METRO®
SetupInstructions
ForSerialNos.720,000&Higher
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#
DescriptionQty.Use
323-4
Screw,HH3/8-16x3/4inch
8
3290-357
Nut,Whizlock3/8-16inch
8
Installingthefrontcasterwheels.
1-633023Stud,FuelTank2
322-3
Screw,HH5/16-18x3/4inch
2
3256-23
Washer,5/16inchSAE
4
1-805005
Washer,Lock5/16inchHeavy
2
1-633349
Spring,Compression
2
3296-47
Nut,Nyloc5/16-18inchThin
2
Installingthefueltank.
323-6
Screw,HH3/8-16x1inch
4
3296-39
Nut,Nyloc3/8-16inch
4
Installingthehandleassembly.
1-806003Hairpin,Cotter2InstallthePTOengagementlinkage.
1-808286
Pin,Clevis(PistolGripOnly)
2
1-806003
Hairpin,Cotter(PistolGripOnly)
2
322-9
Screw,HH5/16-18x13/4inch(ECS
Only)
2
3296-29
Nut,Nyloc5/16-18inch(ECSOnly)
2
Installingandadjustingthewheel
drivelinkages.
1-303287Tie,Cable2Connectingwireharness.
—
WarrantyRegistrationForm
1
103-2106
Key,ExmarkLogo
1
1-603511
Key,Standard
1
Filloutwarrantyregistrationformand
placekeysintoliteraturepack.
LiteraturePack
Part#
DescriptionQty.Use
—
Manual,Operator’s
1
—Manual,Parts1
Readbeforeoperatingthemachine.
—Manual,EngineOperator’s1
Forunitswith15hpKawasakiengines.
Readbeforeoperatingthemachine.
UncratingtheUnit
1.Leavingtheunitonthepallet,placetheupperhandle
assembly,thefueltank,andtheshifterleveratthe
rearofthemachine.Placethecastersatthefront
oftheunit.
2.Placealengthof4inchx4inch(10cmx10cm)
blockbetweenthefrontofthemowerdeckandthe
pallet.
©1997–2007—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4500-279Rev.A
PrintedintheUSA.
AllRightsReserved
3.Removetheboltbagfromunderthemowerdeck
beltshield.
4.Refertothepartsmanualtohelpyouidentifyand
locatethepartsandtheirproperposition.
InstallingtheFrontCasterWheels
Installthecasterstothefrontofthedeckusingeight
3/8-16x3/4inchboltsandeight3/8inchwhizlock
nuts.Tightenthelowerfourboltsrst,thenthetopfour.
InstallingtheFuelTank
1.Applyretainingadhesive“Fel-ProProLockRetaining
IorRetainingII”or“LoctiteRC609or680”onthe
twothreadedstudsfromtheboltbagandinstallinto
thetwoleftholesunderneathfueltank.Installthe
fueltankontopofthefueltanksupportwiththe
studsgoingthroughtheslotsinthesupport.
2.Installtwo5/16x3/4inchscrewswitha5/16inch
SAEatwasherand5/16inchlockwasherintothe
threadedholesintherightsideofthefueltank.Do
notovertighten.
3.Placea5/16inchSAEatwasher,thenaspring,
overeachofthestudsandfastenwitha5/16inch
nylocnut.Tighten5/16inchnylocnutfullythen
backoffa1/2turn.Thisistoallowfornormal
fueltankexpansionandcontractionwithchangesin
temperatureandfuellevels.Donotovertighten.
4.Attachthefueltankhosetothetankttingand
securewiththeclampprovided.
InstallingtheHandleAssembly
Positionthelowerendofthehandleassemblyonthe
outsideoftheupperrearsectionofthefueltankand
handlesupport.Installone3/8-16x1inchbolt(from
theoutsidein)intheupperholeoneachsideofthe
handle.Looselysecureeachscrewwitha3/8”nyloc
nut.Thehandlecannowbepivotedtoallowpositioning
inoneofthethreeholesallowingvariousadjustments
foroperatorcomfort(Figure1andFigure2).Oncea
properpositionisfound,installone3/8x1inchboltin
thebottommountingholesoneachsideofthehandle.
Secureeachboltwitha3/8inchnylocnut.Tightenall
hardware.
Figure1
1.Frontoftheunit
3.Upperhandle
2.Upperhandlemounting
tab
Note:Ifthemowerhasbeencompletelyassembled
andthehandlepositionischanged,itwillbenecessary
toreadjustthedriveandbrakelinkage.
Figure2
AdjustmentHolesareactuallyinthesideofthefueltank
support.
1.Upperhandle3.Adjustmentholes
2.Upperhole4.Fueltanksupport
AttachingtheThrottleCable
Routethethrottlecablealongtheleftsideoftheupper
handle,throughtheclip,underthefueltanksupport,
andpositionthecableonthefrontoftheengine.
Attachthrottlecabletoengine:
1.Positionthethrottlecontrollever(locatedonthe
console)inthefullthrottleposition.Youwillfeela
detentwhenthethrottleleverispushedtowardsthe
upperendoftheslot.
2
2.Attachtheinnerwireofthethrottlecabletothe
topholeinthethrottlecontrolleverasshownin
Figure3.
3.Loosentheclamp,placethecablebehindit,andpull
onthecabletomovethethrottlelinkagetothefull
throttleposition.Tightenthecableclampscrew .
Figure3
1.Throttlecontrollever
3.Clamp
2.Chokecable
4.Throttlecable
InstallthePTOEngagement
Linkage
1.Installthebladeengagementlinkagetothebellcrank
ontheLeftHandsideoftheenginedeck.
2.Insertrodthroughtheholefromtheoutsideand
fastenwithcotterhairpin.
InstallingandAdjustingtheShifter
Lever
1.Removethe3/8inchnylocnutandthespringdisc
washerfromthestudontopofthetransmission.
Installtheshifterleverthroughtheslotinthe
shifterleverplateandontothestudontopof
thetransmission.Besurethesquare-holewasher
remainsbetweentheleverandthetransmission.
Replacethespringdiscwasherandthenylocnut
(Figure4).Torquethe3/8inchnutto35ft-lb(47
N-m).
Figure4
1.Shifterlever
3.Transmission
2.Squareholedwasher
2.Shiftthelevertosecondgearandcheckthe
alignmentoftheleverintheslotoftheshifterplate.
Clearancebetweenthetopoftheleverandthetop
oftheslotshouldbeaboutequaltotheclearance
betweenbottomoftheleverandthebottomofthe
slot(Figure5).Ifitisnot,removetheleverandbend
itslightlytoadjust.DONOTbendtheleverwhile
itisattachedtothetransmission.Reinstallthelever
andtightenthehardware.
Figure5
1.Equaldistance
3.Shifterplate
2.Shifterlever
3.Shiftthelevertotheneutralposition.Thelever
shouldnotcontacttheleftedgeoftheupperslot.
Pushtheleverdown.Thelevershouldnotcontact
therightedgeofthebottomslot(Figure6).The
shifterplatecanbeadjustedsidetosidetoadjust
thepositionoftheleverrelativetotheslotinplate.
Loosenthetwoboltssecuringtheshifterplatetothe
shifterleverlegs.Adjustshifterplateandretighten
bolts.
3
Figure6
1.Shifterlever
3.Adjustmentslots
2.Equaldistance
InstallingandAdjustingtheWheel
DriveLinkages
ForPistolGripHandles:
1.Screwthethreadedendofthedrivelinkagesintothe
swivelsinthewheeldriveidlerarms.
2.Inserttheclevispinfromtheboltbagthroughthe
drivelinkage,theleverandtheslotintheneutral
lock/parkbrakelatches(Figure7).Maketheproper
adjustmentsbeforeaddingthehairpins.
Figure7
1.Drivelinkage
3.Neutrallock/parkbrake
latch
2.Clevispin
4.Drivelever
3.Adjustthedrivelinkagelengthbythreadingitinto
oroutoftheswiveluntilthereisa3/16inchto
1/4inch(4.7mmto6.4mm)clearancebetweenthe
linkageassemblyandthebottomoftheslotinthe
neutrallock/parkbrakelatch(Figure8).
Figure8
1.3/16inchto1/4inch(4.7mmto6.4mm)
2.Neutrallock/parkbrakelatch
3.Drivelinkage
Note:Theneutrallock/parkbrakelatchclearance
shouldbecheckedwherethereisaslightupward
forceplacedonthedriveleverstoremoveany
“slack”inthelinkage.
4.Aftertheclevispinhasbeeninserted,installthe
hairpinintotheholeontheclevispinbetweenthe
neutrallock/parkbrakelatchandthedrivelever
(Figure9).
Figure9
1.Drivelever
4.Neutrallock/parkbrake
latch
2.Clevispin
5.Hairpin
3.Drivelinkage
5.Repeattheprocedureonoppositesideofunit.
ForECSHandles:
1.Locatethedriveleverlinkageswhichhavethe
balljointandthejamnutsinstalledononeend.
Locatetwo5/16-18x13/4inchhexcapscrewsand
two5/16-18inchnylocnutsintheboltbag.
4
2.Threadthedriveleverlinkageintotheswivellocated
onthewheeldriveidlerarm.Threadthedrivelever
linkageinuntiltheatedgeofthedriveleveraligns
withthebottomoftherollernotchintheneutral
lock/parkbrakelatchwhenthe5/16-18x13/4
inchhexcapscrewisinsertedthroughtheholeinthe
driveleverandtheholeintheballjoint.
3.Securewiththe5/16-18inchnylocnut.Tighten
thenut.
4.Repeattheprocedurefortheotherside.See
Figure10andFigure11.
Figure10
RightSideofUnitShown
1.Wingnut
5.5/16-18x13/4inchhex
capscrew
2.Transmissionleverin
neutral
6.Driveleverlinkage
3.5/16-18inchnylocnut7.Swivel
4.Driveleversinneutral8.Brakerod
Figure11
1.Notchinneutrallock/parkbrakelatch
2.Drivelever
AdjustingtheBrakes
1.Adjusttheparkbrakebyrotatingthewingnutonthe
upperendofeachbrakerod.Tightenthewingnut
untilthebrakesengagewhenthedriveleversare
squeezedenoughtoallowtheneutrallock/park
brakelatchestobeplaceintothe“parkbrake”
position.SeeFigure12forPistolGripHandlesand
Figure13forECSHandles.
Figure12
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
Figure13
1.Driveleverindriveposition
2.Driveleverinneutralposition
3.Driveleverlockedinneutralposition
4.Driveleverlockedinparkposition
5
2.Checkthebrakeforcorrectadjustment:
A.Placethedriveleversinthe“park
brake”position.Themowershouldnot
moveforwardorbackward.Ifitdoes,tighten
thewingnuts.
B.Placethedriveleversinthe“neutrallock”
position.Themowershouldmoveforward
andbackwardfreely.Ifitdoesnot,loosenthe
wingnuts.
Note:Theneutrallock/parkbrakelatchesmustbe
abletobemovedintotheparkbrakeposition,ifnot,
thebrakelinkagesmustbeadjustedagain.
ConnectingWireHarness
1.Routethelong,unattachedwiringharnessleadup
thelefthandsideofthehandleandconnecttheag
terminals,inanyorder,totheoperatorpresence
controlswitchterminalsontheinsideofthecontrol
console.
2.Connecttheconnectorontheendoftheotherlead
tothekeyswitch.
3.Fastentheleadtothehandlewithtwosmallwireties,
fromboltbag,oneattheupperendofthehandle
nexttotheconsoleandoneattheverylowerendof
thehandlewhereitattachestothefueltanksupport.
OnECSunits:Fastenleadstothesmallholeinthe
channelundertheconsole.
InstallingtheMufer
Themufercomesinstalledontotheengineexhaust
manifoldbutrotatedrearwardtotinthecrate.
1.Loosentheclamp,rotatethemuferaheadand
securethebracketonthemufertothebracketon
theenginewiththehardwareprovided.
2.Tightentheclamp.
PositioningtheDischargeChute
Loosentwo5/16inchnylocnutsattachingdischarge
chute.Lowerthedischargechuteintoposition.
Retightennylocnutsuntilchuteissnugbutcanpivot
freely.
CheckingTirePressure
1.Checkthetirepressureinthedrivetires.Proper
inationfordrivetiresis12-16psi(83-110kPa).
2.Adjustifnecessary.
GreasingtheUnit
Note:Theunitisnotgreasedatthefactory.
LubricatettingswithNGLIgrade#2multi-purpose
gungrease.RefertothefollowingchartandFigure14
forttinglocationsandinitialpumps.
LubricationChart
Fitting
Locations
Initial
Pumps
NumberofPlacesService
Interval
32inch
Deck
36inch
Deck
48inch
Deck
1.Front
Caster
Wheel
Bearings
12222
Daily
2.Front
Caster
Pivots
2222
Daily
3.Drive
Wheels
18222
Daily
4.Drive
Wheel
IdlerArm
2222
Daily
5.Brake
Arm
2222
40hours
6.Trans-
mission
Output
Shaft
Coupler
2222
40hours
7.Mower
DeckIdler
Pivots
2111
40hours
Number4and7(IdlerArmPivots)Disassembleand
greaseonceamonthundera“NoLoad”condition.
Number6(TransmissionCoupler)Locatedbelowfuel
tanksupport.
6
Figure14
48inchDeckShownforReferenceOnly
ServicingtheEngine
RefertoEngineOwner’sManual.
FillingOuttheWarranty
RegistrationForm
Filloutwarrantyregistrationformandplacekeysinto
literaturepack.
7
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