Page 2 - WARNING
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: The engine in this product is not equipped with a spark arrester muffler. It is aviolation of Cali...
Page 3 - Introduction; CONGRATULATIONS
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation. This manual contains operating, maintenance,adjustment, and safety instructions for your Exmark...
Page 4 - Contents
Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...
Page 5 - Safety; Safety Alert Symbol; Safe Operating Practices; Training
Safety Safety Safety Alert Symbol This lawn mower meets or exceeds the B71.4specifications of the American National StandardsInstitute in effect at the time of production. Exmark designed and tested this lawn mower to offerreasonably safe service; however, failure to complywith the following instruc...
Page 6 - DANGER; Avoid prolonged breathing of vapors.
Safety DANGER In certain conditions gasoline is extremelyflammable and vapors are explosive. A fire or explosion from gasoline can burnyou, others, and cause property damage. • Fill the fuel tank outdoors on level ground,in an open area, when the engine is cold.Wipe up any gasoline that spills. • Ne...
Page 7 - Operation; DO NOT; Slope Operation; Extreme
Safety Operation WARNING Operating engine parts, especially the muffler,become extremely hot. Severe burns can occuron contact and debris, such as leaves, grass,brush, etc. can catch fire. • Allow engine parts, especially the muffler, tocool before touching. • Remove accumulated debris from mufflera...
Page 8 - Do Not mow slopes when grass is wet.; Maintenance and Storage
Safety DANGER Operating on wet grass or steep slopes cancause sliding and loss of control. Loss of controland/or loss of operator’s footing could result in afall with an arm or leg getting under the moweror engine deck which may result in seriousinjury, death or drowning. • Mow across slopes, never ...
Page 9 - Safety and Instructional Decals
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease,dirt and debris from safety signs and instructionallabels. • Replace all worn, damaged, or missing safetysigns. • When replacement components are installed, besure that current safety signs are affixed to there...
Page 12 - Specifications; Model Numbers
Specifications Specifications Model Numbers Serial Nos: 920,000 and Higher MG16KA322P; MG16KA322PCA; MG16KA362; MG16KA362CA; MG16KA362P; MG16KA483;MG16KA483CA; MG16KA483P Systems Engine • Engine Specifications: See your Engine Owner’sManual • Engine Oil Type: Exmark 4–Cycle PremiumEngine Oil • RPM: ...
Page 13 - Cutting Deck; Dimensions; Torque Requirements
Specifications Cutting Deck • 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 ...
Page 14 - Product Overview; Controls
Operation Product Overview Figure 3 1. Controls 4. ECS Handles 2. Fuel Cap 5. Blade Spacers 3. Pistol Grip Handles Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Operator Presence Control (OPC)Levers Located on the upper handle assembly...
Page 15 - Drive Levers; For Pistol Grip Handles:; Choke Control
Operation Figure 5 ECS Handle 1. OPC Lever 2. Rotate latch for neutral lock and park brake positions 3. Neutral Lock Latch/Park Brake Latch 4. Drive Lever Drive Levers Located on each side of the upper handle assemblyahead of and below the handle grips (see Figure 4and Figure 5). These levers indivi...
Page 16 - Never use methanol, gasoline; Operating Instructions; Open the Fuel Shut-Off Valve
Operation Pre-Start Fill fuel tank on level ground. For best results useonly clean, fresh regular grade unleaded gasoline withan octane rating of 87 or higher. Important: Never use methanol, gasoline containing methanol, gasohol containing morethan 10% ethanol, premium gasoline, or whitegas because ...
Page 17 - Driving the Machine; For Pistol Grip Handles; For ECS Handles; CAUTION
Operation 7. Remove the key to prevent children or other unauthorized persons from starting engine. 8. Close the fuel shut-off valve when the machine will not be in use for a few days, whentransporting, or when the unit is parked insidea building. Driving the Machine Drive Lever/Neutral Lock/Park Br...
Page 18 - Driving Forward; Changing Gears; Transporting; Transporting a Unit; If necessary, use assistance when loading.
Operation To place the drive levers in the “drive” position,slightly squeeze the drive levers while placingthumbs on the outer thumb lobe of the neutrallock/park brake latches (or the index finger onthe front lobe) and rotate them from under thedrive levers. Slowly and carefully release the drivelev...
Page 19 - Maintenance
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are beingmade, someone could start the engine.Accidental starting of the engine could seriouslyinjure you or other bystanders. Remove the key f...
Page 20 - Periodic Maintenance; Check Engine Oil Level; Check Mower Blades; Service Interval: Before each use or daily; Service Interval: As required
Maintenance Periodic Maintenance Check Engine Oil Level Service Interval: Before each use or daily 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 dips...
Page 21 - Check for Loose Hardware; Service Air Cleaner; Service Interval: Every 25 hours—Service
Maintenance Figure 9 1. Rod 4. Mower deck 2. Spring 5. Discharge deflectorbracket 3. Discharge deflector 6. Assembled view 3. Hook the bent end of the rod around the front discharge deflector bracket to retain it fromsliding out. Place the leg of the spring with theloop in the notch in the discharge...
Page 22 - Change Engine Oil; Service Interval: After the first 5 hours; Check Tire Pressures; Check Condition Of Belts; Service Interval: Every 40 hours; Lubricate Grease Fittings; See chart for service intervals.
Maintenance Change Engine Oil Service Interval: After the first 5 hours Every 100 hours (Mayneed more often undersevere conditions.) 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...
Page 23 - Check; Check Spark Plugs; Service Interval: Every 160 hours; Change Fuel Filter
Maintenance Lubrication Chart (cont'd.) Fitting Locations Initial Pumps Number of Places Service Interval 6. Trans-missionOutputShaftCoupler 2 2 2 2 40 hours 7. MowerDeckIdlerPivots 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...
Page 24 - Transmission Belt Adjustment; Thread Locking Adhesives
Maintenance 6. Check for side play caused by bearing wear on the input and output shafts of the transmission.Replace bearings if necessary. 7. Remove the six bolts that fasten the upper case to the lower case and carefully remove the uppercase half 8. Check the grease level in the lower case. The gr...
Page 25 - Adjustments; Adjusting the Cutting Height; Adjusting the Axle Position,; Adjusting the Cutting
Maintenance Adjustments Note: Disengage PTO, shut off engine, wait for all moving parts to stop, engage parking brake, andremove key before servicing, cleaning, or making anyadjustments to the unit. Adjusting the Cutting Height The cutting height of the mower deck is adjustedfrom 1 inch to 4 1/4 inc...
Page 26 - Adjusting the Axle Position
Maintenance Cutting Height Adjustment Table (1 inch to 4 1/4 inches (2.5 cm-10.8 cm)) (cont'd.) Number Of Spacers Below Caster Support Hub Number of 1/4 inch (.64 cm) Blade Spacers Below Spindle Cutting Height Range Axle Position (Figure 10) 1/2 inch (1.2 cm) 3/16 inch (.48 cm) 4 3 2 1 0 2 1/8– 3 1/...
Page 27 - Brake and Wheel Drive Linkage
Maintenance 8. With the jack, raise or lower the back end of the engine deck so that two axle adjustment bolts canbe reinstalled in desired hole location. A taperedpunch can be used to help align the holes. 9. Retighten all four bolts, lower unit and remove jack. 10. Install mower deck belt shield.1...
Page 28 - Engine to Mower Deck Belt
Maintenance 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 to75...
Page 29 - Belt Guide Adjustment; Blade Brake Adjustment
Maintenance Check belt tension after the first hour of operationand at least twice during the first 24 hours ofoperation. 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 thebelt when there is no...
Page 32 - Shifter Lever Adjustment
Maintenance Figure 22 Right Side of Unit Shown 1. Wingnut 5. 5/16–18 x 1 3/4 inch hexcapscrew 2. Transmission Lever inneutral 6. Drive Lever Linkage 3. 5/16–18 inch nyloc nut 7. Swivel 4. Drive Levers in neutral 8. Brake Rod Shifter Lever Adjustment The shifter lever in neutral should not contact th...
Page 33 - Shifter Detent Adjustment; Screwing setscrew in too far will; Handle Height Adjustment; If the handle height position is
Maintenance Shifter Detent Adjustment Transmission shifter detent can be adjustedby adjusting the setscrew on the back side oftransmission located just behind the neutral startswitch. Turn setscrew in (clockwise) to hold thetransmission shifter more positively in each gear andto increase the force o...
Page 34 - Cleaning; Service Interval: Every 100 hours
Maintenance Figure 27 1. More traction applied asbolt moves down 4. Position C–Most Severe 2. Position A–NormalConditions 5. Front of Unit 3. Position B–More Severe Cleaning Clean Engine and ExhaustSystem Area Service Interval: Before each use or daily (May be required moreoften in dry or dirtycondi...
Page 35 - Clean Debris From Machine; Waste Disposal; Motor Oil Disposal
Maintenance Clean Debris From Machine Service Interval: Before each use or daily 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 deckbelt shields, around the fue...
Page 36 - Troubleshooting; condition prior to mower use.
Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, do not overlook the simple causes. For example: starting problems could be causedby an empty fuel tank. The followi...
Page 38 - Schematics
Schematics Schematics KEY SWITCH PTO SWITCH N.O. TRANSMISSION N.C. TO SAFETY INTERLOCK MODULE OPC SWITCH N.O. RED BL A CK B R O WN DK BLUE ORANGE YELL O W GREEN BLACK ENGINE GROUND ENGINE KILL TERMINAL RED CONNECTORS ARE VIEWED FROM WIRE ENDN.C. = NORMALLY CLOSEDN.O. = NORMALLY OPEN G006816 ABCDEF 3...
Page 39 - Exmark Commercial Turf Equipment
Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part on these products and found by us (in the exercise of our reason...
Page 41 - Service Record
Service Record Date: Description of Work Done: Service Done By: 41
Page 44 - M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S; SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS; WALK-BEHIND ACCESSORIES AND OPTIONS
M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS WALK-BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO-MULCH SYSTEM TURF STRIPER STANDON CUSTOM RIDE SEAT SUSPENSION SYSTEM FULL SUSPENSION SEAT DECK LIFT ASSIST KIT HITCH KI...
