Exmark METRO Manuel

Page 1 of 5

109-2020 Rev. A

Loose Parts

Note: Use the chart below to verify that all parts have been shipped.

109-2590 Dealer Pack

Part # Description Qty Use

103-1309 Warranty Registration Form 2 Fill out and return to Exmark

103-2106

1-603511 Key, Exmark Ignition

Key, Standard Ignition 1

1 Unit ignition

323-4

3290-357 Screw, HH 3/8-16 x 3/4

Nut, Whizlock 3/8-16 8

8 Components to install the Front Caster Wheels

1-633023

322-3

3256-23

1-805005

1-633349

3296-47

Stud, Fuel Tank

Screw, HH 5/16-18 x 3/4

Washer, 5/16 SAE

Washer, Lock 5/16 Heavy

Spring, Compression

Nut, Nyloc 5/16-18 Thin

Components to install fuel tank

323-6

3296-39 Screw, HH 3/8-16 x 1

Nut, Nyloc 3/8-16 4

4 Components to install handle assembly

1-806003 Hairpin, Cotter 2 Component to install the blade engagement linkage

and speed control rod assembly

1-808286

1-806003 Pin, Clevis

Hairpin, Cotter 2

2 Units with Pistol Grip Handles: Components to

install wheel drive linkages

322-9

3296-29 Screw, HH 5/16-18 x 1 3/4

Nut, Nyloc 5/16-18 2

2 Units with ECS Handles: Components to install

wheel drive linkages

1-303287 Tie, Cable 5 1/2 (Small) 2 For fastening wiring harness to handle assembly

109-0623 Literature Pack

Part # Description Qty Use

109-9911

109-9910 Manual, Operator’s

Manual, Parts 1

1 Read before operating machine

103-5466 Manual, Engine Operator’s 1 For units with 15HP Kawasaki engines

Uncrate Unit

1. Leaving it on the pallet, place upper handle

assembly, fuel tank, and shifter lever at the rear

of the machine. Place casters at the front of the

unit.

2. Place a length of 4” x 4” (10x10 cm) block

between the front of the mower deck and the

pallet.

3. Remove the bolt bag from under the mower deck

belt shield.

4. Refer to Parts Manual to help you identify and

locate parts and their proper position.

Installing the Front Caster Wheels

1. Install casters to front of deck using eight 3/8-16

x 3/4 bolts and eight 3/8” whizlock nuts. Tighten

the lower four bolts first, then the top four.

Positioning the Discharge Chute

1. Loosen the two (2) 5/16 nyloc nuts attaching

discharge chute. Lower the discharge chute into

position. Retighten nyloc nuts until chute is

snug but can pivot freely.

METRO

SETUP INSTRUCTIONS

For Serial Nos. 600,000 and Highe

Page 2 of 5

109-2020 Rev. A

Installing the Fuel Tank

1. Apply retaining adhesive “Fel-Pro ProLock

Retaining I or Retaining II” or “Loctite RC 609 or

680” on the two threaded studs from the bolt bag

and install into the two left holes underneath fuel

tank. Install the fuel tank on top of the fuel tank

support with the studs going through the slots in

the support.

2. Install two 5/16 x 3/4 screws with a 5/16 SAE flat

washer and 5/16 lock washer into the threaded

holes in the right side of the fuel tank. Do not

over tighten.

3. Place a 5/16 SAE flat washer, then a spring, over

each of the studs and fasten with a 5/16 nyloc

nut. Tighten 5/16 nyloc nut fully then back off a

1/2 turn. This is to allow for normal fuel tank

expansion and contraction with changes in

temperature and fuel levels. Do not over

tighten.

4. Attach the fuel tank hose to the tank fitting and

secure with the clamp provided.

Installing the Handle Assembly

1. Position the lower end of the handle assembly on

the outside of the upper rear section of the fuel

tank and handle support. Install one 3/8-16 x 1

bolt (from the outside in) in the upper hole on

each side of the handle. Loosely secure each

screw with a 3/8” nyloc nut. The handle can now

be pivoted to allow positioning in one of the three

holes allowing various adjustments for operator

comfort (See Figures 1 & 2). Once a proper

position is found, install one 3/8 x 1” bolt in the

bottom mounting holes on each side of the

handle. Secure each bolt wth a 3/8” nyloc nut.

Tighten all hardware.

FIGURE 1

NOTE: 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

Attaching Throttle Cable

Route the throttle cable along the left side of the upper

handle, through the clip, under the fuel tank support,

and position the cable on the front of the engine.

Attach throttle cable to engine:

1. Position the throttle control lever (located on

console) ¼” (.64 cm) from the upper end of the slot.

2. Attach inner wire of the throttle cable to the top hole

in the throttle control lever as shown in Figure 4.

3. Loosen the clamp, place the cable behind it, and

pull on the cable to move the throttle linkage to the

full throttle position. Tighten the cable clamp

screw.

FIGURE 4

4. This step needs to be done after the unit has

been assembled and the engine has been

started. Refer to Section 4 (Operation

Instructions).

There is not a “STOP” position. Turn the ignition switch

to the “off” position to stop the engine.

Attaching the fuel tank hose

1. Attach the fuel tank hose to the tank fitting and

secure with the clamp provided

Install the blade engagement

linkage

1. Install the blade engagement linkage to the bell

crank on the Left Hand side of the engine deck.

2. Insert rod through the hole from the outside and

fasten with cotter hairpin.

Page 3 of 5

109-2020 Rev. A

3/16” TO 1/4” (.47-.64 cm)

Drive Linkage

Neutral Lock /

Park Brake Latch

Install and adjust shifter lever

1. Remove the 3/8” nyloc nut and spring disk

washer from the stud on top of the transmission.

Install the shifter lever through slot in shifter lever

plate and onto the stud on top of transmission.

Be sure the square-hole washer remains

between the lever and transmission. Replace the

spring disk washer and nyloc nut (See Figure 5).

Torque the 3/8” nut to 35 ft. lbs. (47 N-m).

2. 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. DO NOT bend lever while it is attached to

transmission. Reinstall lever and tighten

hardware.

3. Shift to neutral position. Lever should not contact

the left edge of the upper slot. Push lever down.

Lever should not contact the right edge of the

bottom slot (See Figure 7). Shifter plate can be

adjusted side to side to adjust position of lever

relative to the slot in plate. Loosen the two bolts

securing the shifter plate to the shifter lever legs.

Adjust shifter plate and retighten bolts.

FIGURE 5

FIGURE 6

FIGURE 7

Install and adjust wheel drive

linkages

For Pistol Grip Handles:

1. Screw threaded end of drive linkages into

swivels in wheel drive idler arms.

2. Insert clevis pin from bolt bag through drive

linkage, lever and slot in the neutral lock/park

brake latches (See Figure 8). Make proper

adjustments before adding hairpins.

FIGURE 8

3. Adjust drive linkage length by threading into or

out of the swivel until there is a 3/16” to 1/4”

(.47-.64 cm) clearance between the linkage

assembly and the bottom of the slot in the

neutral lock/park brake latch (See Figure 9).

FIGURE 9

NOTE: Neutral lock/park brake latch clearance

should be checked where there is a slight

upward force placed on the drive levers to

remove any “slack” in the linkage.

After clevis pin has been inserted, install hairpin

into hole on the clevis pin between the neutral

lock/park brake latch and drive lever (See Figure

10). Repeat procedure on opposite side of unit.

FIGURE 10

Drive

Left Side

Shown

Neutral Lock /

Park Brake Latch

Drive

Lever

Hairpin

Clevis Pin

Drive

Lever

Neutral Lock/

Park Brake Latch

Drive

Linkage

Clevis Pin

Page 4 of 5

109-2020 Rev. A

For ECS Handles:

1. Locate the drive lever linkages which have the

balljoint and jam nuts installed on one end.

Locate the (2) 5/16-18 x 1 3/4 Hex cap screws

and (2) 5/16-18 nyloc nuts in the bolt bag.

Thread drive lever linkage into the swivel located

on the wheel drive idler arm. Thread in until the

flat edge of the drive lever aligns with bottom of

the roller notch in the neutral lock/park brake

latch when the 5/16-18 x 1 3/4 hex cap screw is

inserted through the hole in the drive lever and

the hole in the ball joint. Secure with the 5/16-18

nyloc nut. Tighten nut. Repeat for the other side.

See Figures 11 and 12.

FIGURE 11

FIGURE 12

Adjusting the Brakes

1. Adjust the park brake by rotating the 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 place into the “park

brake” position. See Figure 13 for Pistol Grip

Handles and Figure 14 for ECS Handles.

FIGURE 13

FIGURE 14

2. Check the brake for correct adjustment:

Place the drive levers in the “park brake”

position. The mower should not move forward

or backward. If it does, tighten the wingnuts.

Place the drive levers in the “neutral lock”

position. The mower should move forward and

backward freely. If it does not, loosen the

wingnuts.

NOTE: The neutral lock/park brake latches

must be able to be moved into the park brake

position, if not, the brake linkages must be

adjusted again.

PARK

BRAKE LATCH IS IN

THE DRIVE

POSTION

ROTATE FORWARD

FOR PARK BRAKE

POSITION

ROTATE BACK FOR

NEUTRAL LOCK

POSITION

FULL SPEED

FORWARD

NEUTRAL

LOCK

NEUTRAL - HOLD IN THIS POSITION

FORWARD - RELEASE DRIVE LEVER

REVERSE - SQUEEZE DRIVE LEVER

Page 5 of 5

109-2020 Rev. A

Connecting Wire Harness

1. Route the long, unattached wiring harness lead

up the left hand side of the handle and connect

the flag terminals, in any order, to the operator

presence control switch terminals on the inside of

the control console.

2. Connect the connector on the end of the other

lead to the key switch.

3. Fasten the lead to the handle with two small wire

ties, from bolt bag, one at the upper end of the

handle next to the console and one at the very

lower end of the handle where it attaches to the

fuel tank support.

On ECS units: Fasten leads to the small hole in

the channel under the console.

Installing the Muffler

The muffler comes installed onto the engine exhaust

manifold but rotated rearward to fit in the crate.

1. Loosen the clamp, rotate the muffler ahead and

secure the bracket on the muffler to the bracket

on the engine with the hardware provided.

2. Tighten the clamp.

Servicing the Engine

Refer to Engine Owner’s Manual.

Grease Unit

NOTE: Unit is not greased at the factory.

1. Lubricate fittings with NGLI grade #2 multi-purpose

gun grease. Refer to the following chart for fitting

locations and initial pumps.

LUBRICATION CHART

No.6 (Trans. Coupler): Located Below Fuel Tank Support

No. 4 & 7 (Idler Arm Pivots): Disassemble and grease

once a Month under a “No Load” condition

48” Deck Shown for Reference Only

FITTING LOCATIONS INITIAL

PUMPS FITTING QTY

32" 36" 48" SERVICE

INTERVAL

1. Caster Wheel Bearings 12 2 2 2 Daily

2. Caster Pivots 2 2 2 2 Daily

3. Drive Wheels 18 2 2 2 Daily

4. Drive Wheel Idler Arm 2 2 2 2 Daily

5. Brake Arm 2 2 2 2 Weekly

6. Trans. Output Shaft

Coupler 2 2 2 2 Weekly

7. Mower Deck Idler Pivots 2 1 1 1 Weekly

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