Exmark Metro HP manual

Part No. 103-9184 For Serial Nos. 540,000 & Higher[...]

ii WA RNING POTENT IAL HAZARD ♦ This product is a piece of power equipment. W HAT CAN HAPPEN ♦ Failure to f ollow safe operating pr act ices can result in serious operator inj ur y or even death. HOW TO AVO ID THE HAZARD ♦ Keep all shields, guar ds, and saf ety devices (especially the grass discharge system) in place and in pr oper working co[...]

iii EXMARK PA RTS PLUS ® PROGRA M EFFECT IVE DA TE: September 1, 1995 Progra m If your Exmar k dealer does not have the Exmar k part in stock , Exm ark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed! ! How the Pro gram Works 1. If dealer does not have part in stock for a "down" unit at the tim[...]

iv CONGRAT ULATIONS on the purchase of your Exmark Mow er . T his product has been caref ully designed and manuf actured to g ive you a max im um am ount of dependability and years of t r ouble- fr ee oper at ion. OPERA TOR'S M ANUA L This manual cont ains assem bly, oper at ing , maintenance, adj ust ment, and saf ety instructions for your E [...]

v TA BLE OF CONTENTS 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 This SAFE TY A LER T SYM BOL is used both in this manual and on the m achine to identif y import ant safet y messag es which must be followed to avoid accidents. T his symbol means: A TTENTION! BECOME ALERT ! YOUR SA FETY IS I NVOLVED! The saf ety alert symbol appears above inform at ion which alerts you t[...]

- 2 - 1.3.4 Thoroug hly inspect the area where the equipment is to be used and remove all stones, stick s, wires, bones, and other f oreign obj ect s which may damage the equipment or cause per sonal inj ury to the operator or bystander s. WA RNING POTENT IAL HAZARD ♦ Engine exhaust contains carbon m onoxide, which is an odorless deadly poison. W[...]

- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g a soline vapors. A f ire or explosion from g asoline can burn you, others, and cause property damag e. HOW TO AVO ID THE HAZARD ♦ Purchase and store g asoline only in an approved con[...]

- 4 - WA RNING POTENT IAL HAZARD ♦ Operating engine parts , especially the m uf fler , becom e extremely hot. W HAT CAN HAPPEN ♦ Severe burns can occur on contact. ♦ Debris, such as leaves, gr ass, br ush, et c. can catch f ir e. HOW TO AVO ID THE HAZARD ♦ Allow engine parts, especially the m uf f ler, to cool befor e touching. ♦ Remove a[...]

- 5 - • See inside the back cover t o det er m ine the approximate slope angle of the area to be mowed. • Progre ssively great er car e is needed as t he slope increases. • Alway s avoid sudden starting or st opping on a slope. If tires lose tract ion, disengage t he blades and proceed slowly off the slope. • Be aware that loss of t r actio[...]

- 6 - 1.4.17 Do Not mow with the grass def lector raised, r em oved or alt er ed unless t her e is a grass collect ion system or mulch kit in place and working properly. 1.4.18 Be aware of the mower discharge and dir ect discharge away from other s. 1.4.19 Do NOT operate t he mower under the inf luence of alcohol or drug s. 1.4.20 Use care when app[...]

- 7 - PART NO. 1- 303508 LOCATIO N: Front of Mower Deck , Top Surf ace PART NO. 1- 513746 LOCAT ION: On Engine Blower Housing next to Muf fler & on Center Belt Cover PART NO. 1- 303517 LOCATI ON: LH Side of Rear Surface of Mower Deck PART NO. 1- 303518 LOCAT ION: Tr ansmis sion Shifter Plate PART NO. 1- 403005 LOCATION: RH & LH Corners of M[...]

- 8 - PART NO. 1- 553049 LOCATIO N: Front of Mower Deck Top Sur face PART NO. 103- 7491 LOCATI ON: On T op LH Side of Mower Deck PART NO. 103- 1623 LOCATI ON: Console PART NO. 103- 1798 LOCATIO N: RH Side of Console PART NO. 98- 5954 LOCATIO N: Under Mower Deck Belt Shield(s) PART NO. 103- 2244 LOCATI ON: LH Side of Console PART NO. 103- 2245 LOCAT[...]

- 9 - 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: MH P3615KAC; MHP4815KAC 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 g al. (18.9 L.) 2.3.2 Type of Fuel: Regular unleaded g asoline, 87 octane or hig her . I n countries using the research m et hod, it should b[...]

- 10 - 2.10 DIMENSIONS 2.10.1 Ove rall W idth: 36” 48” Discharge chut e down 46.25” (117.5 cm ) 58.25” (148.0 cm ) Discharge chute up (Transport only ) 36.1” (91.7 cm) 48.1” (122.2 cm ) 2.10.2 Overall Leng th: 36” 48” 77.0” (196 cm ) 73.0” (185 cm ) 2.10.3 Curb W eight: 36” 48” 517 lbs. (234 k g) 565 lbs. (256 k g) ∗ W eig[...]

- 11 - FIGURE 1 UPPER HA NDLE MO UNTING 3.8 Route the t h r ot t le cable along the rig ht side of the upper handle, t hrough the clip, under the f uel tank support , and position the cable on the left side of the eng ine. Attach thr o t t le cable t o eng ine: a) Posi tion the throttle control lever (l ocated on console) ¼” (6mm) f rom the uppe[...]

- 12 - 3. 10 Install and adjust shif ter lever. a) Remove the 3/8” nyloc nut and spring disc washer f rom the stud on t op of the transmission. I nst all the shift er lever throug h slot in shif ter lever plat e and onto the stud on t op of transmission. Be sur e t he sq uare-hole washer remains between the lever and transm ission. Replace t he s[...]

- 13 - b) T he bend in the drive lever linkages should be posit ioned downw ard and slightly outward. I f adjustm ent is needed, loosen jam nut below balljoint and rotate lin k age. Tighte n jam n ut. Shift t r ansmission lever to fif th gear . Insure that bend in r ig ht hand linkag e is rotated out ward enoug h t hat linkag e clear s shifter leve[...]

- 14 - 3.12 Route the long unattached wiring harness lead, up t he left hand side of the handle and connect the connector on t he end of the short er lead t o t he key switch. Connect the two f lag t erminals that ar e on t he long er lead (in any order) to t he operator pr esence cont r ol switch terminals underneath t he cont r ol console. Fasten[...]

- 15 - FIGURE 9 NEUTRA L LOCK/PARK BRA KE LA TCH 4.1.5 PTO Eng agement : Locat ed on the left side of the upper handle. To engag e the blades, push the lever f orward, or away from t he oper at or, until the linkag e lock s over-center. To disengag e the blades, pull the lever t o t he r ear , or towards the operat or . 4.1.6 Choke Cont r o l : Cho[...]

- 16 - Do not add oil to g a soline. Do not overf ill fuel t ank . Never f ill t he f uel tank so t hat the f uel level rises above a level that is 1/2” ( 1. 3 cm) below the bottom of the f iller neck to allow f o r f uel expansion and prevent fuel spillag e. 4.2.3 Make sure you understand the contr ols, t heir locations, their f unctions and the[...]

- 17 - FIGURE 10 DRIVE LEVER, NEUTRA L LO CK/PA RK BRAKE LA TCH OPERA TION 4.3.5 Drive W heel Eng ag ement and T ur n ing : W it h dr ive levers in “neut r al” or “park brake” position, shif t transm ission int o desir ed g ear. Sq ueeze both dr ive levers and move both neutral lock /park br ak e latches f rom the “neut r al” or “park[...]

- 18 - DA NGER POTENT IAL HAZARD ♦ An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander ’s dir ect ion. Also, contact with the blade could occur. W HAT CAN HAPPEN ♦ Thrown objects or blade cont act can cause serious injury or death. HOW TO AVO ID THE HAZARD ♦ Never operate the mower with the dischar[...]

- 19 - 5. MAINTENA NCE & A DJUSTMENTS WA RNING POTENT IAL HAZARD ♦ W hile maint enance or adj ustments are being made, someone could start t he eng ine. W HAT CAN HAPPEN ♦ Accidental start ing of the eng ine could seriously injure you or other bystanders. HOW TO AVO ID THE HAZARD ♦ Remove the key f rom the ig nit ion switch and/or pull th[...]

- 20 - b) Raise deck to t he highest position. Lif t the f ront of unit and support unit using jack st ands or eq uivalent support. CA UTION POTENT IAL HAZARD ♦ Raising the m ower deck f or service or maint enance relying solely on mechanical or hydraulic jack s could be dangerous. W HAT CAN HAPPEN ♦ The mechanical or hydraulic j ack s may not [...]

- 21 - CA UTION POTENT IAL HAZARD ♦ Operating a mower deck with loose or weakened blade bolts can be danger ous. W HAT CAN HAPPEN ♦ A loose or weakened blade bolt could allow a blade rotating at a high speed to come out f rom under t he deck , causing serious injur y or pr oper t y damage. HOW TO AVO ID THE HAZARD ♦ Always re-install original[...]

- 22 - a) St op eng ine and wait for all moving par t s t o st op. Remove key or spark plug wi re(s). b) Dr ain oil while engine is warm f rom oper at ion. c) The oil drain valve is located on left hand side of engine. Place pan under machine to cat c h oil and t ur n valv e counter clock wise with a 10 mm wrench to open valve. Allow oil to drain, [...]

- 23 - b) Rem ove deck suppor t belt shield to check mower deck drive belt condition. c) Look under eng ine deck to check the transmission dr ive and clutching belt condition. d) I nspect wheel drive belt conditions e) Check the wheel drive idler arms to be sur e t hey pivot f reely. Disassemble, clean and grease pivot bushing s if necessary. 5.1.1[...]

- 24 - d) Lubricate drive wheel hubs once a y ear . Fir st remove wheel, then remove hub cap. Lubricate t he g rease fit t ing on each wheel hub w ith an NG LI grade no. 2 multipur pose g un grease, unt il grease appears t hr oug h outer bearing . Reinstall hub caps and wheels. e) Replace 5- speed g earbox grease yearly. Use 18 oz. of Peer less g r[...]

- 25 - 5.1.21 M obil HTS gr ease (or f ood- g rade antisieze) is used in the f ollowing locations: a) Between the cutt er housing spindle and bearing s. b) Between the cutt er housing spindle and sheave. c) Under top cutter housing bear ing guard. 5.1.22 Dielectric gr ease is used on all blade type electrical connections to prevent corrosion and lo[...]

- 26 - FIGURE 13 A NTI-SCALP ROLLER BOLT INSTA LLA TION A NTI-SCALP ROLLER A ND CUTTING HEIG HT A DJUSTMENT c) Adjust anti-scalp roller s f or Norm al O per at ing Conditions. St op eng ine and wait for all m oving par ts to stop. Place r ollers in one of t he positions shown in Figure 13. Rollers will maintain 3/4 in. (19 mm) clearance to the grou[...]

- 27 - 5.2.4 Engine to Cut t er Deck Belt : No adjustment necessary . 5.2.5 Transm ission Belt Adj ustment : a) St op eng ine and wait for all m oving par t s to stop. Rem ove k ey or spar k plug wi re(s). b) T o tighten t r ansm ission belt , loosen t he 3/8” nyloc nut on transmission belt idler pulley. Slide bolt inward in slot and ret ighten n[...]

- 28 - FIGURE 15 DRIVE BELT TENSION A DJUSTMENT POSITIO NS 6. WA STE DISPOSAL 6.1 MOTOR OIL DISPOSA L Eng ine oil is a pollutant to t he environm ent . Dispose of used oil at a cer t ified recycling center or accor d ing to your state and local reg ulations. 7. TROUBLE SHOOTING 7.1 MOWER PULLING LEFT OR RIGHT. a) Check idler arm pulleys and drive s[...]

- 29 - f) Check that t he spark plug wire(s) ar e properly connected. g) Check f or loose or f ault y wiring connections. I f it is necessary to disconnect wire connectors, Do Not pull on the wires while disconnecting. h) Check f or corrosion at all wiring connect ions. Even minor cor r osion may cause a fault y connection. Clean connect or termina[...]

- 30 - 8. WIRING DIA GRAM – 15 HP KA W A SA KI[...]

- 31 - 9. 2-Ye ar Limited Warran ty Exmark Tu rf Equipment (For units pur chased on or af ter October 1, 2004) Conditions and Products Covered Exmark M fg. Co. Inc. and its affiliate, Exmark W arranty Company, pursuant to an agreement betw een them, jointly warrant on the terms and conditions herein, that w e will repair, replace or adjust any part[...]

- 32 - NOTES[...]

- 33 - SERVICE RECORD Date Descripti on of Work Done Service Done By[...]

- 34 - 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 VE RT ICAL SURFACE (TREE, BUIL DIN G, FENCE POST , PO L E ET C. ) EXAMPLE: COMP ARE SLOPE WITH FOLDED EDGE. FOLD ALONG AP PROPRIA TE LINE T H I S I S A 2 0 ° S L O P E[...]

® M FG . CO. IN C. SEE EXMA RK’S COMPLETE LINE OF A CCESSORIES RIDING A CCESSORIES CUSTOM RIDE SEAT SUSPENSION SYSTEM DECK LIFT ASSIST KIT HITCH KIT LI GHT K IT MICRO-MULCH SY ST EM ROLL OVER PROTECT ION SYSTEM (ROPS) SNOW BLADE SUN SHADE TRASH CONT AINER TURF STRIPER ULTRA VAC COLLECT ION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WA LK BEHIND A CC[...]