Exmark Metro manual

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i WA RNING The engine exhaust f rom this pr oduct contains chemicals k now n t o the State of Califor nia to cause cancer, birth def ects, or other r eproductive harm. IMPORTANT W hen the m ow er is used or operated on any Califor nia forest, brush or grass covered land, a work ing spark ar rester must be at tached to the muf fler. I f not, the ope[...]

ii EXMARK PA RTS PLUS     PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not have the Exmark part in stock, Exmark w ill get the parts to the dealer the next business day or the part will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in stock for a "dow n" unit at t[...]

iii CONGRAT ULATIONS on the purchase of your Exmark Mow er . This product has been caref ully designed and manufactur ed to give you a maximum amount of dependability and years of tr ouble-free oper ation. OPERA TOR'S MA NUA L This manual cont ains assembly, operating, m aintenance, adjustm ent and safety instructi ons for your Ex mark mower. [...]

iv TA BLE OF CONTENTS 1. SA FETY PA GE 1.1 Sa f ety Alert Sy mbol ............................................................................... 1 1.2 Trai ning ................................................................................................. 1 1.3 Preparatio n .......................................................................[...]

- 1 - 1. SA FETY 1.1 SA FETY A LERT SYMBOL THIS SA FETY A LERT SYMBO L IS US ED BOT H IN TH IS MA NUA L A ND ON T HE MA CHINE TO IDENT IFY IMPOR TA NT SA FET Y MESSA GES WHICH MUST BE FOLLOWED TO AVOID A CCI DENTS. TH IS SYMBO L MEA NS: A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appears above inform ation w hich a[...]

- 2 - WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, w hich is an odorless deadly poison. W HAT CAN HAPPEN ♦ Carbon monoxide can kill you and is also known to t he State of California t o cause birth defect s. HOW T O AVOI D THE HAZARD ♦ Do not run eng ine indoors or in a small conf ined area where dangerous carbon mon[...]

- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions gasoline is extremely flam mable and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A fire or explosion from g asoline can burn you, others, and cause property damag e. HOW T O AVOI D THE HAZARD ♦ Purchase and store g asoline only in an approved conta[...]

- 4 - is responsible f or safe operat ion on slopes. See inside back cover to determ ine the approximate slope ang le of the area t o be mowed. 1.4.5 Stop the blades when crossing surf aces other than g rass, if mower must be tilted for transportation, and when transpor ting the mower to and f rom the area t o be mowed. 1.4.6 Never operate the mowe[...]

- 5 - 1.5.4 Store f uel in a container specif ically designed for th is purpose. Store the f uel container in a cool, dr y place. 1.5.5 Keep the mower and fuel cont ainer in locked storag e to prevent children f rom playing or tam pering with them. 1.5.6 Gasoline powered equipment or fuel containers should not be stored in a basement or any enclose[...]

- 6 - PART NO. 403143 LOCATI ON: Right Rear of Engine Deck KOHLER, 13 HP KAW , & 10.5 B&S PART NO. 323688 LOCATI ON: Console 12.5 HP KAW , KOHLER & 10.5 HP B&S PART NO. 323689 LOCATI ON: RH Side of Console 15 & 17 hp KAW PART NO. 323691 LOCATI ON: RH Side of Con sole 15 & 17 HP KAW PART NO. 323699 LOCATI ON: Console[...]

- 7 - 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: Serial Nos. 220, 000 & Higher M3211B; M 3213KA; M3613KA; M3613KC; M3615KA; M 4815KC; M 4815KA; M 4817KA 2.2 ENGINE 2.2.1 Engine Specif ications: See your engine owner's manual. 2.2.2 RPM (No Load): 3600 rpm 2.3 FUEL SYSTEM 2.3.1 Capacity: 5 gal. (18.9 liter) 2.3.2 Type of Fuel: Use only clean, fr[...]

- 8 - 2.6.2 Speed range: 1st 2.0 mph (3. 22 km/h) 4th 4.1 mph (6. 60 km/h) 2nd 2.7 mph (4. 35 km/h) 5th 6.2 mph (9. 98 km/h) 3rd 3.5 mph (5. 63 km/h) Rev 3.1 mph (4.99 km /h) 2.7 WHEEL DRIVE SY STEM Banded double A-Section V-belt s, single top- side idlers and replaceable bolt-on dr ive sheaves and brake drums. (Single B-Section V- belts for t he 3[...]

- 9 - 2.11 TORQUE RE QUIREMENTS BOLT LO CATION TORQ UE Blade/Cu tter Housing Spindle B olt ....................................75-80 ft-lbs. Caster Bracket M ounts......................................................30-35 ft-lbs. Cutter De ck /Engine De ck M ount .......................................30-35 f t-lbs. Engine Mounting Bolts 15 & [...]

- 10 - IMPORTA NT: If the mower has been compl etely assembled and the handle position is changed , it will be necessary to readj ust the drive and brake linkage. FIG. 2 UPPER HA NDLE HEIGHT A DJUSTMENT 3.8.1 Attach thr ottle cable to engine. For Kohler, Kaw asaki, and B&S 10. 5 hp Engines with "p ositive" de tents in throttle c able [...]

- 11 - FIG 4 12.5 HP KA W A SA KI SPEED CONTROL (THROTTLE CA BLE HOO K-UP) FIG 5 B&S 10.5 HP SPEED CONTROL (THROTTLE CA BLE HOO K-UP) FIG 6 15 & 17 HP KA WASA KI SPEED CONTROL (THROTTLE CA BLE HOO K-UP) d) Pull cable upward for 12.5 HP Kawasaki and Kohler units (rear ward for B&S or to the rig ht when facing t he control plate on the 15[...]

- 12 - e) Check t hat the choke adjust ing screw just comes in contact with the chok e lever when throttle contr ol is in the full t hrottle position. ( B&S 10.5 hp does not have a choke adjust ing screw.) Choke link should not move when throttle control is moved to the f ull thrott le position. Be sure choke is f ully closed when throttle leve[...]

- 13 - FIG. 8 THIS CLEA RANCE SHOULD BE EQUA L FIG. 7 SHIFTER LEVER TO T RA NSMISS ION FIG. 9 THIS CLEA RANCE SHOULD BE EQUA L 3.8.5 Inst all and adjust wheel drive linkages. a) Screw threaded end of drive linkages int o swiv els in wheel drive idler arms. b) Insert clevis pin from bolt bag through dr ive linkage, lever and slot in t he neutral loc[...]

- 14 - FIG. 11 NEUTRA L LOCK LEVER CLEA RANCE NOTE: Neutral lock/ park brake latch clearance should be checked w hen there is a slight upward f orce placed on the drive levers to remove any "slack" i n the linkage. Aft er clevis pin has been inser ted, install hairpin int o hole on the clevis pin betw een the neutral lock /park br ake lat[...]

- 15 - 3.8.8 Route the long, unattached wiring harness lead up the lef t hand side of t he handle and connect the two leads, in any order, t o the operator presence cont rol switch terminals on t he inside of the contr ol console. Fasten the lead to the handle with two large wire ties, f rom bolt bag, one at the upper end of the handle next to the [...]

- 16 - FIG. 13 DRIVE LEVER, NEUTRA L LO CK/PA RK BRAKE LA TCH OPERA TION 4.1.4 Operator Presence Control (OPC) Levers: Located on the upper handle assem bly directly abov e t he handle grips. W hen these levers are depressed, t he OPC system senses that the oper ator is in the normal operat or's position. W hen the levers are r eleased, the OP[...]

- 17 - 4.1.8 Transm ission Shift Lever: Located under the cont rol console and behind the fuel t ank. It shifts the 5- speed transmission into five forward gear s, neutral and reverse. Shif t transm ission only when drive lev ers are in the neutral position. Shif ting without drive levers in neutral may cause damag e to the transmission. NOTE: Reve[...]

- 18 - Do not add oil to g asoline. Do not overfill f uel tank . Never fill the f uel tank so t hat the f uel level rises abov e a level that is ½” below the bott om of the f iller neck to allow for f uel expansion and prevent f uel spillage. DA NGER POTENT IAL HAZARD ♦ In certain condit ions gasoline is extremely flam mable and highly explosi[...]

- 19 - 4.3 OPERA TING INSTRUCTIONS 4.3.1 Read the Engine Owner's Manual caref ully for detailed operat ing instruct ions and maintenance reg arding the eng ine. Befor e attempting to operate the unit , refer to Section 1 (Saf ety) and follow all safet y, operating, and prepar ation guidelines as stated in t hat section. 4.3.2 Starting Engine P[...]

- 20 - 4.3.4 Drive Lever/Neutral Lock/ Park Brak e Latch Operation: To lock the drive levers in “neutral” sq ueeze the drive levers back to the neut ral position. Place thum bs on the upper portion of the neutral lock /park br ake latches and move them t o the rear. Release dr ive lev er s (See Figure 13). To lock the levers in “park br ake?[...]

- 21 - 4.4 TRA NSPORTING WA RNING POTENT IAL HAZARD ♦ Loading the m ow er onto a trailer without str ong enough or pr operly supported ramps could be dangerous. W HAT CAN HAPPEN ♦ The ram ps could collapse causing the unit to f all, which could cause injury. HOW T O AVOI D THE HAZARD ♦ Use proper ramps t hat are secured to the t ruck or trail[...]

- 22 - WA RNING POTENT IAL HAZARD ♦ The engine can becom e very hot. W HAT CAN HAPPEN ♦ Touching a hot engine can cause severe burns. HOW T O AVOI D THE HAZARD ♦ Allow the engine to cool complet ely before service or making repairs around the eng ine area. 5.1.1 Check eng ine oil level. Service Interval: See Engine Ow ner's Manual a) Mak[...]

- 23 - a) Diseng age blades. b) Stop eng ine and remove spark plug wire(s) . c) Raise deck, suppor t properly using saf ety precautions. d) Clean out any grass build- up from under side of deck and in deck discharge chute. e) Inspect blades and shar pen or replace as required. f) If blade removal is necessary, be careful f or the sharp cut ting edg[...]

- 24 - 5.1.6 Check f or loose hardware. Serv ice Interva l: Daily a) Stop eng ine and remove spark plug wire(s) . b) Visually inspect machine f or any loose hardware or any other possible problem. T ighten or replace any hardware bef ore operating. 5.1.7 Service pre-cleaner element and air cleaner. Service Interval: See Engine Ow ners Manual a) Sto[...]

- 25 - f) Check f or side play caused by bearing wear on the input and output shaf ts of the transm ission. Replace bearings if necessary. g) Remove the six bolts that f asten the upper case t o the lower case and caref ully remove the upper case half. h) Check t he grease level in the lower case. The g rease level should be approximately 1-1/2&quo[...]

- 26 - c) Replace 5-speed gearbox g rease yearly. Use 18 oz. Of Peerless g rease (Part No. 788067). See Section 5.1.10. d) Lubricate pivot point s w it h a spray penetrating lubricant as directed below. SPRA Y LUBRICANT CHA RT PIVOT POI NTS NO. of P LA CES 32" 36" 48" SERVICE INTERVA L 1. Blade Engagement Bel lcrank 1 1 1 Weekly 5.1.[...]

- 27 - 5.1.20 Dielectric gr ease is used on all blade type electrical connections to prevent corrosion and loss of contact. 5.2 A DJUSTMENTS 5.2.1 Adjusting cut ting height with blade spacers. Blades may be adjusted f or cutting heig ht by using the f our 1/4" spacers f ound on the blade spindle bolts (f actory setting is two above and tw o be[...]

- 28 - FIG. 15 FIG. 16 CA ST ER HEIGH T A DJUS TMENT A XLE HEIGHT AD JUST MENT These models have f iv e ( 5) axle positions; four ( 4) 1/2" caster spacer s; one (1) 3/16" cast er spacer, and f our (4) blade spacers. NOTE: The axle positions are in 1/2" increments and the large caster spacers are 1/2" thi ck. Therefore, by adjust[...]

- 29 - b) To t ighten transmission belt , loosen the 3/8" nyloc nut on transm ission belt idler pulley. Slide bolt inward in slot and ret ighten nyloc nut. c) W hen properly adjust ed, the belt should have 1/2" of deflection with thr ee pounds of pr essure on the belt midway between the transmission and engine pulley. 5.2.4 W heel drive b[...]

- 30 - e) Check belt guide under the eng ine deck to see that it is properly set. (See Section 5.2.7) . Also check the blade brak e adjustment . (See Section 5.2.6) 5.2.6 Blade Brake Adj ustment: a) Stop engine and rem ove spark plug wire(s). b) Disengage blades. c) Make sure the blade brak e pad rests against t he sheave. Adjust the spring mountin[...]

- 31 - 5.2.11 Shift er detent adjustm ent - Transm ission shifter detent can be adjusted by adjusting the setscrew on the back side of transmission locat ed just behind the neutral star t switch. Turn set screw in (clockwise) to hold the transm ission shifter mor e positively in each gear and t o increase the for ce on the lever required t o shift [...]

- 32 - 5.2.15 Adjust thr ottle lever tension (B&S Engines onl y ) . a) Stop engine. b) Tension in throt tle levers can be increased or decreased by adjusting t he tightness of the lever pivot bolt which is located under the console. 6. TROUBLE SHOOTING 6.1 MOWER PULLING L EFT OR R IGHT. a) Check idler arm pulleys and drive sheav es f or mud and[...]

- 33 - NOTE: A fter caref ully checking the previous steps, attempt to st art the engine. If it does not start, cont act y our aut horized Exmark service dealer. ENGINE TROUBLESHOOTING W hen a problem occur s, do not overlook the sim ple causes. For example, start ing problems could be caused by an empty f uel tank, k ey sw itch not "ON" [...]

- 34 - 8. WIRING DIA GRAMS[...]

- 35 - 9. WA RRANTY Limited W a rranty Exmark Comm ercial Turf Equipment Exmark Mfg. Co. Inc. (" Exmark") warrant s on the term s and conditions herein, that it will repair, replace or adjust any part manufact ured by Exmark and found by Exmark (in the exercise of its r easonable discretion)to be def ective in factory mat erial or workman[...]

- 36 - As a condition to this warrant y, customer shall have read the operator 's manual and shall have returned to Exmark, within the pr escribed time, the enclosed warranty reg istration card. The sole liability of Exmark with respect to t his warranty shall be repair and replacement as set for th herein. Exmark shall have no liability for a[...]

- 37 - SERVICE RECORD Date Description of Work Done Service Done By[...]

- 38 - T H I S I S A 1 5 ° SL O P E T H I S I S A 1 0 ° S L O P E T H I S I S A 5 ° S L O P E ALIGN THIS EDGE WITH A VERTICAL SURF ACE (TREE, BUILDING, FENCE POST , POLE ETC.) EXAMPL E: COMP ARE SLOPE WIT H FOLDED EDGE. FOLD ALONG APPROPRIA TE LINE T H I S I S A 2 0 ° S L O P E[...]

SEE EXMARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z ™ LAZER Z ™ HP TURF RANGER ® TURF TRACER ® TURF TRACER ® HP VIKING HYDRO METRO ™ METRO ™ HP SELF STEERIN G SULKY GRASS CATCHER MICRO-MULCH ™ ACCESS ORY ® MF G . C O. I N C . ©1997,1998, 1999 PA RT NO. 850651 Rev B. EXMA RK M FG. CO. I NC. (402) 223-6300 INDUSTRIA L PARK B[...]