Metro®

• Engine Specifications: See your Engine Owner’s Manual

• Engine Oil Type: Exmark 4–Cycle Premium Engine Oil

• RPM: Full Speed: 3600 (No Load)

  Idle: 1550 RPM

• Capacity: 5.0 gal. (18.9 L)

• Fuel Recommendations:

  • For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

  • Oxygenated fuel with up to 10% ethanol or 15% MTBE by volume is acceptable.

  • Do Not use ethanol blends of gasoline (such as E15 or E85) with more than 10% ethanol by volume. Performance problems and/or engine damage may result which may not be covered under warranty.

  • Do Not use gasoline containing methanol.

  • Do Not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.

  • Do Not add oil to gasoline.

• Fuel Filter: Replaceable In-line

• Fuel Shut-Off Valve: 1/4 turn

Operator must have the transmission in neutral and PTO disengaged to start engine. Release of Operator Presence Control (OPC) levers will cause engine to stop if transmission is not in neutral and/or PTO is engaged.

Fingertip drive control levers provide independent control of traction, braking, and neutral to each drive wheel for moving, stopping, and power turning. Parking brakes are engaged by locking drive control levers in the “brake” position.

• Peerless 700-070A, five speeds forward and one reverse.

• Speed range:

  • 1st: 2.0 mph (3.22 km/hr)

  • 2nd: 2.7 mph (4.35 km/hr)

  • 3rd: 3.5 mph (5.63 km/hr)

  • 4th: 4.1 mph (6.60 km/hr)

  • 5th: 6.2 mph (9.98 km/hr)

  • Reverse: 3.1 mph (4.99 km/hr)

Banded double A-Section V-belts, single top-side idlers and replaceable bolt-on drive sheaves and brake drums. (Single B-Section V-belts for the 32 inch Model)

• Cutting Width:

  • 32 inch Deck: 31.75 inches (80.7 cm)

  • 36 inch Deck: 35.38 inches (89.9 cm)

  • 48 inch Deck: 47.25 inches (120.0 cm)

• Discharge: Side

• Blade Size:

  • 32 inch Deck: 16.25 inches (41.3 cm) — Quantity: 2

  • 36 inch Deck: 18.00 inches (45.7 cm)— Quantity: 2

  • 48 inch Deck: 16.25 inches (41.3 cm)— Quantity: 3

• Deck Drive: Manual engagement of belt with over-center lock. Blade belt tension is adjustable via turnbuckle.

• Blade Brake: When the blade engagement control is moved to the disengaged position a friction brake pad stops the rotation of the blades.

• Deck Mounting: Bolted directly to engine deck.

• Deck Depth:

  • 32 inch Deck: 5.0 inches (12.7 cm)

  • 36 inch Deck: 5.0 inches (12.7 cm)

  • 48 inch Deck: 5.0 inches (12.7 cm)

• Cutting Height Adjustment:

  Adjusts from 1 inch (2.5 cm) to 4 1/4 inches (10.8 cm) in 1/4 inch (6.4 mm) or smaller increments by various adjustments of caster spacers, blade spacers, and axle height.

Located on the upper handle assembly directly above or below the handle grips.

When these levers are depressed, the OPC system senses that the operator is in the normal operator's position. When the levers are released, the OPC system senses that the operator has moved from the normal operating position and the engine must begin shutdown if either the transmission shift lever is not in the neutral position or the PTO is engaged (see Figure 4 and Figure 5).

Figure 4

Left Pistol Grip Handle Shown

1. Neutral Lock/Park Brake Latch
2. OPC Lever
3. Handle grip
4. Drive Lever

Figure 5

Left ECS Handle Shown

1. Neutral Lock Latch/Park Brake Latch
2. Drive Lever
3. Handle grip
4. OPC Lever

Located on each side of the upper handle assembly ahead of and below the handle grips (see Figure 4 and Figure 5).

These levers individually control clutching action of the wheel drive belts and brakes. When the drive levers are all the way down, the brakes disengage and the wheel drive belts engage.

Gradually squeezing the left or right hand drive lever disengages the wheel drive belts, causing the left hand or right hand wheel to slow down until they reach neutral or stop. This makes the machine turn to the left or right respectively. Squeezing further engages the park brakes. The sharpness of the turn varies by how much the lever is squeezed. For straight ahead motion, smoothly release both drive levers to engage both drive wheels simultaneously.

• For Pistol Grip Handles: Located on handles ahead of the grips.

• For ECS Handles: Located on the upper handle assembly on the ends of the handle grips.

The latches allow the operator to lock the drive levers in a “neutral” position where neither the wheel drive belts nor the brakes engage or in a “park brake” position where the wheel drive belts are not engaged and the park brake is engaged (see Figure 4 and Figure 5).

Located on the front left corner of the fuel tank support.

Choke is used to aid in starting a cold engine. The choke control is pulled out to be in the “ON” position and pushed in to be in the “OFF” position. Do Not run a warm engine with choke in the “ON” position.

Located on the on the control console right side.

The throttle is used to control engine speed. Moving the throttle control forward will increase engine speed and moving it to the rear will decrease engine speed. Moving the throttle forward into the detent is full position.

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.

Note: Reverse is “reverse assist” only, meaning when the transmission is in reverse, the operator has to pull the unit backward to “assist” with the movement of the unit.

Located on the control console.

Turn the key to the “Run” position to allow the engine to be started. Turn the key to the “Off” position to shut engine off.

Located in the fuel line midway between the tank and engine.

The fuel shut-off valve is used to shut off the flow of fuel when parking inside a building, during transportation to and from the job sites, and when the machine will not be used for a few days.

Rotate valve 1/4 turn clockwise to shut fuel off. Rotate valve 1/4 turn counterclockwise to turn fuel on.

Fill fuel tank on level ground. See Fuel Recommendations in the Specifications section for additional gasoline information.

Do Not add oil to gasoline.

Do Not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system.

Make sure you understand the controls, their locations, their functions, and their safety requirements.

Refer to the Maintenance section and perform all the necessary inspection and maintenance steps.

Rotate the valve 1/4 turn counterclockwise to turn fuel on.

Note: Always engage the left and right neutral lock/park brake latches in the “park brake” position when starting the engine

1. On a cold engine, place the throttle midway between the “SLOW” and “FAST” positions and place the choke in the “ON” position. On a warm engine, place the throttle lever midway between “SLOW” and “FAST” positions and leave the choke in the “OFF” position.

2. Turn ignition switch to “RUN” position. Pull the recoil rope to start engine.

3. On a cold engine, gradually return choke to the “OFF” position after engine starts and warms up.

   Note: Kawasaki engines generally need to be “choked” even when warm.

The PTO switch engages the cutting blades. Be sure that all persons are clear of mower deck and discharge area before engaging the PTO.

1. Set throttle to “MIDWAY” position.

2. Pull the PTO switch outward to the “ROTATE” position to engage the blades.

3. Place the throttle in the “FAST” position to begin mowing.

1. Set throttle to “MIDWAY” position.

2. Pull the blade engagement lever to the full rearward position to disengage the blades

1. Disengage the PTO.

2. Bring the unit to a full stop.

3. Lock drive levers in “park brake” position.

4. Disengage the PTO.

5. Move transmission shift lever to “neutral”.

6. Place the throttle midway between the “SLOW” and “FAST” positions.

7. Allow the engine to run for a minimum of 15 seconds, then turn the ignition switch to the “OFF” position to stop the engine.

8. Remove the key to prevent children or other unauthorized persons from starting engine.

9. Close the fuel shut-off valve when the machine will not be in use for a few days, when transporting, or when the unit is parked inside a building.

Drive Lever/Neutral Lock/Park Brake Latch Operation

• For Pistol Grip Handles

  To lock the drive levers in “neutral”, squeeze the drive levers back to the neutral position. Place thumbs on the upper portion of the neutral lock/park brake latches and move them to the rear. Release the drive levers.

  To lock the levers in “park brake”, squeeze the drive levers back to the brake position. Place thumbs on the upper portion of the neutral lock/park brake latches and move them to the front. Release the drive levers (see Figure 6)

  Caution

  If the neutral lock/park brake latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position. If the drive levers slip into the drive position, the unit could lurch forward and cause injury or property damage.

  Be sure the pins protruding through the slots of each neutral lock latch are completely engaged in the rear slot of each latch.

  To place the drive levers in the drive position, firmly hold the drive levers, place thumbs on the upper portion of the neutral lock/park brake latches and move them out of the “neutral” or the “park brake” position. Slowly and smoothly release the drive levers.

  

  Figure 6

  1. Latch is in the drive position
  2. Rotate forward for park brake position
  3. Rotate back for neutral lock position
  4. Park brake
  5. Full speed forward
  6. Neutral lock
  7. Forward — release drive lever
  8. Neutral —hold in this position
  9. Reverse—squeeze drive lever

• For ECS Handles

  To lock the drive levers in “neutral lock”, squeeze the drive levers to the “neutral” position. See Figure 7 position 2. Place thumbs on the inner thumb lobe of the neutral lock /park brake latches and rotate them to the “neutral” position. See Figure 7 position 3. Release the drive levers.

  To lock the drive levers in “park brake”, squeeze the drive levers farther to the “brake” position. Place thumbs on the inner thumb lobe of the neutral lock/park brake latches and rotate them to the “park” position. See Figure 7 position 4. Release drive levers.

  Caution

  If the neutral lock/park brake latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position. If the drive levers slip into the drive position, the unit could lurch forward and cause injury or property damage.

  Be sure the drive levers are securely seated at the bottom of the “neutral” or “park” areas of the neutral lock latches.

  To place the drive levers in the “drive” position, slightly squeeze the drive levers while placing thumbs on the outer thumb lobe of the neutral lock/park brake latches (or the index finger on the front lobe) and rotate them from under the drive levers. Slowly and carefully release the drive levers. See Figure 7 position 1.

  

  Figure 7

  Left ECS Handle Shown

  1. Drive Lever in drive position
  2. Drive Lever in neutral position
  3. Drive Lever locked in neutral position
  4. Drive Lever locked in park position

Driving Forward

1. With drive levers in the “neutral” or “park brake” position, shift transmission into desired gear.

2. Squeeze both drive levers and move both neutral lock/park brake latches from the “neutral” or “park brake” position to the “drive” position.

3. To move forward in a straight line, smoothly release both drive levers to engage drive wheels.

   To turn left or right, squeeze the right hand drive lever to turn right and the left hand drive lever to turn left.

   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.

Driving in Reverse

Note: Reverse gear is reverse assist only, the operator must pull the unit backwards.

To move rearward, squeeze the drive levers to neutral position and move the shifter to the “R”.

Smoothly release both drive levers to engage drive wheels.

Pull the unit backward to “assist” with the movement of the unit.

To stop, squeeze drive levers all the way back to engage the brakes. Move the neutral lock latches into the “park brake” position and release drive levers. Move the speed control lever to the neutral position.

When changing gears, always squeeze drive levers to the neutral position. The shift lever may be moved with a knee or by hand (engage the neutral lock latches if shifting by hand).

Note: Reverse gear is “reverse assist” only, the operator must pull the unit backwards.

1. Stop engine and wait for all moving parts to stop. Make sure unit is on a level surface.

2. Check with engine cold.

3. Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick and push it all the way down into the tube. Do Not screw into place. Remove the dipstick and read the oil level.

4. If the oil level is low, wipe off the area around the oil fill cap, remove cap and fill to the “FULL” mark on the dipstick. Exmark 4-Cycle Premium Engine Oil is recommended; refer to the Engine Owner's manual for an appropriate API rating and viscosity. Do Not overfill.

Important: Do Not operate the engine with the oil level below the “LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lift deck and secure in raised position as stated in the Clean Grass Build-Up Under Deck procedure.

3. Inspect blades and sharpen or replace as required.

4. Re-install the blades (if they were removed) and torque blade bolts to 75-80 ft-lb (102-109 N-m). Be sure the spring disc washer cone is installed toward the bolt head (see Figure 8).

   

   Figure 8

   1. Spring disc washer (cone towards bolt head)
   2. Blade bolt torque to 75-80 ft-lb (102-109 N-m).

1. To remove a damaged or worn discharge deflector, lift the leg of the spring with the loop out of the notch in the discharge deflector and slide the rod out of the discharge deflector brackets, and discharge deflector.

2. To install new discharge deflector, orient the spring on the rod as shown in Figure 9. Slide the rod through the front discharge deflector bracket, discharge deflector, and rear deflector bracket.

   

   Figure 9

   1. Rod
   2. Spring
   3. Discharge deflector
   4. Mower deck
   5. Discharge deflector bracket
   6. Assembled view

3. Hook the bent end of the rod around the front discharge deflector bracket to retain it from sliding out. Place the leg of the spring with the loop in the notch in the discharge deflector to hold the discharge deflector in the down position (see Figure 9).

   Important: The discharge deflector must be spring loaded in the down position. Lift the deflector up to test that it snaps to the full down position.

Remove spark plugs, check condition and reset gaps, or replace with new plugs. See Engine Owner's Manual.

Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use.

Note: If machine does not pass any of these tests, Do Not operate. Contact your authorized EXMARK SERVICE DEALER.

Check the Normal Engine Starting Chart

		System
		Neutral Lock/Parking Brake	PTO (Blades)	Ignition Key	Transmission Shift Lever	Outcome
	State of System	Engaged	Disengaged	Run	In neutral	Starter should crank

Check Engine Starting Circuit Chart

Note: In the Check Engine Starting Circuit Chart, the state of system item that is bold is being checked in each scenario.

		System
		Neutral Lock/Parking Brake	PTO (Blades)	Ignition Key	Transmission Shift Lever	Outcome
	State of System	Engaged or Disengaged	Disengaged or Engaged	Off	In Neutral or Any speed except neutral	Starter must not crank
		Engaged	Disengaged	Run	Any speed except neutral	Starter must not crank
		Engaged	Engaged	Run	In Neutral	Starter must not crank
		Disengaged	Engaged	Run	In Neutral	Starter must not crank
		Disengaged	Disengaged	Run	Any speed except neutral	Starter must not crank

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Visually inspect machine for any loose hardware or any other possible problem. Tighten hardware or correct the problem before operating.

1. Stop engine, wait for all moving parts to stop, and remove key or spark plug wire(s). Engage parking brake.

2. See the Engine Owner's Manual for maintenance instructions.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Drain oil while engine is warm from operation.

3. Remove the oil drain plug from the right hand side of the engine. Allow oil to drain, replace drain plug.

4. Replace the oil filter per the engine owner's manual. Clean around oil filter and unscrew filter to remove. Before the new filter is installed, apply a thin coating of Exmark 4–Cycle Premium Engine Oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter, then tighten filter an additional 2/3 to 3/4 turn.

5. Clean around oil fill cap and remove cap. Fill to specified capacity and replace cap.

6. Use oil recommended in the Check Engine Oil Level section. Do Not overfill. Start the engine and check for leaks. Stop engine and recheck oil level.

7. Wipe up any spilled oil from engine deck mounting surfaces.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Check tire pressure in drive tires.

3. Inflate drive tires to 12–16 psi (83–110 kPa).

4. Inflate tires to pressures stated above. Measure the circumference of each drive tire. Adjust tire pressures within the above range to try to make tire circumferences match as closely as possible.

5. Semi-pneumatic caster tires Do Not need to be inflated.

Note: A more uniform cutting height may be obtained with higher tire pressure on rough terrain. A lower tire pressure provides more flotation.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Remove the mower deck belt shield to check mower blade drive belt condition.

3. Look under engine deck to check the transmission drive belt condition.

4. Inspect wheel drive belt conditions.

5. Check all idler arms to be sure they pivot freely. Disassemble, clean and grease pivot bushings if necessary.

Note: See chart for service intervals.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Lubricate fittings with NLGI grade #2 multi-purpose gun grease.

   Refer to the following chart for fitting locations and lubrication schedule.

   Lubrication Chart

   Fitting Locations	Initial Pumps	Number of Places			Service Interval
   		32 inch Deck	36 inch Deck	48 inch Deck
   1. Front Caster Wheel Bearings	12	2	2	2	Daily
   2. Front 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	40 hours
   6. Trans-mission Output Shaft Coupler	2	2	2	2	40 hours
   7. Mower Deck Idler Pivots	2	1	1	1	40 hours

   48 inch Deck Shown for Reference Only

   Number 4 and 7 (Idler Arm Pivots) Disassemble and grease once a month under a “No Load” condition

   Number 6 (Transmission Coupler) Located below fuel tank support

3. Replace 5-speed gearbox grease yearly. Use 18 oz. of Peerless grease (Part No. 788067). See Check Grease Level, Input and Output Shaft Bearing Wear on Peerless Transmission section for special lubrication instructions.

4. Lubricate pivot points with a spray penetrating lubricant as shown in the Spray Lubricant Chart.

   Spray Lubricant Chart

   	Number of Places
   Pivot Points	32 inch Deck	36 inch Deck	48 inch Deck	Service Interval
   1. Blade Engagement Bellcrank	1	1	1	40 hours

A fuel filter is installed in the fuel line between the fuel tank and the engine. Replace when necessary.

The cutting height of the mower deck is adjusted from 1 inch to 4 1/4 inches (2.54 cm to 11.4 cm) in 1/4 inch (.64 cm) increments by adjusting the axle position, number of spacers below the caster hub, and number of spacers between blade and spindle.

Refer to the Cutting Height Adjustment table and select a cutting height range in the left hand column which corresponds to the range of cutting heights you will most often be using. Adjustments within this range can then be made by adjusting the number of blade spacers between the blade and the bottom of the spindle (this is a much easier adjustment to make than adjusting axle position and number of spacers below caster support hub).

Note that:

• For the best cut and discharge, place a minimum of two spacers between the blade and the spindle.

• For highest quality cut, place all four spacers between the blade and the spindle.

• If mulching kit is installed, the highest quality cut can be obtained with 3 spacers between the blade and the spindle (minimum is 1 for a good cut).

• When mulching leaves it is best to have fewer spacers between blade and spindle.

Refer to the table and select desired cutting height range. Refer to Adjusting the Axle Position, Adjusting the Number of Spacers below Caster Support Hub, and Adjusting the Cutting Height with Blade Spacers and sections to make adjustments make adjustment to obtain specific cutting height.

Cutting Height Adjustment Table (1 inch to 4 1/4 inches (2.5 cm-10.8 cm))

Important: Always adjust the Number of Spacers below Caster Hub to correspond to the Axle Position as shown in table to obtain proper “rake” (blades should always be level to the ground or tipped slightly down at the front).

Desired cutting height range can be obtained by adjusting the rear axle and placing caster spacers above or below the caster arm (See Figure 10 and Figure 11 along with the Cutting Height Adjustment Chart). It may be necessary to readjust wheel drive and brake linkages.

To adjust rear axle:

1. Stop the machine and move the drive levers to the neutral lock position.

2. Disengage the PTO.

3. Place the drive levers in the neutral lock position.

4. Remove mower deck belt shield for access to axle adjustment bolts.

5. Loosen but do not remove the two axle pivot bolts and the two axle adjustment bolts (see Figure 10).

6. Place a jack under the rear center of the engine deck.

7. Raise the back end of the engine deck up enough to remove the two axle adjustment bolts.

8. With the jack, raise or lower the back end of the engine deck 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. Retighten all four bolts, lower unit and remove jack.

10. Install mower deck belt shield.

11. Adjust wheel drive and brake linkages as required (see Brake and Wheel Drive Linkage Adjustment section).

    

    Figure 10

    1. Axle Pivot Bolt
    2. Axle Adjustment Holes (Located in the side of the rear deck.)
    3. Position A
    4. Position B
    5. Position C
    6. Position D
    7. Position E
    8. Place jack here

Note: The axle positions are in 1/2 inch (1.3 cm) increments and the large caster spacers are 1/2 inch (1.3 cm) thick. Therefore, by adjusting the same number of 1/2 inch (1.3 cm) caster spacers as axle hole positions the blades will retain the same front-to-back tip (rake).

1. Stop the machine and move the drive levers to the neutral lock position.

2. Disengage the PTO.

3. Place the drive levers in the “park brake” position.

4. Push down on handles to lift front casters off the ground.

5. Support with jackstands.

6. Remove “quick pin” from one caster and remove caster from hub (see Figure 11).

   

   Figure 11

   1. Four 1/2 inch (127 mm) spacers
   2. Quick Pin
   3. 3/16 inch (4.8 mm) spacer
   4. Caster support

7. Adjust the number of 1/2 inch spacers between bottom of hub and caster yoke to obtain the desired cutting height from the Cutting Height Adjustment Table in the Adjusting the Cutting Height section.

8. Install remaining spacers on top of hub.

9. Install “quick pin”.

10. Repeat for other caster.

1. Stop the machine and move the drive levers to the neutral locked position.

2. Disengage the PTO.

3. Engage the park brake.

4. Stop the engine, remove the key and wait for all moving parts to stop.

5. Blades may be adjusted for cutting height by using the four 1/4 inch (.64 cm) spacers found on the blade spindle bolts (factory setting is two above and two below). This allows a 1 inch (2.5 cm) range in 1/4 inch (.64 cm) increments of cutting height in any axle position. The same number of blade spacers must be used on all blades to achieve a level cut (two above and two below, one above and three below, etc.).

6. Raise front of deck and support with jack stands.

7. Hold blade bolt on bottom and loosen spindle nut on top.

8. Adjust number of spacers between bottom of spindle and blade as indicated in the Cutting Height Adjustment Table and notes in the Adjusting the Cutting Height section.

9. Install unused spacers between top of spindle and spindle nut.

10. Torque 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)

1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s).

2. To tighten transmission belt, loosen the 3/8 inch nyloc nut on transmission belt idler pulley. Slide bolt inward in slot and retighten nyloc nut.

3. When properly adjusted, the belt should have 1/2 inch (1.3 cm) of deflection with three pounds of pressure on the belt midway between the transmission and engine pulley.

1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s).

2. Be sure mud and grass scraper, on each side, is adjusted properly and centered in the pulley grooves. The pointed part of the scraper should be centered and as deep in the pulley groove as possible without rubbing at any point.

1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s).

2. Check the adjustment of the lower blade drive linkage located between the bellcrank on the engine deck and assist arm on the mower deck. Lengthen or shorten the linkage. When properly adjusted, there should be 1/16 inch to 1/8 inch (2–3 mm) of clearance between bell-crank and transmission output shaft when belt is engaged. Make sure the assist arm is against the rear assist arm stop on the deck (see Figure 13). Push the lever down to the disengaged position. The assist arm should contact the front assist arm stop on the deck. If it does not contact, readjust so that the bellcrank is closer to the transmission output shaft.

3. Belt must be tight enough to not slip during heavy loads while cutting grass. Over-tensioning will reduce belt and spindle bearing life. To adjust belt tension, loosen the 5/16 inch 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 13). Leave a minimum of 5/16 inch (.79 cm) of the eyebolt threads engaged on both ends of the turnbuckle.

   For 48” Decks: If there is no adjustment left in the turnbuckle and the belt is still loose, the rear idler pulley can be repositioned in the front hole (See Figure 12). The belt guide located next to the pulley must also be repositioned in the front hole when the pulley is moved. The turnbuckle will need to be readjusted.

   Check belt tension after the first hour of operation and at least twice during the first 24 hours of operation. Adjust as necessary.

   

   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 deck only)
   3. Belt guide must be moved to the front position if the pulley is moved. (48 inch deck only)
   4. Turnbuckle
   5. 5/16 inch (.79 cm) minimum engagement
   6. 5/16 inch whizlock nut
   7. Rear Assist Arm Stop
   8. Assist Arm
   9. Front Assist Arm Stop
   10. Point “A”

4. Proper belt tension will require about 10 lb (4.5 kg) side pull on belt, halfway between pulleys (see Figure 13, item 10–Point A) to deflect belt 1/2 inch (12 mm).

5. Check belt guide under the engine deck to see that it is properly set (see Belt Guide Adjustment section). Also check the blade brake adjustment (see Blade Brake Adjustment section).

Mower Deck Belt Routings:

Figure 14

32 inch and 36 inch Mower Deck

Figure 15

48 inch Mower Deck

1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s).

2. Disengage blades.

3. Make sure the blade brake pad rests against the sheave. Adjust the spring mounting bolts to properly align the pad on the sheave (see Figure 16).

4. Check the distance between the spacer and the nut at the end of the blade brake rod. The distance should be between 1/8 inch and 3/16 inch (3–5 mm) (see Figure 16).

5. Engage the blade control and check to make sure the blade brake pad clears the sheave.

   

   Figure 16

   Shown with Blades Disengaged

   1. Blade Brake Rod
   2. Spring Mounting Bolts
   3. 1/8 inch to 3/16 inch (3–5 mm)

1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s).

2. Engage the blade drive belt.

3. Check belt guide under the engine deck for proper adjustment (See Figure 17 and Figure 18). Adjust as necessary.

   The disengaged belt should not drag or fall off pulley when guides are properly adjusted.

Figure 17

32 inch and 36 inch Belt Guide Location (Viewed from underneath the deck)

1. 3/4 inch (19 mm)

Figure 18

48 inch Belt Guide Location (Viewed from underneath the deck)

1. 3/4 inch (19 mm)

1. Check for correct brake 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, brake adjustment is necessary

2. 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” position.

   See Figure 6 for Standard Pistol Grip handles and Figure 7 for ECS handles.

   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.

3. Check for correct wheel drive linkage adjustment.

   • For Pistol Grip Handles

     Allow drive levers to drop into the full forward position: The clevis pin should rest in the neutral lock latch with approximately 3/16 inch to 1/4 inch (4.7–6.4 mm) clearance from the bottom of the slot (see Figure 19). Adjust if necessary.

     To adjust the wheel drive linkage:

     1. For wheel drive linkage adjustment, remove the hairpin between the neutral lock latch and drive lever (Figure 19).

        

        Figure 19

        Left Side Shown

        1. Drive Lever
        2. Clevis Pin
        3. Drive Linkage
        4. Neutral Lock/Park Brake Latch
        5. Hairpin

     2. Adjust drive linkage length by threading into or out of the swivel until there is a 3/16 inch to 1/4 inch (.47-.64 cm) clearance between the linkage assembly and the bottom of the slot in the neutral lock/park brake latch (see Figure 20).

        

        Figure 20

        1. 3/16 inch to 1/4 inch (.47 cm-.64 cm)
        2. Neutral Lock/Park Brake Latch
        3. Drive Linkage

        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" in the linkage.

     3. Re-install hairpin into hole on the clevis pin between the neutral lock/park brake latch and drive lever (See Figure 19). Repeat procedure on opposite side of unit.

   • For ECS Handles:

     Allow drive levers to drop into the full forward position: the flat edge of the drive lever should align with the bottom roller notch (See Figure 21). Adjust if necessary

     

     Figure 21

     1. Notch in Neutral Lock/Park Brake Latch
     2. Drive Lever

     To adjust the wheel drive linkage:

     1. Locate a drive lever linkage on one side of the unit and remove the 5/16-18 x 1 3/4 inch hex cap screw and 5/16-18 inch nyloc nut (see Figure 22).

     2. Thread drive lever linkage into or out of the swivel located on the wheel drive idler arm until the flat edge of the drive lever aligns with bottom of the roller notch in the neutral lock/park brake latch (see Figure 22).

     3. Re-install the 5/16-18 x 1 3/4 inch hex cap screw and secure with the 5/16-18 inch nyloc nut. Repeat for the other side (see Figure 22).

        

        Figure 22

        Right Side of Unit Shown

        1. Wingnut
        2. Transmission Lever in neutral
        3. 5/16–18 inch nyloc nut
        4. Drive Levers in neutral
        5. 5/16–18 x 1 3/4 inch hex capscrew
        6. Drive Lever Linkage
        7. Swivel
        8. Brake Rod

The shifter lever in neutral should not contact the upper or lower edge of the slot or the left edge of the upper slot or the right edge of the bottom slot (See Figure 23 and Figure 24). The clearance should be equal. Adjust the shifter lever and shifter plate if necessary.

Figure 23

1. Equal distance
2. Shifter Lever
3. Shifter Plate

Figure 24

1. Shifter Lever
2. Equal distance
3. Adjustment slot

• To adjust the shifter lever:

  1. Remove the 3/8 inch nyloc nut and spring disc washer from the stud on top of the transmission (See Figure 25).

     

     Figure 25

     1. Shifter Lever
     2. Square Holed Washer
     3. Transmission

  2. Remove the shifter lever and bend it slightly. Do Not bend the lever while it is attached to the transmission.

  3. Re-install lever and torque the 3/8 inch nyloc nut to 35 ft-lb (47 N-m).

• To adjust shifter plate:

Note: The square-hole washer must be between the lever and the transmission.

Place shifter lever in the neutral position. Loosen the two bolts securing the shifter plate to the shifter lever legs. Adjust shifter plate and retighten bolts.

Transmission shifter detent can be adjusted by adjusting the setscrew on the back side of transmission located just behind the neutral start switch. Turn setscrew in (clockwise) to hold the transmission shifter more positively in each gear and to increase the force on the lever required to shift gears.

Turn setscrew out (counterclockwise) to decrease force on lever required to shift gears. Factory setting is to turn setscrew all the way in then back out 1 1/2 turns.

Important: Screwing setscrew in too far will prevent the transmission from shifting.

1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s).

2. With the blades disengaged and the bellcrank touching the engine deck, adjust the blade safety switch (if needed) until the bellcrank depresses the plunger by 1/4 inch (.64 cm).

3. Be sure the bellcrank does not contact the switch body to prevent damage to the switch.

4. Retighten switch mounting hardware.

The handle can be pivoted to allow positioning in one of the three holes allowing various adjustments for operator comfort (see Figure 26).

To adjust the handle height:

1. Remove the bottom mounting hardware on each side of the handle.

2. Pivot the handle to one of the three positions.

3. Re-install hardware and tighten.

   Important: If the handle height position is changed, it will be necessary to readjust the drive and brake linkage (see Check Brake and Wheel Drive Linkage Adjustment section in Operation.)

   

   Figure 26

   1. Upper Handle
   2. Upper Hole
   3. Adjustment Holes
   4. Fuel Tank Support

   Note: Adjustment Holes are actually in the side of the fuel tank support.

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.

1. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s).

2. Disengage neutral lock/park brake latches and release drive levers to lower spring force.

3. Remove the 5/16-18 inch whizlock nut securing the adjustment bolt to the drive wheel shield. Locate bolt assembly in the desired position as follows:

   • Position A-Normal Conditions

   • Position B-More Severe

   • Position C-Most Severe

   Note: Lever force is lowest with bolt assembly in Position A and will increase in Positions B and C (see Figure 27).

   

   Figure 27

   1. More traction applied as bolt moves down
   2. Position A–Normal Conditions
   3. Position B–More Severe
   4. Position C–Most Severe
   5. Front of Unit

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Clean all debris from rotating engine air intake screen, around engine shrouding, and exhaust system area.

3. Wipe up any excessive grease or oil around the engine and exhaust system area

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Remove cooling shrouds from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine which can cause improper cooling.

3. Make sure cooling shrouds are properly reinstalled. Operating the engine without cooling shrouds will cause engine damage due to overheating.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Clean off any oil, debris, or grass build-up on the machine and cutting deck, especially under deck belt shields, around the fuel tank, around engine and exhaust area.

   Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, around the engine, hydraulic pumps, and motors.

1. Disengage PTO.

2. Stop engine and wait for all moving parts to stop. Engage parking brake. Remove key or spark plug wire(s).

3. Raise deck and support unit using jack stands or equivalent support.

4. Clean out any grass build-up from underside of deck and in discharge chute.