Exmark VH3615KA manual

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ii WA RNING The engine exhaust f rom this pr oduct contains chemicals k nown to the St at e of Califor nia t o cause cancer , birth def ect s , or other r epr oduct ive harm. IMPORTANT W hen the m ower is used or operat ed on any California f or est , brush or gr ass covered land, a work ing spark ar r est er m ust be attached to t he m uf fler. If[...]

iii EXMARK PA RTS PLUS     PROGRA M EFFECTIVE DATE: September 1, 1995 Program If your Ex mark dealer does not have the Exmark part in stock, Exmark w ill 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 "dow n" unit at [...]

iv CONGRAT ULATIONS on the purchase of your Exmark Mower. This product has been caref ully designed and manuf actured to g ive y ou a m aximum amount of dependability and years of trouble-f ree operation. OPERA TOR'S M ANUA L This manual cont ains assem bly, oper at ing , maintenance, adj ustment and saf ety instructions f or your Exmark m owe[...]

TABLE OF C ONTENTS v 1. SA FETY ................................................................................................... PA GE 1.1 Sa f ety Alert Sy mbol ...................................................................................... 1 1.2 Trai ning ..................................................................................[...]

- 1 - 1. SA FETY 1.1 SA FETY A LERT SYMBOL THI S SAFETY ALERT SY MBO L IS US ED BOT H IN TH IS MA NU A L A ND ON THE MA CHINE TO I DENTIFY IMPORTA NT SA FETY MESSA G ES W HICH MUST BE FOLLOW ED TO AVOID A CCIDENTS. THIS SYM BO L MEA NS: A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appear s above infor mation which a[...]

- 2 - WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, which is an odorless deadly poison. W HAT CAN HAPPEN ♦ Carbon monoxide can kill you and is also known to t he State of California t o cause bir t h def ects. HOW T O AVOI D T HE HAZARD ♦ Do not run eng ine indoor s or in a sm all confined area where dangerous carbon [...]

- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions gasoline is extremely flam m able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A f ire or explosion from g asoline can burn you, others, and cause property damag e. HOW T O AVOI D T HE HAZARD ♦ Purchase and store g asoline only in an approved co[...]

- 4 - 1.4.5 Stop the blades when crossing surf aces other than g r ass; and w hen transport ing t he mower to and from t he ar ea t o be mowed. 1.4.6 Never operate the mower with defect iv e g uards, shields, or covers. Alw ays have safety shields, guards, switches, and other devices in place and in proper working condit ion. 1.4.7 Do Not chang e t[...]

- 5 - 1.5.5 Keep the mower and fuel cont ainer in locked storag e to prevent children f r om playing or tam per ing with them. 1.5.6 Gasoline powered equipment or fuel containers should not be stored in a basement or any enclosed area, where open pilot lig hts or heat appliances are present. 1.5.7 Max imum mowing result s and saf ety can only be ac[...]

- 6 - PART NO. 323741 LOCATI ON: Console PART NO. 323691 LOCATION: RH Side of Console PART NO. 303517 LOCATI ON: Left Side of Rear Surface on Engine Dec k PART NO. 403143 LOCATI ON: Right Side of Rear Surface on Engine Dec k PART NO. 413214 LOCATI ON: Right Side of Hydro Control Crank Arm PART NO. 603845 LOCATIO N: Rear Center of T op Surface of En[...]

- 7 - 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: Serial Nos. 220, 000 & Hi gher: VH3615KA; VH4815KA 2.2 ENGINE 2.2.1 Engine Specif icat ions: See your Engine Owner's Manual. 2.2.2 3600 RPM (No Load). 2.3 FUEL SYSTEM 2.3.1 Capacity: 5.0 gal. (18.9 L.) 2.3.2 Type of Fuel: Regular unleaded g asoline, 87 oct ane or higher. I n countries using the r[...]

- 8 - 2.6.2 Hydraulic Filter is replaceable cart ridge type. P/N 513211: 10 microns, 18 psi bypass (Summer use above 32 ° F) P/N 523541: 40 microns, 18 psi bypass (W inter use below 32 ° F) 2.6.3 Speed Range: Forward 0 - 6. 2 m ph ( 10.0 km/ h) Reverse 0 - 2.2 mph ( 3. 5 k m/h) 2.7 WHEEL DRIVE SY STEM: Drive wheels are direct coupled to Park er/R[...]

- 9 - 2.11 TORQUE REQUIREMENTS BOLT LO CATION TORQ UE Blade/Cu tter Housing Spindle B olt ................................. 75-80 ft-lbs. Caster Bracket M ounts .................................................. 30-35 f t-lbs. Cutter De ck /Engine De ck M ount .................................... 30-35 ft-lbs. Engine M ounting Bolts (Kohler & K[...]

- 10 - b) Loosen clamp on eng ine control plate (See Fig ure 2). Att ach inner wire of the throt tle cable to the contr ol plat e lever and posit ion cable under cable clamp, do not t ig hten clamp. FIG 2 15 HP KA WASA KI SPEED CONTROL (THROTTLE CA BLE HOO K- UP) c) Pull the cable to the r ight when facing t he control plate until t he alignment ho[...]

- 11 - 3.13 Install the speed cont rol rod assembly (linka g e wi th the yoke inst alled on one end) into the end of the speed control lever located under neat h t he cent er of t he console. Insert t he end of the link age (opposite t he yok e) int o t he end of the speed control lever f rom the rig ht hand side and f asten with a hairpin cotter f[...]

- 12 - 4. OPERA TION INSTRUCTIONS 4.1 Controls 4.1.1 Operator Pr esence Control (OPC) Levers: Locat ed on the upper handle assembly directly above the handle grips. When these l evers are depressed, the OPC system senses that t he operat or i s i n t he normal operat or's position. When the levers are released, the O PC system senses t hat the[...]

- 13 - Once the eng ine has st ar t ed, move the throt t le cont r ol lever t o t he m idway point and allow the engine to warm- up bef ore going to f ull t hr ottle. 4.1.7 “Of f-Run” Switch: Locat ed on t he console. Turn k ey to the “Run” position to allow the engine to be star t ed. Turn k ey to t he “ O f f” posit ion to shut engine[...]

- 14 - 4.2.1 Fill fuel t ank . For best r esult s use only clean f resh regular g rade unleaded gasoline with an octane rat ing of 87 or hig her . Regular g rade leaded gasoline may also be used; however, combustion chamber and cylinder head will requir e m or e f requent ser vice. See Eng ine Owner's Manual. Do not add oil to g a soline. DA N[...]

- 15 - WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, which is an odorless deadly poison. W HAT CAN HAPPEN ♦ Carbon monoxide can kill you and is also known to t he State of California t o cause bir t h def ects. HOW T O AVOI D T HE HAZARD ♦ Do not run eng ine indoor s or in a sm all confined area where dangerous carbon[...]

- 16 - CA UTION POTENT IAL HAZARD ♦ If t he neut ral lock latches ar e not completely engag ed t he drive levers could unexpectedly slip into the for ward drive position. W HAT CAN HAPPEN ♦ If t he drive levers slip into the drive position, t he unit could lurch f or ward and cause injur y or property damage. HOW T O AVOI D T HE HAZARD ♦ Be s[...]

- 17 - 4.3.8 Blade Disengagem ent : Push forward and down completely on the eng ag ement knob to diseng age the blades (See Section 4. 1.5). 4.4 TRA NSPORTING WA RNING POTENT IAL HAZARD ♦ Loading the m ower onto a t r ailer wi t hout strong enough or pr oper ly supported r amps could be dangerous. W HAT CAN HAPPEN ♦ The ram ps could collapse ca[...]

- 18 - 5.1 PERIODIC MA INTENA NCE 5.1.1 Check eng ine oil level. Serv ice Interv al: See Engine Ow ner's Manual a) Make sure engine is st opped and on a level surf ace. b) Check with engine cool. c) Clean area around dipstick. Remove dipstick and wi pe oil off . Reinsert the dipstick ( DO NOT screw into place). Rem ove dipstick and check oil l[...]

- 19 - h) Remove jack st ands ( or eq uivalent support) and lower deck t o g round. FIG. 6 BLA DE BOLT IN STA LLA T ION 5.1.4 Check saf et y interlock system. Serv ice Interv al: Daily a) For your saf et y, your Exmark mower is equipped with Operat or Pr esence Controls (O PC) . W hen either t he mower blades are engaged, or the speed control lever[...]

- 20 - d) Remove the oil drain plug from t he r ight hand side of the engine. Allow oil to drain, t hen replace drain plug. e) Replace the oil f ilter as per Eng ine O wner's Manual. Clean around oil filt er and unscr ew filter to r em ove. Before r einst alling new filter , apply a thin coating of oil on the surf ace of the r ubber seal. Turn[...]

- 21 - e) Loosen f ilt er 1/2 turn and allow a small amount of oil to leak f rom the oil filt er ( this allows air to be purged f rom the oil f ilter and supply hose f r om the hydraulic reservoir). Turn f ilt er clockwise until rubber seal cont act s t he filt er adapt er. Then t ig hten the f ilt er an additional 2/3 to 3/4 t ur n. f) Raise the r[...]

- 22 - e) To “pr ime” charge pump, loosen t wo hex socket head capscrews (shown in Figure 7) 1-1/2 turns only. Make sure engine is not runni ng. Lift charge pum p housing upward and w ait f or a steady f low of oil t o f low out fr om under housing . Retighten capscrew s . Do this for bot h pum ps. Note: Hydraulic reser voir can be pr essur ize[...]

- 23 - No. 4 Idler Pivot ( Pump Drive) Located Under Eng ine Deck No. 4 & 6 (Idler Pivots) Disassemble and grease once a month under a “ No Load” condit ion. c) Lubricate pivot points with a spray penetrating lubricant as directed below. SPRA Y LUBRICA NT CHART PIVOT POINT NO. OF P LACES 36” 48 ” SERVICE INTERVAL 1. Blade Engag ement Up[...]

- 24 - c) OPC lever setscrew s. d) Shoulder bolts in ends of speed control crank . e) Between the fuel t ank studs and the f uel tanks. f) Betw een t he shifter lever and t he k nob. Adhesives such as “Loctite RC/609 or RC/ 680” or “Fel-Pro Pro- Lock Retaining I or Retaining II” ar e used on t he f ollowing: a) OPC lever hubs and cross-shaf[...]

- 25 - 5.2.1 Blade Spacers: Blades may be adjusted f or cutting heig ht by using the f our 1/ 4" spacer s found on the blade spindle bolts (f actory setting is two above and tw o below). T his allows a 1" range in 1/4" incr em ent s of cutt ing height in any axle position. The same number of blade spacers must be used on all blades t[...]

- 26 - FIG. 8 A XLE and CAST ER HEI G HT A DJUSTMENT Refer t o t he following chart t o pr operly adjust desired cutt ing height. CUTTING HEIGHT A DJUS TME NT (1" to 4 1/4") AX L E POSITIO N (FIG. 9) NO. OF S PA CERS BELOW CAST ER 1/2" 3/16" NUMBER OF 1/ 4” BLADE SPA CERS BELOW SPI NDLE 4 3 2 1 0 A 0 0 1" 1 1/4" 1 1/[...]

- 27 - b) W ith blade drive engag ed (lever pulled up, adjust t he link age lengt h to where the lower end of the bellcrank just clears t he axle support g usset (See Figure 9) . Make sur e t he assist ar m is against the r ear assist arm stop on the deck ( See Fig ure 10). Push the lever down to the diseng ag ed position. T he assist ar m should c[...]

- 28 - FIG. 10 CUTTER DECK BELT ADJUSTMENT e) Proper belt t ension will require about 10 lbs. side pull on belt , halfway between pulleys, to deflect belt 1/2”. (See Fig ure 10, Point A). 5.2.6 Blade Brake Adj ust ment: a) Stop eng ine and r em ove spark plug wire(s). b) Disengag e the blades. c) Make sure the blade brake pad r est s ag ainst the[...]

- 29 - Note: T hese dr awings ar e viewed from under neat h t he engine deck FIG. 12 FIG. 13 36" B ELT GUIDE LOC A TION 48" B ELT GUIDE LOC A TION 5.2.8 Pump Drive Belt Tension Adj ustment: No adjustment necessary . 5.2.9 Hydro Drive Linkage Adj u st m ent : a) Adjust Speed Cont rol Linkag e and neut r al saf ety switch 1. Move the speed [...]

- 30 - Make sure you have not reached the end of t he neutral lock lat ch slot . If you have, short en t he dr ive lever link ag e. If the wheel turns while holding the dr ive lever in neutr al, the neutral contr o l link ages need to be adjusted. I f wheel stop then go to st ep 7. FIG. 15 HYDRO DRIVE LI NKAGE A DJUSTMENT 4. Loosen the nut against [...]

- 31 - Aft er adj usting the lef t hydro control link a g e, move the speed control lever to the mid-speed posit ion and then back to t he neut ral position. Recheck the lef t drive wheel rotation to see if fur t her adjustment is necessary - be sure the speed cont r ol lever is in t he neut r al position. If inconsi st ent neut ral occurs, check t[...]

- 32 - 4. If the unit tr ack s to one side or the ot her , t ur n the quick t rack k nob . Turn t he k nob right t o “ s t eer ” right, t u r n t he k nob left t o “ s t eer ” left. 5.2.10 Hydro Pump Spr ing Tension Setting : a) For medium or heavy duty drive conditions such as operation with a sulky on steep slopes, a hig her spr ing force[...]

- 33 - e) Check t hat there is f uel in t he t ank and that t he f uel valve is open. f) Check that t he spark plug wire(s) ar e pr oper ly connected. g) Check f or loose or f aulty w iring connections. I f it is necessary to disconnect wire connectors, Do Not pull on t he wi r es while disconnecting. h) Check f or corrosion at all wiring connect i[...]

- 34 - 8. WIRING DIA GRAM[...]

- 35 - 9. HYDRA ULIC DIAGRA M[...]

- 36 - 10. WA RRANTY Limited W arranty Exmark Comm ercial Turf Equipment Exmar k Mfg. Co. Inc. ("Exmar k ") warrants on the ter m s and condit ions her ein, t hat it will repair, replace or adj ust any part manuf act ur ed by Exmark and found by Exmark( in t he exercise of its reasonable discretion) to be defect ive in f act or y material[...]

- 37 - As a condition to this warrant y, cust om er shall have read t he oper at or's manual and shall have returned t o Exmark , within the prescribed time, the enclosed warranty registrat ion car d. The sole liability of Exmar k with respect to this warrant y shall be repair and r eplacem ent as set for t h her ein. Exmark shall have no liab[...]

- 38 - T H I S I S A 1 5 ° S L O P E T H I S I S A 1 0 ° S L O P E T H I S I S A 5 ° S L O P E ALIGN THIS EDGE WITH A VERTICAL SURF ACE (TREE, BUILDING, F E NCE POST , POLE ETC.) EXAMPLE: COMP ARE SLOPE WITH FOLDED EDGE. FOLD ALONG APP ROPRIA TE LINE T HI S I S A 2 0 ° S L O P E[...]

SEE EXMARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z ™ LAZER Z ™ HP TURF RANGER ® TURF TRACER ® TURF TRACER ® HP VIKING HYDRO METRO ™ METRO ™ HP SELF STEERIN G SULKY GRASS CATCHER MICRO-MULCH ™ ACCESS ORY ® MFG. C O. I NC. ©1997,1998, 1999 PA RT NO. 850654 EXMARK MFG. CO . INC. (402) 223-6300 INDUSTRIAL PA RK BOX 808 FA X ([...]