Exmark TT3615KAC manual

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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 con[...]

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 . T his product has been caref ully designed and m anufactur ed t o give you a maximum amount of dependabilit y and years of tr ouble- free oper at ion. OPERA TOR'S M ANUA L This manual cont ains assem bly, oper at ing , maintenance, adj ustment, and safety in structions for you r Exmar[...]

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 SAFET Y ALERT SYMBOL 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. This symbol means: A TTENTION! BECOME A LERT! YOUR SA FETY IS INVOLVED! The saf ety alert symbol appears above inform at ion, which alerts you to un[...]

- 2 - 1.3.4 Thoroug hly inspect t he ar ea where the equipment is t o be used and r em ove all stones, stick s, wires, bones and other f oreign object s which may damage t he 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 poiso[...]

- 3 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions gasoline is extremely f lamm able and highly explosive. W HAT CAN HAPPEN ♦ A static charg e can ignite g asoline vapors. A fire 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 conta[...]

- 4 - 1.4 OPERA TION Although hazard control and acci dent prevent ion are partiall y dependent upon t he design and configurat i on of t he equipment, these f act ors are al so dependent upon the awareness, concern, prudence and proper t r ai ni ng of t he personnel involved in the operation, t r ansport , mai nt enance and st orage of the equipme[...]

- 5 - 1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of tr act ion and/or contr ol could occur . Mow across slopes with walk behind mowers, never up and down. Loss of contr ol and/ or loss of operator ’s f ooting could r esult in a fall with an arm or leg g etting under t he m ower or eng ine deck and sustaining serious in[...]

- 6 - 1.4.17 Be aware of the m ower discharg e direction and do not point it at anyone. 1.4.18 Do NOT oper at e t he m ower under the influence of alcohol or drugs. 1.4.19 Use care when approaching blind corners, shr ubs, t rees, or other obj ects that may obscure vision. 1.4.20 If j um p starting is r equired: ( Elect r ic st ar t unit s only) a) [...]

- 7 - WA RNING POTENT IAL HAZARD ♦ Hydraulic fluid escaping under pr essur e can penet rate skin and cause injur y. W HAT CAN HAPPEN ♦ Fluid accidentally injected into t he skin must be surgically removed within a few hours by a doctor fam iliar with t his f orm of injury or g angrene may result . HOW TO AVO ID THE HAZARD ♦ Make sure all hydr[...]

- 8 - PART NO. 1- 303517 LOCATI ON: Left Side of Rear Surface of Engine Deck PART NO. 1- 403005 LOCATION: RH & LH Corners of Mower Deck PART NO. 1- 303508 LOCATIO N: Right Front of Mower Deck Top Surface PART NO. 1- 303293 LOCATIO N: On Top RH Side of Fuel T ank PART NO. 1- 513746 LOCAT ION: On Engine Blower Housing Next to Muf fler and On Cent[...]

- 9 - 36” Deck s PART NO. 1- 413206 LOCATIO N: Top of Cutter Deck Under Center Belt Shield PART NO. 103- 1798 LOCATION: RH Side Console Standard Pistol Gr ip Handles 15 & 17 HP Kawasaki Manual Start PART NO. 103- 1974 LOCATI ON: Console ECS Handles 17 HP Kawasaki Elec tric Start PART NO. 103- 1976 LOCATI ON: Console PART NO. 103- 2103 LOCAT I[...]

- 10 - 48” & 52” Deck s PART NO. 1- 413327 LOCATIO N: Top Center of Cutter Deck Under Center Belt Shield PART NO. 1- 323540 LOCATIO N: Front of Mower Deck Top Surf ace ECS Handles 15 & 17 HP Kawasaki Manual Start PART NO. 103- 1977 LOCATI ON: Console PART NO. 98- 5954 LOCATIO N: Under Mower Dec k Belt Shield(s) ECS Handles PART NO. 103-[...]

- 11 - 2. SPECIFICA TIONS 2.1 MODEL NUMBE R: Serial Nos. 320, 000 & Hi gher: TT 3615KA; T T4817KA; T T5217KA; T T 3615KAC; TT 4817KAC; T T5217KAC; T T4817KAEC; T T 5217KAEC 2.2 ENGINE 2.2.1 Engine Specif ications: See your Engine Owner's Manual. 2.2.2 3600 RPM (No Load). 2.3 FUEL SYSTEM 2.3.1 Capacity: 5.0 ga l. ( 18. 9 L.) 2.3.2 Type of F[...]

- 12 - 2.9 TIRES 36” Drive 48” & 52” Drive Front Caster Pneumatic (Air - Filled) Pneumatic (Air - Filled) Semi-Pneumat ic Size 16 x 6.50-8 16 x 7.50-8 9 x 3.50-4 Quantit y 2 2 2 Tread Turf Master Turf Master Smooth Ply Rating 4 4 Pressure 14 psi (97 kPa) 14 psi (97 kPa) 2.10 DECK 2.10.1 Cutting W idth: Model 36 in. .......................[...]

- 13 - 2.12 TORQUE REQUIREMENTS BOLT LO CATIO N TORQ UE Blade M ounting Bolt .................................................... 115-120 ft-lbs. Cutte r Hou sing S pindl e Nu t .............................................. 75-80 ft-lbs . Anti -Scal p Rolle r Bolts ...................................................... 4 0-45 ft-lbs. Mo we r Deck [...]

- 14 - CA UTION POTENT IAL HAZARD ♦ If t he ignition is in the “ O N” position there is pot ent ial for spar ks and engag ement of com ponent s. W HAT CAN HAPPEN ♦ Sparks could cause an explosion or m oving par t s could accidentally engage causing personal injury. HOW TO AVO ID THE HAZARD ♦ Be sure ignit ion switch is in the “ O FF” [...]

- 15 - 3.9 Route the thr ot t le cable along the right side of the upper handle, under t he f uel tank support, and posit ion t he cable on the left side of the eng ine. Attach thr o t t le cable t o eng ine: a) Position the throttle control l ever (located on console) ¼” (6mm) from the upper end of t he slot . b) Attach inner wire of t he throt[...]

- 16 - 3.12 Connect t he lower end of the speed contr ol link age to t he speed cont r ol crank located at the t op rear of t he f uel tank suppor t . Secure with clevis pin and hairpin fr om t he bolt bag. 3.13 I nst all dr ive lever linkages. For Standard Pistol G rip Handles: Ref er to f igures 4 and 5. Posit ion speed control lever in neutr al.[...]

- 17 - FIGURE 6 ECS HA NDLES DRIVE LEVER LINKAGE INSTA LLA TIO N 3.14 Connect wiring harness. For recoil start model s: Rout e the long unatt ached por t ion of the wiring harness up the lef t handle and under the console. Connect the connect or on the end of t he shorter lead t o t he keyswitch. Connect the two f lag terminals that ar e in the lon[...]

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

- 19 - 4.1.7 Throt t le Cont r ol: Located on the control console’s r ig ht side. The t hrottle is used to control eng ine speed. Moving the thr ottle control f orward will increase engine speed and moving it to t he r ear will decrease engine speed. 4.1.8 “O ff -Run” Switch (15 & 17 HP Kawasaki Manual St art onl y) : Located on the conso[...]

- 20 - DA NGER POTENT IAL HAZARD ♦ In certain condit ions g asoline is extremely flamm able and highly explosive. W HAT CAN HAPPEN ♦ A fire or explosion f rom gasoline can bur n you, ot her s, and cause property damag e. HOW TO AVO ID THE HAZARD ♦ DO NOT smok e while refueling , and st ay away from an open flame or where g asoline f umes may [...]

- 21 - 4.2.2 Refer t o Maintenance and Adjust ment Section 5 and perf orm all of the necessary inspection and maintenance steps. 4.2.3 Familiarize yourself with the cont r ols and oper at ion of unit. See Cont rols section 4.1 and Operat ing Instructions sect ion 4.3. 4 . 3 OPERA TING INSTRUCTIONS 4.3.1 Refer t o Engine Owner’s Manual for detaile[...]

- 22 - CA UTION POTENT IAL HAZARD ♦ If t he neut ral lock latc hes ar e not completely engaged t he drive levers could unexpectedly slip into the f or 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 TO AVO ID THE HAZARD ♦ Be su[...]

- 23 - 4.3.6 To Stop: Sq ueeze drive levers back to the neut r a l posit ion. Mov e neut r al lock latches into t he neut r al lock position and release dr ive lev ers. Move the speed control lever to t he neutral position. 4.3.7 PTO Eng agement: DA NGER POTENT IAL HAZARD ♦ The rot at ing blades under the mower deck are dangerous. W HAT CAN HAPPE[...]

- 24 - 5. MAINTENA NCE & A DJUSTMENTS 5.1 PERIODIC MA INTENA NCE WA RNING POTENT IAL HAZARD ♦ If you leave the k ey in the ig nition switch, 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 nition [...]

- 25 - 5.1.3 Clean grass build- up under deck and check mower blades. Serv ice Interv al: Daily 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 be enough support or m ay misf uncti[...]

- 26 - FIGURE 8 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 safet 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 is not in neut r al and bot h hands are removed fr om the handles, the mowe[...]

- 27 - 5.1.7 Change eng ine oil. Serv ice Interv al: See Engine Ow ner's Manual NOTE: Change oil aft er f i rst f i ve (5) hours of operation. Fol l ow engi ne manufacturer’s recommendati ons f or f ut ure oi l changes. a) Disengage blade clutch. b) Stop engine and wait for all moving parts t o st op. Remove ignition k ey or spark plug wire([...]

- 28 - 5.1.9 Change hydraulic system f ilter. Serv ice Interv al: A fter Fi rst 250 hrs, t hen yearly thereafter. Note: Use only Exmark Par t No. 513211 for Sum m er use above 32 ° F (0 ° C) or Part No. 523541 f or W inter use below 32 ° F (0 ° C). Ref er to 2. 7. 2 for f ilter specificat ions. a) Place unit on a level surf ace, st op engine an[...]

- 29 - d) Thoroughly clean the area ar ound each of the charg e pum p housings. FIGURE 9 CHA RG E PUM P LO CA TION e) To “prime” char g e pump, loosen two hex socket head capscrews (shown in Figure 11) 1- 1/ 2 turns only. Make sure engine is not running . Lif t charg e pump housing upward and wait for a st eady flow of oil to f low out from und[...]

- 30 - b) E ngage PTO l ever . c) Look thr ough the round hole in t he lef t rear cor ner of the engine deck to inspect blade clutching belt tension. Bolt on blade eng ag ement link ag e bellcrank and indicat o r ar m should align within 1/16” (See Fig ure 12). Ref er to section 5.2. 2 f or adjust m ent . 5.1.14 Lubricat ion Serv ice Interv al: R[...]

- 31 - a) Stop engine and wait for all moving parts t o st op. Remove ignition k ey or spark plug wire(s). b) Remove cooling shrouds fr om engine and clean cooling f ins. Also clean dust, dirt, and oil f rom external sur f aces of eng ine, which can cause improper cooling. c) Make sure cooling shrouds ar e pr operly reinstalled. Oper at ing the eng[...]

- 32 - Note: T o pr event dam ag e due to f r eezing, battery should be f ully charg ed before putting away for winter stor ag e. a) Check t he voltag e of the bat tery with a digital voltmet er . Locate the voltage reading of the batter y in the table below and charge the batt er y f or the recommended t im e int e r val to br ing the charge up t [...]

- 33 - FIGURE 10 CUTTING HEIGHT A DJUSTMENT FIGURE 11 A NTI-SCALP ROLLER BOLT INSTA LLA TION A NTI-SCALP ROLLER A ND CUTTING HEIG HT A DJUSTMENT c) Adjust ant i- scalp r o ller s For Normal Operat ing Conditions. Place rollers in one of t he posit ions shown in Figure 11. Rollers will maintain 3/ 4 in. (19 mm) clearance to the g round to minimize g[...]

- 34 - FIGURE 12 BLA DE ENGAGEMENT LINKA G E 5.2.3 PTO Saf ety Switch: Mounted to a tab on the inside lef thand side of t he f uel tank support. a) Stop engine and wait f or all moving part s to stop. Rem ove ig nit ion key or spark plug wire(s). b) W ith PTO diseng aged and the bellcrank touching t he r ear of t he slot in t he engine deck , adj u[...]

- 35 - 1. Raise the rear of the machine up onto j ack stands hig h enoug h to raise the drive wheels off of the g r ound. 2. Start t he engine and move the thr ot tle ahead to the f ull thrott le position. Place the neutral lock latches in the dr ive position as shown in Figure 7 and move the speed control lever to t he “mid-speed” posit ion. N[...]

- 36 - neutral, unt il left wheel stops rot at ing for ward. Turn the r ear nut an additional 1/2 tur n and t ig hten the f r ont nut mak ing sure not to put a bind on the linkag e. Make sure f lat part of linkage is per pendicular to pin part of swivel. See Figure 15. FIGURE 15 HYDRO CONTROL LI NK/ SWIVEL AD JUSTMENT Aft er adj usting the lef t hy[...]

- 37 - ST AN DA RD PIS TOL GRIP H A NDLES ECS HA NDLES FIGURE 16 DRIVE LEVER A ND LATCH IN NEUTRA L POSITION 3. Make this adjustm ent f or both sides. e) Tracking Adj ust ment 1. Stop engine and wait for all m oving par ts to stop. Raise t he rear of t he machine, rem ove jack stands and caref ully low er t he m achine to the ground. ( Check the dr[...]

- 38 - 6.2 BA TTERY DISP OSA L DA NGER POTENT IAL HAZARD ♦ Battery electr olyte cont ains sulf uric acid, which is poisonous and can cause severe burns W HAT CAN HAPPEN ♦ Swallow ing electrolyte can be f a t al or if it t ouches sk in can cause severe burns. HOW TO AVO ID THE HAZARD ♦ W ear saf ety glasses to shield eyes, and rubber g loves t[...]

- 39 - h) Check that the spar k plug wire(s) ar e pr operly connected. i) Check f or loose or f aulty wi ring connections. I f it is necessary to disconnect wire connectors, Do Not pull on the wires while disconnecting. j) Check f or corrosion at all wiring connect ions. Even minor cor r osion may cause a fault y connection. Clean connect or termin[...]

- 40 - 8. WIRING DIA GRA M S[...]

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

- 42 - 10. WA RRANTY Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg . Co. Inc. and it s aff iliate, Exmark W arrant y Company, pursuant to an agr eement between them, joint ly w ar r ant on t he terms and conditions her ein, t hat we w ill repair, r eplace or adjust any part m anuf actured by Exmark and f ound by us (in the exercise o[...]

- 43 - As a condition to this warrant y, cust om er shall have read t he oper at or's manual and shall have completed and ret ur ned to Exmark W arrant y Company, within the prescr ibed t ime, the Exmark wa rranty registrati on. The sole liability of Exmark and Exmark W arr ant y Company w it h r espect to this warranty shall be repair and rep[...]

- 44 - NOTES[...]

- 45 - SERVICE RECORD Date Description of Work Done Service Done By[...]

- 46 - 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 , POLE ETC. ) 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[...]

SEE EXMARK’S CO MPLETE LINE OF PRODUCTS FOR TURF CARE LA ZER Z ® LAZER Z ® HP LA ZER Z ® XP TURF RA NGER ® TURF TRA CER ® TURF TRA CER ® HP MET RO ® METR O ® HP VIKING HYDRO ULTRA VAC ™ GRA SS CA TCHER SELF STEERING SULKY MI CRO-MULCH ™ A CCESSORY WA RN ING The engine ex haust from this produc t contains chem icals known to the State [...]