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Exmark Metro Series Operator's Manual
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Exmark Metro Series Operator's Manual

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For Serial Nos.
510,000 & Higher
Part No. 103-8850

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Summary of Contents for Exmark Metro Series

  • Page 1 For Serial Nos. 510,000 & Higher Part No. 103-8850...
  • Page 2 Replacements may be ordered through the engine manufacturer. Exmark reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously. Exmark, or its distributors and dealers, accept no responsibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication.
  • Page 3 3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time, Exmark pays for the part and freight. 4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark pays for the part.
  • Page 4 If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor. 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS 1. SAFETY PAGE 1.1 Safety Alert Symbol................1 1.2 Training....................1 1.3 Preparation ..................1-3 1.4 Operation ................... 3-6 1.5 Maintenance & Storage................6 1.6 Riding Attachments................6 1.7 Safety Signs..................6-9 2. SPECIFICATIONS 2.1 Model Numbers..................9 2.2 Engine....................9 2.3 Fuel System ...................9 2.4 Safety Interlock System .................9 2.5 Steering/Brake Control................9 2.6 Transmission..................10...

  • Page 6: Safety Alert Symbol

    MAY result in minor or moderate injury. 1.2 TRAINING 1.2.1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit. 1.2.2 Read the instructions carefully. Familiarize yourself with the controls and the proper use of the equipment.
  • Page 7 1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders. WARNING POTENTIAL HAZARD ♦...

  • Page 8: Operation

    DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline vapors. A fire or explosion from gasoline can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD ♦...
  • Page 9 WARNING POTENTIAL HAZARD ♦ Operating engine parts, especially the muffler, become extremely hot. WHAT CAN HAPPEN ♦ Severe burns can occur on contact. ♦ Debris, such as leaves, grass, brush, etc. can catch fire. HOW TO AVOID THE HAZARD ♦ Allow engine parts, especially the muffler, to cool before touching.
  • Page 10 • See inside the back cover to determine the approximate slope angle of the area to be mowed. • Progressively greater care is needed as the slope increases. • Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope.

  • Page 11: Maintenance & Storage

    All replacement parts must be the same as or equivalent to the parts supplied as original equipment. 1.6 RIDING ATTACHMENTS Use only Exmark riding attachments. The use of other than Exmark riding attachments may create a hazardous condition resulting in injury. 1.7 SAFETY SIGNS 1.7.1...
  • Page 12 PART NO. 1-323427 PART NO. 103-5626 LOCATION: 32” & 36” Decks Under Belt LOCATION: 48” Decks Under Belt Shield Shield Kawasaki Units PART NO. 103-1798 LOCATION: RH Side of Console PART NO. 1-513746 PART NO. 1-303517 LOCATION: Engine Blower LOCATION: Left Side, Rear Surface Engine Deck Housing Next to Muffler ECS Handle Units...
  • Page 13 Pistol Grip Handle Units PART NO. 1-323550 LOCATION: Upper Handles (Both Sides) Kohler Units PART NO. 1-323689 LOCATION: RH Side of Console Kohler ECS Handle Units PART NO. 103-1641 LOCATION: Console Kawasaki Pistol Grip Handle Units PART NO. 103-1967 LOCATION: Console - 8 -...

  • Page 14: Specifications

    PART NO. 1-403143 LOCATION: Right Rear of Engine Deck Kawasaki ECS Handle Units PART NO. 103-1623 LOCATION: Console 2. SPECIFICATIONS 2.1 MODEL NUMBER: M3213KA; M3613KA; M4815KA; M3613KAC; M3615KCC; M4815KCC; M4815KAC 2.2 ENGINE 2.2.1 Engine Specifications: See your engine owner's manual. 2.2.2 RPM (No Load): 3600 rpm 2.3 FUEL SYSTEM 2.3.1 Capacity: 5 gal.

  • Page 15: Transmission

    2.6 TRANSMISSION 2.6.1 Peerless 700-070A, five speeds forward and one reverse. 2.6.2 Speed range: 2.0 mph (3.22 km/h) 4.1 mph (6.60 km/h) 2nd 2.7 mph (4.35 km/h) 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 SYSTEM Banded double A-Section V-belts, single top-side idlers and replaceable bolt-on drive sheaves and brake drums.

  • Page 16: Bolt Torque Requirements

    2.10.4 Tread Width∗∗ 32" 36" 48” Standard Pistol Grip & 32.1 in (81.4 cm) 35.6 in (90.4 cm) 35.6 in (90.4 cm) ECS Handles ∗∗ To outside of tires. 2.10.5 Overall Height Standard Pistol Grip Handles 40.0 in (101.6 cm) ECS Handles 42.1 in (106.9 cm) 2.11 TORQUE REQUIREMENTS...
  • Page 17 FIGURE 1 UPPER HANDLE MOUNTING IMPORTANT: If the mower has been completely assembled and the handle position is changed, it will be necessary to readjust the drive and brake linkage. FIGURE 2 UPPER HANDLE HEIGHT ADJUSTMENT Attach throttle cable to engine. For Kohler engines with "positive"...
  • Page 18 d) Pull cable upward until alignment holes in control plate lever and control plate line up. For Kohler units a 19/64” drill bit can be inserted through these two holes to align them. Once holes are aligned, tighten clamp onto throttle cable. e) Check that the choke adjusting screw just comes in contact with the choke lever when throttle control is in the full throttle position.
  • Page 19 b) Shift lever to second gear and check alignment of lever in slot of shifter plate. Clearance between top of lever and the top of the slot should be about equal to the clearance between bottom of the lever and the bottom of the slot (See Figure 6). If it is not, remove lever and bend it slightly to adjust.
  • Page 20 3/16” TO 1/4”(.47-.64 cm) Neutral Lock / Park Brake Latch Drive Linkage FIGURE 9 PISTOL GRIP HANDLES NEUTRAL LOCK LEVER CLEARANCE NOTE: Neutral lock/park brake latch clearance should be checked when there is a slight upward force placed on the drive levers to remove any "slack"...
  • Page 21 FIGURE 11 ECS HANDLE DRIVE LEVER LINKAGE INSTALLATION FIGURE 12 ECS HANDLE DRIVE LEVER SETTING 3.14 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”...

  • Page 22: Operation Instructions

    3.17 Service Engine: Follow the recommendations in the Engine Operators Manual. 3.18 Grease unit. NOTE: UNIT IS NOT GREASED AT THE FACTORY! Refer to Section 5.1.12 for locations and grease amounts. 3.19 Follow pre-start instructions as outlined in Section 4.2. 4.
  • Page 23 FIGURE 14 ECS HANDLE NEUTRAL LOCK/PARK BRAKE LATCH 4.1.5 PTO Engagement Lever: Located on the left side of the upper handle. To engage the blades, push the lever forward, or away from the operator, until the turnbuckle locks over-center. To disengage the blades, pull the lever to the rear, or towards the operator. 4.1.6 Throttle-Choke-Kill Control (Kohler engines): The throttle-choke-kill control lever is located on the control console right side.

  • Page 24: Pre-Start

    4.1.10 Transmission Shift Lever: Located under the control console and behind the fuel tank. 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.
  • Page 25 4.3.3 Stopping Engine: Lock the drive levers in “park brake” position, disengage PTO, and position transmission to neutral. Place the throttle control midway between the “slow” and “fast” positions. Allow the engine to run a minimum of 15 seconds. For Kohler engines: Move throttle to full rear position to stop the engine. For Kawasaki engines: Turn the key to the “Off”...
  • Page 26 For ECS Handles: To lock the drive levers in “neutral lock”, squeeze the drive levers to the “neutral” position. See Figure 16 (b). Place thumbs on the inner thumb lobe of the neutral lock /park brake latches and rotate them to the “neutral” position.
  • Page 27 4.3.6 To Stop: 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. 4.3.7 PTO Engagement: DANGER POTENTIAL HAZARD ♦ The rotating blades under the mower deck are dangerous.

  • Page 28: Transporting

    4.4 TRANSPORTING WARNING POTENTIAL HAZARD ♦ Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous. WHAT CAN HAPPEN ♦ The ramps could collapse causing the unit to fall, which could cause injury. HOW TO AVOID THE HAZARD ♦...
  • Page 29 5.1.1 Check engine oil level. Service Interval: See Engine Owner's Manual Stop engine and wait for all moving parts to stop. Make sure machine is on a level surface. Check with engine cold. Clean area around dipstick. Remove dip stick and wipe off oil. Reinsert the dipstick (Do not screw into place).
  • Page 30 Service Interval: Daily a) 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.
  • Page 31 NOTE: Change oil after first five (5) hrs. of operation. Follow engine manufacturer's recommendations for future oil changes. a) Disengage PTO. b) Stop engine and wait for all moving parts to stop. Remove key or spark plug wire(s). c) Drain oil while engine is warm from operation or if oil is to be changed after the unit has been sitting for awhile, run engine for a few minutes to get it warm.
  • Page 32 5.1.11 Inspect belt wear. Service Interval: 40 hrs. a) Stop engine and wait for all moving parts to stop. Remove key or spark plug wire(s). b) Remove the mower deck belt shield to check mower blade drive belt condition. c) Look under engine deck to check the transmission drive belt condition. d) Inspect wheel drive belt conditions.

  • Page 33: Adjustments

    c) Make sure cooling shrouds are properly reinstalled. Operating the engine without cooling shrouds will cause engine damage due to overheating. 5.1.14 Check spark plugs. Service Interval: See Engine Owner's Manual Remove spark plug, check condition and adjust plug gap, or replace with new plug (See Engine Owner’s Manual).
  • Page 34 If the mulching kit is installed, the highest quality cut can be obtained with 3 spacers between the blade and spindle (minimum is 1 for a good cut). If you need to cut higher or lower than what the spacers will allow, it will be necessary to adjust the rear axle height and caster position.
  • Page 35 CUTTING HEIGHT ADJUSTMENT (1" to 4 1/4") # OF SPACERS AXLE BELOW NUMBER OF 1/4" BLADE SPACERS POSITION CASTER BELOW SPINDLE (FIG. 20) SUPPORT HUB 1/2" 3/16" 1" (2.5 cm) 1 1/4" (3.2 cm) 1 1/2" (3.5cm) 1 3/4" (4.4cm) 2"...
  • Page 36 c) Belt must be tight enough to not slip during heavy loads while cutting grass. Overtensioning will reduce belt and spindle bearing life. To adjust belt tension, loosen the 5/16" 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 20).
  • Page 37 5.2.7 Belt Guide Adjustment a) Stop engine and wait for all moving parts to stop. Remove key or spark plug wire(s). b) Engage the blade drive belt. c) Check belt guide under the engine deck for proper adjustment (See Figures 22 and 23).

  • Page 38: Waste Disposal

    5.2.14 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. a) Stop engine and wait for all moving parts to stop. Remove key or spark plug wire(s).

  • Page 39: Blades Do Not Stop When Disengaged

    For Kawasaki: Check that the key switch is in the “Run” position. NOTE: After carefully checking the previous steps, attempt to start the engine. If it does not start, contact your authorized Exmark service dealer. ENGINE TROUBLESHOOTING When a problem occurs, do not overlook the simple causes. For example, starting problems could be caused by an empty fuel tank, key switch not "ON"...

  • Page 40: Belt Routing (Mower Decks)

    8. MOWER DECK BELT ROUTING FIGURE 26 FIGURE 27 32" and 36" MOWER DECK 48” MOWER DECK - 35 -...

  • Page 41: Wiring Diagrams

    9. WIRING DIAGRAMS - 36 -...

  • Page 42: Warranty

    This warranty extends only to replace or adjust any part manufactured by Exmark and found turf equipment operated under normal conditions. You by us (in the exercise of our reasonable discretion) to be...
  • Page 43 ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) - 38 -...
  • Page 44 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. ©1997-2004 EXMARK MFG. CO. INC. PART NO. 103-8850 INDUSTRIAL PARK BOX 808 (402) 223-6300 BEATRICE, NE 68310 FAX (402) 223-5489 ®...