Exmark MHP3615KA 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 Mow er. This product has been caref ully designed and manuf actured to g ive y ou a m aximum 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 ustment and saf ety instructions for your E xmar[...]

v TA BLE OF CONTENTS 1. SA FETY .............................................................................................PAGE 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 SA FETY A LERT SYMBO 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 HI CH MUST BE FOLLOWE D TO A VOID A CC IDENT S. THIS S YMBOL MEA NS : A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appears above inform at ion whi[...]

- 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 ive guar ds, shields, or covers. Alway s have safety shields, g uar ds, switches, and ot her devices in place and in proper working condit ion. 1.4.7 Do Not chang e[...]

- 5 - 1.5.5 Keep the mower and fuel cont ainer in lock ed storage t o prevent children fr 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 - 14 HP Kawasaki,Br iggs & Stratton, & 15HP Kohler – All Serial Nos. (Serial Nos. 150,000- 189,999: 17 HP Kawasaki PART NO. 323688 LOCATI ON: Console 14 HP Kawasaki & 15HP Kohler PART NO. 323689 LOCATIO N: RH Side of Console Serial Nos. 190,000 & Higher 15 & 17 HP Kawasak i PART NO. 323699 LOCATI ON: Console 15 & 17 HP[...]

- 7 - PART NO. 403143 LOCATIO N: RH Side of Rear Surfac e of Engine Deck PART NO. 303517 LOCATI ON: LH Side of Rear Surface of Mower Deck PART NO. 553049 LOCATIO N: Front of Mower Deck Top Surf ace PART NO. 513746 LOCAT ION: On Engine Blower Housing next to Muffler & on Center Belt Cover PART NO. 323540 LOCATIO N: Front of Mower Deck Top Surf a[...]

- 8 - 2. SPECIFICA TIONS 2.1 MODEL NUMBER: Serial Nos. 150,000 – 189,999: MHP4816BV; M HP5216BV Serial Nos. 150,000 – 219,999: MHP3614KA; M HP4814KA Serial Nos. 150,000 & Higher: M HP3615KC; MHP4815KC Serial Nos. 160,000 & Higher: M HP4817KA; MHP5217KA Serial Nos. 190,000 & Higher: M HP4815KA Serial Nos. 220,000 & Higher: M HP36[...]

- 9 - 2.7 WHEEL DRIVE SYSTEM: Banded double A-Section V-Belt s, single top side idlers and r eplaceable bolt - on drive sheaves and brake drums. 2.8 TIRES Drive Front Caster Siz e 16 x 6.5 0-8 ...... 9 x 3.50 -4 Quantity ............................. 2 ......................................... 2 Tread................ Turf Sav er/Turf Master .......[...]

- 10 - 2.11 TORQUE REQUIREMENTS BOLT LO CATION TORQ UE Blade M ounting Bolt ......................................................... 75-80 f t -lbs. Cutte r Hou sing S pindle Nut .............................................. 75-80 ft-lbs. Anti -Scalp Ro lle r Bolts ...................................................... 40-45 ft-lbs. Mo wer D eck [...]

- 11 - a) Position the thr ot tle control lever (on console) in t he f ull throt t le ( but not choke) posit ion. You will feel a detent when the throt tle lever is approximately 3/4” f rom the upper end of the slot ( t his is f ull throt t le position). b) Loosen clamp on engine cont r ol plat e (See Figures 2, 3 & 4) . Attach inner wire of [...]

- 12 - c) Pull cable upward (pull the cable to the r ig ht when facing t he cont rol plate on 15 & 17 HP Kawasaki units) unt il alig nment holes in control plat e lever and control plate line up. For Kawasaki 15/64” (6mm ) drill bit can be inserted thr oug h these two holes to align t hem . For Kohler use a 19/64” drill bit. Once t he holes[...]

- 13 - FIG 5 BLA DE ENGAGEMENT LINKA G E 3.10 Inst all and adjust shif t er lever. a) Remove the 3/8” nyloc nut and spring disc washer f rom the stud on t op of the transm ission. I nstall the shif t e r lever t hr oug h slot in shift er lever plate and onto the stud on t op of transmission. Be sur e t he sq uare-hole washer remains between the l[...]

- 14 - FIG. 8 THIS CLEA RANCE SHOULD BE EQUA L 3.11 Inst all and adj ust wheel driv e linkag es. a) Screw threaded end of dr ive linkages into swivels in wheel drive idler arms. b) Insert clevis pin f rom bolt bag t hr ough drive linkag e, lever and slot in the neutral lock / park brak e latches (See Figur e 9) . Make pr oper adj ustments befor e a[...]

- 15 - FIG. 11 DRIVE LEVER HA RDW A RE LOCAT I ON d) Adjust brak es by adjusting wingnut on upper end of each brake rod so that when brakes ar e eng aged there is appr oximately 1/4” of clearance between ends of drive levers and handle gr ips ( See Fig ure 10) Note: Adjust ment should allow the brakes t o be eng aged, yet allow the neutral lock /[...]

- 16 - The sharpness of the turn varies by how much the lever is squeezed. If bot h levers are squeezed all the way back, both br ak es will engage and the machine will stop. For straig ht ahead motion, sm oot hly release both drive levers to engag e bot h dr ive wheels simultaneously. 4.1.3 Neutral Lock/ Par k ing Brak e Latch: Located direct ly a[...]

- 17 - 4.1.7 “Of f-Run” Switch (B&S and 15 & 17 HP Kawasaki only) : Locat ed on the console (Serial No.s 190, 000 and hig her) or f ront, lef t corner of the fuel t ank support (Ser ial No. s 150, 000- 189,999). T ur n k ey to the “Run” position t o allow the engine t o be st ar ted. Turn k ey to the “Of f” posit ion to shut eng[...]

- 18 - 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 c[...]

- 19 - 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[...]

- 20 - CA UTION POTENT IAL HAZARD ♦ If t he nuet 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[...]

- 21 - 4.3.9 Changing G ear s W hen changing gears, al ways squeeze drive levers and/or engag e neutral lock latches or par k brak es. T he shift lever may be moved with a knee or by hand. NOTE: Reverse gear is reverse assist only , the operator must pull t he uni t backw ards. 4.3 TRA NSPORTING WA RNING POTENT IAL HAZARD ♦ Loading the m ower ont[...]

- 22 - WA RNING POTENT IAL HAZARD ♦ The engine can becom e very hot. W HAT CAN HAPPEN ♦ Touching a hot engine can cause severe burns. HOW T O AVOI D T HE HAZARD ♦ Allow the engine to cool complet ely bef ore service or making r epairs around the eng ine ar ea. 5.1.1 Check eng ine oil level. Serv ice Interv al: See Engine Ow ner's Manual [...]

- 23 - a) Disengage blade clutch. b) Stop engine and remove spark plug wire(s). c) Raise deck and block up using proper saf et y precaut ions. d) Clean out any grass build-up f r om underside of deck and in deck discharge chute. e) Inspect blades and sharpen or replace as r eq uired. f) If blade r em oval is necessary, be caref ul for t he sharp cu[...]

- 24 - 5.1.6 Check Brak e and W heel Drive Linkag e Adjustment Serv ice Interv al: Daily Refer t o Sect ion 3.11. Note any bent link ag e or hardware which may need servicing or replacing . 5.1.7 Service pre-cleaner element and air cleaner . Serv ice Interv al: See Engine Ow ner's Manual 5.1.8 Change engine oil. Serv ice Interv al: See Engine [...]

- 25 - 5.1.10 Check tire pressur es. Serv ice Interv al: 40 hrs. a) Stop engine and r em ove spark plug wire(s). Check air pressure in tires; recommended t ire pr essur e is: rear, 12 to 16 psi; pneum at ic casters, 22 psi. b) Inflat e t ir es t o pr essur es st at ed above. M easur e cir cum f erence of each drive tire. Adjust t ire pressures with[...]

- 26 - No. 5 (C lutch Arm Pi vot) Located Under Eng ine Deck No. 7 (T r ans. Coupler) Located Below Fuel Tank Suppor t No. 4 & 7 (Idler Arm Pivots) Disassemble and grease once a Month under a “No Load” condition c) Lubricat e pivot points with a spray penetrat ing lubricant as direct ed below. SPRA Y LUBRICANT CHA RT PIVOT POINT NO. OF PLAC[...]

- 27 - e) Lower Sheave retaining bolt on clutch ar m. Adhesives such as “Loctite RC/609 or RC/ 680” or“Fel-Pro Pro- Lock Retaining I or Retaining I I ” are used on the f ollowing: a) OPC lever hubs and cross-shaf t NOTE: Care must be used not to bond the bearing, next t o each OPC hub, to the cross shaf t w hich coul d cause bi nding of the[...]

- 28 - clearance to g r ound. Do Not adjust roller s t o suppor t the deck. Be sur e roller bolts and nut s ar e installed with the spring disc washer between head of bolt and m ount ing bracket . Torque to 40-45 ft-lbs. , or loss of roller may result . c) W hen oper at ing in extremely rough condit ions it may be necessary to position the anti- sc[...]

- 29 - b) Be sure mud and gr ass scr aper, on each side, is adjust ed pr oper ly and centered in the pulley gr ooves. T he pointed part of the scraper should be centered and as deep in the pulley gr oove as possible w ithout r ubbing at any point. 5.2.7 Br ak e Adjustment : See 3.11 5.2.8 W heel drive linkag e adjustment : See 3.11 5.2.9 Shif ter l[...]

- 30 - 5.2.12 Adjust Thrott le Lever Tension (B&S Engines only): a) Stop engine and r em ove spark plug. b) Tension in thr ot t le levers can be incr eased or decr eased by adjust ing the tightness of the lever pivot bolt which is located under the console. 6. TROUBLE SHOOTING 6.1 MOWER PULLING LEFT OR RIGHT. a) Check idler ar m pulleys and dri[...]

- 31 - ENGINE TROUBLESHOOTING W hen a problem occur s, do not overlook t he sim ple causes. For example, starting pr oblem s could be caused by an empty fuel tank. The f ollowi ng table list s som e of the common causes of trouble. Do not attem pt to service or replace maj or it ems or any items that call f or special timing or adj ust ment procedu[...]

- 32 - 7. WIRING DIA GRAM[...]

- 33 -[...]

- 34 - 8. WA RRANTY Limited W arranty Exmark Com mercial Turf Equipment Exmark Mfg. Co. Inc. ("Exmark") warrants on the terms and conditions herein, t hat it will repair, replace or adjust any part manufactured by Exmark and f ound by Exmark(in the exercise of its reasonable discretion)to be defectiv e in factory material or workmanship. [...]

- 35 - The sole liability of Exmar k wit h r espect to this warrant y shall be repair and replacement as set fort h herein. Exmark shall have no liabilit y for any other cost , loss or damage, including but not limited to, any incidental or consequent ial loss or damage. In particular, Exmark shall have no liabilit y or responsibility for : ( i) ex[...]

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

- 37 - NOTES[...]

- 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 T HIS EDGE WI TH A VERT ICAL SURF ACE (TREE, BUILDING, FE NCE POST , POLE ET C.) EXAMPLE: COMP ARE SLOPE WITH FOLDED EDGE. FOLD ALON G APPROPRIA TE LINE T H I 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 ® MF G . C O. I N C . ©1997,1998, 1999 PART N O. 850662 EXMARK MFG. CO. INC. (402) 223-6300 INDUSTRIAL PA RK BOX 808 FAX[...]