PARTS MANUAL MFG. CO. INC. For Serial Nos. 440,000 & Higher. Model No. Serial No.

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1 For Serial Nos. 440,000 & Higher MFG. CO. INC. PARTS MANUAL METRO HP CONGRATULATIONS on the purchase of your new Exmark mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor. If you need to order replacement parts from your dealer, always give the model number and serial number of your mower as well as the part number, description and quantity of the part needed. The Serial No. plate is located next to the fuel tank on the top left hand side of the fuel tank support. For ease of ordering and reference, we suggest that you record the information requested in the following identification table. Place Model No. and Serial No. Label Here (Included in Literature Pack) or Fill in Below Model No. Serial No. Engine Model No. and Spec. No. (Code) Engine Serial No. (E/No) Date Purchased Part No

EFFECTIVE DATE: September 1, 1995 Program EXMARK PARTS PLUS PROGRAM If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the

2 EFFECTIVE DATE: September 1, 1995 Program EXMARK PARTS PLUS PROGRAM If your Exmark dealer does not have the Exmark part in stock, Exmark will 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 "down" unit at the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus shipment of six (6) line items or less. 2. Distributor ships part(s) to dealer or customer, as requested by dealer, same day, overnight UPS Distributor bills dealer for part and freight charges where applicable. 3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus order, he contacts Exmark by 3:00 p.m., central time, with an Exmark Parts Plus order of six (6) line items or less. 4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by distributor, same day, overnight UPS Exmark bills the distributor for parts and shipping charges, where applicable. 5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus and if it arrive in accordance to the program. 6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program? A. Under any circumstance the customer does not pay. B. If the part does not arrive overnight due to: 1. The dealer not submitting the Exmark Parts Plus order to his Exmark distributor by 1:00 p.m., the dealer pays for the part and freight. 2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus order to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight. 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. The following restrictions apply -- The Exmark Parts Plus Program is available only through participating Exmark Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery shipments. To qualify, all Exmark Parts Plus orders must be received by Exmark by 3:00 p.m., central time. Orders must be six (6) line items or less. Exclusions from the Exmark Parts Plus Program are: Any wholegood or accessory in its entirety, engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions. Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or Second Day Air. Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered for Next Day Air shipment but will not be guaranteed per the Parts Plus Program. 1

3 READ OPERATOR S MANUAL BEFORE OPERATING OR SERVICING EXMARK EQUIPMENT. Description TABLE OF CONTENTS Page 36" Mower Deck " Mower Deck Decals Engine Deck Group Upper Handles & Controls, ECS Wiring Diagrams

4 36 MOWER DECK Shield, Belt ( ) W/Decals Knob Washer Wld, Support ( ) W/Bushings & Decals Spacer, Front Deck Support Bushing, Deck Support Zerk, 45 1/ Spacer Link, Deck Support Screw, HH 3/8-16 x 1 1/ Nut, Hex 3/ Ring, Retaining Hairpin, Cotter # Zerk, 1/8-27 Str Screw, HH 3/8-16 x Washer, Lock 3/8 Heavy Washer Bearing, Flange Nut, Hex 1/ Washer, Lock 1/ Wld, Caster Screw, HH 1/2-13 x Nut, Whizlock 3/ Washer, Spring Disk 3/ Screw, HH 5/8-11 x 1 G Washer, Spring Disk 5/ Wld, Discharge Chute Belt, Deck Drive Spring, Extension Nut, Nyloc 3/ Washer, 3/8 Std Pivot Bearing Zerk, 90 1/ Screw, HH FLG 3/8-16 x Washer, 3/8 SAE Pulley, Idler Wld, Arm ( ) W/Bushings Bushing, Idler Pivot Bushing, Idler Nut, Nyloc 5/ Nut, Whizlock 5/ Screw, HH 5/16-18 x Rod, Deck Support Rollpin, 1/4 x 1 1/ Screw, HH 5/16-18 x 5/ Wld, Deck ( ) W/Decals, Discharge Baffle & Support Rods Baffle, Discharge Balljoint Screw, HH 3/8-16 x 2 3/ Screw, HH 3/8-16 x 3 1/2 G Roller, Antiscalp Spacer Bearing. Roller Bearing Bushing Spacer Screw, HH 3/8-16x1 3/ Link, Assembly Kit, Link Assembly Asm, Deck Complete Nut, HH 3/4-16 Heavy Washer, Spring Disc 3/ Sheave W/ Hub Guard, Bearing Top Asm, Cutter Housing W/Bearings Asm, Cutter Housing Complete Kit, Tire & Wheel Asm W/Spacer Spacer, Guard Bottom Shaft, Spindle Key, Machine 1/4 x 3/16 x Blade, Notched Blade, Mulching Blade, Low Lift Blade, Solid Blade, Extreme Spacer (Yellow Plated) Spacer (Unplated) Bushing (Groove In Outer Face) Pulley, Idler Bushing (No Groove In Outer Face)...4 Exmark red touch up spray paint - P/N Kit includes antiscalp roller, spacer, & mounting hardware. Link assembly nominal length is 6.89 (or approximately 6 7/8 ) between center of ball joint and center of furthest hole. See diagram on next page. Initially adjust both links to this dimension, then adjust to where both links are equally supporting rear of mower deck by lengthening one link and shortening the other by an equal amount. Complete cutter housings also include items 25 & 26. Requires installation of Micro-Mulch accessory for proper mulching. Mulch kit P/N s MK363(36 ). Apply Mobil HTS grease (P/N oz packet) (or a food-grade anti-sieze) between the spindles & bearings and spindles & sheaves and under top bearing guard. DO NOT use a copper or nickel based anti-sieze. Units have been built with two versions of the wheel and tire assembly (Kit services both versions). Some components are not interchangeable between versions. Component required for caster assembly version A, which can be Component required for caster assembly version B, which can identified by the following: be identified by the following: 1) One sidewall of the tire is stamped Made in the USA. 1) Sidewalls of tire are not stamped with Made in the USA. 2) Front caster spacer (item 71) is yellow plated. 2) Front caster spacer (item 71) is unplated. 3) Caster bushings (item 72) have a groove in the outer face. 3) Caster bushings (item 72) do not have a groove inouter face. 3

5 36 MOWER DECK 4

6 48 MOWER DECK Shield, Belt ( ) W/Decals Knob Washer Wld, Support ( ) W/Bushings & Decals Spacer, Front Deck Support Bushing, Deck Support Zerk, 45 1/ Spacer Link, Deck Support Screw, HH 3/8-16 x 1 1/ Nut, Hex 3/ Ring, Retaining Hairpin, Cotter # Zerk, 1/8-27 Str Screw, HH 3/8-16 x Washer, Lock 3/8 Heavy Washer Bearing, Flange Nut, Hex 1/ Washer, Lock 1/ Wld, Caster Screw, HH 1/2-13 x Nut, Whizlock 3/ Washer, Spring Disk 3/ Screw, HH 5/8-11 x 1 G Washer, Spring Disk 5/ Wld, Discharge Chute Belt, Deck Drive Spring, Extension Nut, Nyloc 3/ Washer, 3/8 Std Pivot Bearing Zerk, 90 1/ Screw, HH FLG 3/8-16 x Washer, 3/8 SAE Pulley, Idler Wld, Arm ( ) W/Bushings Bushing, Idler Pivot Pulley, Idler Bushing, Idler Nut, Nyloc 5/ Exmark red touch up spray paint - P/N Kit includes antiscalp roller, spacer, & mounting hardware. Link assembly nominal length is 6.89 (or approximately 6 7/8 ) between center of ball joint and center of furthest hole. See diagram on next page. Initially adjust both links to this dimension, then adjust to where both links are equally supporting rear of mower deck by lengthening one link and shortening the other by an equal amount. Complete cutter housings also include items 25 & 26. Requires installation of Micro-Mulch accessory for proper mulching. Mulch kit P/N s MK363(36 ). Apply Mobil HTS grease (P/N oz packet) (or a food-grade anti-sieze) between the spindles & bearings and spindles & sheaves and under top bearing guard. DO NOT use a copper or nickel based anti-sieze Nut, Whizlock 5/ Screw, HH 5/16-18 x Rod, Deck Support Rollpin, 1/4 x 1 1/ Screw, HH 5/16-18 x 5/ Wld, Deck ( ) W/Decals, Discharge Baffle & Support Rods Baffle, Discharge Balljoint Screw, HH 3/8-16 x 2 3/ Screw, HH 3/8-16 x 3 1/2 G Roller, Antiscalp Spacer Bearing. Roller Bearing Bushing Spacer Screw, HH 3/8-16x1 3/ Link, Assembly Shield, Belt Washer, 5/16 Std Bolt, HH 5/16-18 x 3 1/4 Tap Kit, Link Assembly Asm, Deck Complete Nut, HH 3/4-16 Heavy Washer, Spring Disc 3/ Sheave W/ Hub Guard, Bearing Top Asm, Cutter Housing W/Bearings Asm, Cutter Housing Complete Kit, Tire & Wheel Asm W/Spacer Spacer, Guard Bottom Shaft, Spindle Key, Machine 1/4 x 3/16 x Blade, Notched Blade, Mulching Blade, Low Lift Blade, Solid Blade, Extreme Spacer (Yellow Plated) Spacer (Unplated) Bushing (Groove In Outer Face) Bushing (No Groove In Outer Face)...4 Units have been built with two versions of the wheel and tire assembly (Kit services both versions). Some components are not interchangeable between versions. Component required for caster assembly version A, which can be Component required for caster assembly version B, which can identified by the following: be identified by the following: 1) One sidewall of the tire is stamped Made in the USA. 1) Sidewalls of tire are not stamped with Made in the USA. 2) Front caster spacer (item 74) is yellow plated. 2) Front caster spacer (item 74) is unplated. 3) Caster bushings (item 75) have a groove in the outer face. 3) Caster bushings (item 75) do not have a groove inouter face.

7 48 MOWER DECK 6

8 ENGINE DECK GROUP Grip, Foam Nut, Nyloc 3/ Washer, Spring Disc 3/ Washer, Shifter Lever Transmission, Peerless Zerk, 1/4-28 Str Asm, Coupling W/Guard & Zerk Key Woodruff #9 3/4 x 3/ Shaft, Transmission Output Asm, Shift Lever W/Grip Switch, Neutral Start Bolt, HH 5/16-18 x 3/4 Tap Nut, Whizlock 5/ Asm, Shifter Plate ( ) W/ Decals Bolt, Carriage 5/16-18 x 3/ Leg, Shifter Plate Ball, Stainless Steel Washer, Lock 5/16 Heavy Screw, HH 5/16-18 x 3/ Ring, Retaining Bearing, Transmission Shaft Nut, Nyloc 1/ Screw, HH 1/4-20 x 5/ Flange, Output Setscrew, 5/16-18 x 3/ Sleeve, Axle Sheave, Transmission Output Nut, Whizlock 3/ Wld, Axle Spacer, Wheel Bushing, Sleeve Asm, Brake Lever RH W/Bushings (Shown) Asm, Brake Lever LH W/Bushings (Not shown) Bushing, Pivot Washer, 3/8 Std Screw, HH 3/8-16 x Nut, Push 3/ Screw, HH 3/8-16 x 1 3/ Band, Brake Pin, Clevis 1/2 x Nut, Jam 3/ Nut, Nyloc 3/ Spring, Extension Idler, Wheel Drive Bolt, HH 3/8-16 x 3 Tap Swivel, Short Linkage, Brake Wld, Brake Linkage Swivel Wingnut, Nyloc 5/ Asm, Engine Deck Weldmt ( ) W/Decals Klipring, (For 3/8 Shaft) Spacer, Shield Wld, Arm, RH (Shown) Wld, Arm, LH (Not Shown) Screw, HH 5/16-18 x 1 1/ Nut, Nyloc 5/ Screw, HH 3/8-16 x Shield, Wheel Drive Screw, HH 5/16-18 x 1 1/ Drum, Brake Sheave, Wheel Drive W/Offset Sheave, Wheel Drive Seal, Grease Cone, Bearing L Cup, Bearing L Wheel, Hub W/Cups Washer, Spacer Pin, Cotter 9/64 x 1 1/ Nut, Slotted Cap, Grease Asm, Wheel and Tire Tire 16 x Wheel Nut, Lug 1/ Belt, Wheel Drive Banded Clip, Loom 1/ Hanger, Drag Shield Linkage, Drive Guard, Coupler Hairpin, Cotter Wld, Scraper Pin, Threaded Screw, HH 3/8-16 x Shield, Trailing...1 Exmark red touch up spray paint - P/N Exmark black touch up spray paint Gloss black. Use Pro-lock (Nut type) Part No (.5ml tube) on setscrew threads. Apply anti-seize compound between transmission output shafts & bearings and between transmission output shafts and sheaves. 7

9 ENGINE DECK GROUP 8

10 ENGINE DECK GROUP (cont.) Screw, 3/8-16 x 2-1/ Hairpin, Cotter Washer, 5/16 Std Linkage, Lower Nut, Whizlock 5/ Asm, Link Pivot W/Bearings Plate, Guard Zerk, 1/4-28 Str Screw, HH 3/8-24 x 1 Gr Bushing, Idler Pivot Washer, Spring Disc 3/ Bolt, Carriage 3/8-16 x Washer Screw, HH 5/16-18 x 1 1/ Screw, HH 5/16-18 x 3/ Screw, HH 1/4-20 x Sheave, W/Drum (36 ) Nut, Whizlock 1/ Sheave, W/Drum (48 ) Spring, Motion Control Key, Mach 1/4 x 1/4 x Washer, Spring Disc 5/ Wld, Pivot Pin Screw, HH 7/16-20 x 2 1/ Band, Brake Clutch Washer, Spring Disc 7/ Nut, Nyloc 3/ Bushing, Clutch Keeper Washer, Spacer Sheave, Engine Pivot, Bearing Key, Machine 1/4 x 1/4 x 2 5/ Asm, Clutch Arm ( ) W/Bearings Wld, Belt Guide...1 Belt, Blade Clutch Zerk, 45 1/ Sheave, Transmission Bearing, Clutch Shaf Setscrew, 1/4-20 X 3/ Ring, Retaining Washer, 7/16 Std Spacer, Bearing Clutch Washer, 3/8 SAE Washer, Spacer Idler, Transmission Drive Sheave W/Shaft Screw, HH 3/8-16 x 1 1/ Plate, Clutch Pivot Sheave, Transmission Drive Nut, Whizlock 3/ Spacer, Crankshaft Nut, Nyloc 5/ Belt, Transmission Drive Washer, Strut Screw, HH 5/16-18 x 1 1/ Spring, Belt Tension Valve, Oil Drain Spacer, Clutch Anchor Adapter, M / 3/8 NPT Washer, 3/8 Std Screw, 5/16-18 x Pivot, Bearing...2 Exmark red touch up spray paint P/N Exmark black touch up spray paint Gloss black Use anti-seize compound in the following locations: Between the sheave and the engine crankshaft. Between the sheave w/shaft and the bearing bores. Between the sheave w/shaft and the sheave w/drum. Between the transmission shaft and the sheave. Use Pro-lock (Nut type) Part No (.5ml tube) in the following locations: On setscrew locations. On sheave retaining bolt in engine crankshaft. On sheave retaining bolt on clutch arm. Use Teflon Pipe Sealant or equivalent between oil drain valve and adapter. 9

11 ENGINE DECK GROUP (cont.) 10

12 PISTOL GRIP UPPER HANDLES and CONTROLS Wld, OPC Lever LH Bushing, Nylon Setscrew, 5/16-24 x 5/ Wld, OPC Rod Spring, Actuator Knob, Ball Red Bolt, Carriage #10-24 x 1/ Nut, Nyloc # Cable, Throttle Control Wld, OPC Lever RH Grip, Asm. Clutch Lever W/Grip Nut, Nyloc 5/ Washer, 3/8 SAE Spacer Washer, 3/8 SAE Linkage, Upper Turnbuckle, 3/8-16 SS Nut, Hex 3/ Grip Washer, Spring Disc 1/ Latch, Thumb LH (Not Shown) Latch, Thumb RH (Shown) Nut, Nyloc 1/ Wld, Handle Washer, Spring Disc 3/ Screw, HH 3/8-16 x 2 1/ Cap, Fuel Tank Asm, Fuel Tank W/Fitting Stud Spring, Fuel Tank Washer, Lock 5/16 Heavy Nut, Nyloc 5/ Screw, Hex Cap 5/16-18 x 3/ Fitting, Fuel Bulkhead W/Strainer Bracket, Choke Cable Clamp, Fuel Line Hose, Fuel Line Valve, Fuel Kawasaki PN W/6 Fuel Line Harness, Wiring Nut, Nyloc 3/ Switch, On/Off Key, Ignition Key, Exmark Logo Nut, Ignition Switch Plate, Tapped Nut, Whizlock 3/ Screw, PPH #10-24 x 5/ Switch, Neutral Lockout Clip, Loom 3/ Tie, Cable 5 1/2 (Small) Module, Wiring Harness Screw, HH 3/8-16 x 2 1/ Screw, HH 5/16-18 x 1 3/ Bearing Lever, Drive LH Screw, HH 1/4-20 x 3/ Screw, HH 1/4-20 x 2 3/ Nut, Whizlock 1/ Pin, Spring 1/8 x 1/ Washer, 1/4 SAE Screw, HH 1/4-20 x 1 1/8 W/Nylon Lever, Drive RH Nut, Jam 3/ Console ( ) W/Decals Washer, 5/16 SAE Screw, HH 1/4-20 x 5/ Asm, Drive Lever RH (Shown) Asm, Drive Lever LH (Not Shown) Balljoint Bracket, OPC Axle Cable, Choke Push/Pull Screw, HH M6-1 x 16mm Washer, Lock 1/4 Heavy Clip, Cable Clip, Loom 1/ Hose, Fuel Line Screw, HH M x 16mm...1 NOTE: Use dielectric grease on all electrical connections. Exmark black touch up spray paint Gloss black. Use Pro-Lock nut type, Part no (.5cc tube) on setscrew threads, on thumblatch screws, and on fuel fitting. Use Pro-Lock retaining type, Part no (.5cc tube) on inside of bore of OPC hub and on fuel tank studs, where studs are inserted into tank. 11

13 PISTOL GRIP UPPER HANDLES and CONTROLS 12

14 DECAL GROUP Decal, Console Decal, Throttle Decal, LH ECS Instruction Decal, RH ECS Instruction Decal, Muffler Decal, Commercial Decal, Commercial Decal, Bolt Torque Decal, Danger Decal, MHP Model Decal, Trivantage Decal, Exmark Logo Decal, Missing Cover (36 ) Decal, Missing Cover (48 ) Decal, Sulky Warning Decal, Belt Drive Decal, Shifter Decal, Indicator Decal, Belt Routing (36 ) Decal, Belt Routing (48 ) Decal, Mower Deck Decal, Discharge Warning Decal Kit 13

15 ELECTRICAL DIAGRAM 14

16 SEE EXMARK S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z LAZER Z HP LAZER Z XP LAZER Z CT TURF RANGER VIKING HYDRO TURF TRACER TURF TRACER HP METRO METRO HP ULTRA VAC ULTRA VAC QDS GRASS CATCHER MICRO-MULCH ACCESSORY SELF STEERING SULKY EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 BEATRICE, NE ALL RIGHTS RESERVED PART NO (402) FAX (402) PRINTED IN U.S.A. MFG. CO. INC.

MFG. CO. INC. Model No. Serial No. For Serial Nos. 510,000 & Higher

MFG. CO. INC. Model No. Serial No. For Serial Nos. 510,000 & Higher For Serial Nos. 510,000 & Higher MFG. CO. INC. on the purchase of your new Exmark mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years