 1/8 inc hes (5.4–7.9 cm) C 2 0 2 1/8 inch[...]

Maintenance 8. With the jac k, raise or lower the back end of the engine dec k 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. R etighten all four bolts, low er unit and remove jack. 10. Install mo wer dec k belt shield. 11. Adjust wheel driv e and brak e linkag[...]

Maintenance Height Adjustment T able and notes in the Adjusting the Cutting Height section. 9. Install unused spacers between top of spindle and spindle n ut. 10. T orque bolt to 75–80 ft-lb (102–109 N-m) (see Figure 12). Figure 12 1. Spring disc washer (cone towards bolt head) 2. Blade bolt torque to 75–80 ft-lb (102–109 N-m) T ransmission[...]

Maintenance Check belt tension after the rst hour of operation and at least twice during the rst 24 hours of operation. Adjust as necessar y . Figure 13 48 inch Deck Shown for Reference Only 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[...]

Maintenance distance should be between 1/8 inch and 3/16 inch (3–5 mm) (see Figure 16). 5. Engag e the blade control and c heck to mak e sure the blade brak e pad clears the sheav e . Figure 16 Shown with Blades Disengaged 1. Blade Brake Rod 3. 1/8 inch to 3/16 inch (3–5 mm) 2. Spring Mounting Bolts Belt Guide Adjustment 1. Stop engine and w ai[...]

Maintenance A. F or wheel dri ve linkage adjustment, remov e the hair pin between the neutral lock latch and driv e lev er (Figure 19). 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 inc h[...]

Maintenance Figure 22 Right Side of Unit Shown 1. Wingnut 5. 5/16–18 x 1 3/4 inch hex capscrew 2. T ransmission Lever in neutral 6. Drive Lever Linkage 3. 5/16–18 inch nyloc nut 7. Swivel 4. Drive Levers in neutral 8. Brake Rod Shifter Lever Adjustment The shifter lev er in neutral should not contact the upper or lower edge of the slot or the l[...]

Maintenance Shifter Detent Adjustment T ransmission shifter detent can be adjusted by adjusting the setscrew on the bac k side of transmission located just behind the neutral start switch. T ur n setscrew in (clockwise) to hold the transmission shifter more positiv ely in each g ear and to increase the force on the lever required to shift gears . T[...]

Maintenance Figure 27 1. More traction applied as bolt moves down 4. Position C–Most Severe 2. Position A–Normal Conditions 5. Front of Unit 3. Position B–More Severe 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 Excessi v e de bris aro[...]

Maintenance Clean Debris From Machine Service Interval: Before each use or daily 1. Stop engine, wait for all moving parts to stop , and remov e k ey . Engag e parking brak e . 2. Clean off any oil, debris, or grass build-up on the machine and cutting deck, especially under dec k belt shields , around the fuel tank, around engine and exhaust area. [...]

T roubleshooting T roubleshooting 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 ov erlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Idler arm pulleys and driv e sheaves are dirty . 1. Remov e m ud and/or grass buildup . 2. Wheel drive belt pulley scrapers adjustment is not correct 2. Cor rect adjustment. 3. Idler pivot ar ms cannot piv ot freely 3. Lubricate ilder piv ots . 4. Drive belts are w orn. 4. Replace driv [...]

Schematics Schematics KEY SWITCH PT O SWITCH N.O . TRANSMISSION N.C. T O SAFETY INTERLOCK MODULE OPC SWITCH N.O . RED BLA CK BRO WN DK BLUE ORANGE YELLO W GREEN BLA CK ENGINE GROUND ENGINE KILL TERMINAL RED CONNECT ORS ARE VIEWED FROM WIRE END N.C. = NORMALL Y CLOSED N.O . = NORMALL Y OPEN G006816 A B C D E F 38[...]

Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty 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 ex ercise of our reasonable discretion) to be defect iv e in factor[...]

Notes: 40[...]

Service Record Date: Description of W ork Done: Service Done By: 41[...]

42[...]

G01 1841 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.[...]

MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF A CCESSORIES AND OPTIONS W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED[...]