Exmark Vh3615ka, Vh4815ka - Manuals

Page 2 - IMPORTANT; WARNING

ii 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 When the mower is used or operated on any California forest, brush or grass covered land, a workingspark arrester must be attached...

Page 3 - EXMARK PARTS PLUS

iii EXMARK PARTS PLUS     PROGRAM EFFECTIVE DATE: September 1, 1995 Program If your Exmark dealer does not have the Exmark part in stock,Exmark will get the parts to the dealer the next business day or thepart will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in st...

Page 4 - CONGRATULATIONS; instructions for your Exmark mower.; BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS; contact your authorized Exmark equipment dealer or distributor.

iv CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years oftrouble-free operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment and safety instruct...

Page 6 - SAFETY; SAFETY ALERT SYMBOL; YOUR SAFETY IS INVOLVED!

- 1 - 1. SAFETY 1.1 SAFETY ALERT SYMBOL THIS SAFETY ALERT SYMBOL IS USED BOTH IN THIS MANUAL AND ON THE MACHINE TO IDENTIFY IMPORTANT SAFETY MESSAGES WHICH MUST BE FOLLOWED TO AVOID ACCIDENTS. THIS SYMBOL MEANS: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol appears above ...

Page 7 - DO NOT

- 2 - WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you and is also known to the State of California to cause birth defects. HOW TO AVOID THE HAZARD ♦ Do not run engine indoors or in a small confined...

Page 8 - DANGER; Do Not; EXTREME

- 3 - DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline vapors. A fire or explosion from gasoline can burn you, others, andcause property damage. HOW TO AVOID THE HAZARD ♦ Purchase and store gas...

Page 9 - MAINTENANCE AND STORAGE

- 4 - 1.4.5 Stop the blades when crossing surfaces other than grass; and whentransporting the mower to and from the area to be mowed. 1.4.6 Never operate the mower with defective guards, shields, or covers. Alwayshave safety shields, guards, switches, and other devices in place and in properworking ...

Page 10 - RIDING ATTACHMENTS; Exmark

- 5 - 1.5.5 Keep the mower and fuel container in locked storage to prevent children from playing or tampering 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 lights or heat appliances arepresent. 1.5.7 Maximum m...

Page 12 - SAFETY INTERLOCK SYSTEM; hydro transmission is

- 7 - 2. SPECIFICATIONS 2.1 MODEL NUMBER: Serial Nos. 220,000 & Higher: VH3615KA; VH4815KA 2.2 ENGINE 2.2.1 Engine Specifications: 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 gasoline, 87 octane ...

Page 13 - Discharge chute down; Weights will vary slightly depending on engine option.

- 8 - 2.6.2 Hydraulic Filter is replaceable cartridge type.P/N 513211: 10 microns, 18 psi bypass (Summer use above 32 ° F) P/N 523541: 40 microns, 18 psi bypass (Winter use below 32 ° F) 2.6.3 Speed Range: Forward 0 - 6.2 mph (10.0 km/h) Reverse 0 - 2.2 mph (3.5 km/h) 2.7 WHEEL DRIVE SYSTEM: Drive w...

Page 14 - TORQUE REQUIREMENTS; BOLT LOCATION; ASSEMBLY INSTRUCTIONS; Remove the bolt bag from the top of the fuel tank support.; UPPER HANDLE MOUNTING; tank support, and position the cable on the

- 9 - 2.11 TORQUE REQUIREMENTS BOLT LOCATION TORQUE Blade/Cutter Housing Spindle Bolt ................................. 75-80 ft-lbs.Caster Bracket Mounts .................................................. 30-35 ft-lbs.Cutter Deck/Engine Deck Mount .................................... 30-35 ft-lbs.E...

Page 15 - do not; 5 HP KAWASAKI SPEED CONTROL; choke adjusting screw just contacts the choke lever; NOTE: For 15 HP Kawasaki engines; There is not a “STOP” position.; HYDRO CONTROL LINKAGE SWIVEL & DRIVE LINKAGE SWIVEL

- 10 - b) Loosen clamp on engine control plate (See Figure 2). Attach inner wire of the throttle cable to the control plate lever and position cable under cableclamp, do not tighten clamp. FIG 2 15 HP KAWASAKI SPEED CONTROL (THROTTLE CABLE HOOK-UP) c) Pull the cable to the right when facing the cont...

Page 16 - DRIVE LINKAGE TO DRIVE LEVER

- 11 - 3.13 Install the speed control rod assembly (linkage with the yoke installed on one end) into the end of the speed control lever located underneath the center of theconsole. Insert the end of the linkage (opposite the yoke) into the end of the speedcontrol lever from the right hand side and f...

Page 17 - OPERATION INSTRUCTIONS; assembly directly above the handle grips.; DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION

- 12 - 4. OPERATION INSTRUCTIONS 4.1 Controls 4.1.1 Operator Presence Control (OPC) Levers: Located on the upper handle assembly directly above the handle grips. When these levers are depressed, the OPC system senses that the operator is in the normal operator'sposition. When the levers are released...

Page 19 - unleaded; OPERATING INSTRUCTIONS; blade drive disengaged

- 14 - 4.2.1 Fill fuel tank. For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher. Regular grade leaded gasolinemay also be used; however, combustion chamber and cylinder head willrequire more frequent service. See Engine Owner's Manual. Do not ...

Page 20 - SLOWLY

- 15 - WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you and is also known to the State of California to cause birth defects. HOW TO AVOID THE HAZARD ♦ Do not run engine indoors or in a small confine...

Page 21 - CAUTION; Slowly

- 16 - CAUTION POTENTIAL HAZARD ♦ If the neutral lock latches are not completely engaged the drive levers could unexpectedly slip into the forward driveposition. WHAT CAN HAPPEN ♦ If the drive levers slip into the drive position, the unit could lurch forward and cause injury or property damage. HOW ...

Page 23 - PERIODIC MAINTENANCE; See Engine Owner's Manual; mark or over the “F” mark.

- 18 - 5.1 PERIODIC MAINTENANCE 5.1.1 Check engine oil level. Service Interval: See Engine Owner's Manual a) Make sure engine is stopped and on a level surface. b) Check with engine cool. c) Clean area around dipstick. Remove dipstick and wipe oil off. Reinsertthe dipstick ( DO NOT screw into place)...

Page 25 - Do not; After First 250 hrs, then yearly thereafter.

- 20 - d) Remove the oil drain plug from the right hand side of the engine. Allow oilto drain, then replace drain plug. e) Replace the oil filter as per Engine Owner's Manual. Clean around oilfilter and unscrew filter to remove. Before reinstalling new filter, apply athin coating of oil on the surfa...

Page 26 - Changing; Hydraulic system air purge procedure.; CHARGE PUMP LOCATION

- 21 - e) Loosen filter 1/2 turn and allow a small amount of oil to leak from the oilfilter (this allows air to be purged from the oil filter and supply hose fromthe hydraulic reservoir). Turn filter clockwise until rubber seal contacts thefilter adapter. Then tighten the filter an additional 2/3 to...

Page 27 - Retighten capscrews; NOTE: Front caster tires have permanent tire sealant installed.; GREASE LUBRICATION CHART

- 22 - e) To “prime” charge pump, loosen two hex socket head capscrews (shownin Figure 7) 1-1/2 turns only. Make sure engine is not running. Lift charge pump housing upward and wait for a steady flow of oil to flow outfrom under housing. Retighten capscrews . Do this for both pumps. Note: Hydraulic ...

Page 28 - SPRAY LUBRICANT CHART; PIVOT POINT; antisieze

- 23 - No. 4 Idler Pivot (Pump Drive)Located Under Engine Deck No. 4 & 6 (Idler Pivots)Disassemble and grease once amonth under a “No Load” condition. c) Lubricate pivot points with a spray penetrating lubricant as directedbelow. SPRAY LUBRICANT CHART PIVOT POINT NO. OF PLACES 36” 48” SERVICE IN...

Page 29 - Care must be used not to bond the bearing, next to each OPC

- 24 - c) OPC lever setscrews. d) Shoulder bolts in ends of speed control crank. e) Between the fuel tank studs and the fuel tanks. f) Between the shifter lever and the knob. Adhesives such as “Loctite RC/609 or RC/680” or “Fel-Pro Pro-Lock RetainingI or Retaining II” are used on the following: a) O...

Page 30 - top

- 25 - 5.2.1 Blade Spacers: Blades may be adjusted for cutting height by using the four 1/4" spacers foundon the blade spindle bolts (factory setting is two above and two below). Thisallows a 1" range in 1/4" increments of cutting height in any axle position. Thesame number of blade spac...

Page 31 - BELOW CASTER; NUMBER OF 1/4” BLADE SPACERS; BELOW SPINDLE

- 26 - FIG. 8 AXLE and CASTER HEIGHT ADJUSTMENT Refer to the following chart to properly adjust desired cutting height. CUTTING HEIGHT ADJUSTMENT (1" to 4 1/4") AXLE POSITION (FIG. 9) NO. OF SPACERS BELOW CASTER 1/2" 3/16" NUMBER OF 1/4” BLADE SPACERS BELOW SPINDLE 4 3 2 1 0 A 0 0 1&...

Page 32 - BLADE ENGAGEMENT LINKAGE; Be sure the bellcrank

- 27 - b) With blade drive engaged (lever pulled up, adjust the linkage length towhere the lower end of the bellcrank just clears the axle support gusset(See Figure 9). Make sure the assist arm is against the rear assist armstop on the deck (See Figure 10). Push the lever down to the disengagedposit...

Page 33 - CUTTER DECK BELT ADJUSTMENT; Blade Brake Adjustment:; BLADE BRAKE ADJUSTMENT; Belt Guide Adjustment:

- 28 - FIG. 10 CUTTER DECK BELT ADJUSTMENT e) Proper belt tension will require about 10 lbs. side pull on belt, halfwaybetween pulleys, to deflect belt 1/2”. (See Figure 10, Point A). 5.2.6 Blade Brake Adjustment: a) Stop engine and remove spark plug wire(s). b) Disengage the blades. c) Make sure th...

Page 34 - No adjustment necessary; NEUTRAL SAFETY SWITCH ADJUSTMENT

- 29 - Note: These drawings are viewed from underneath the engine deck FIG. 12 FIG. 13 36" BELT GUIDE LOCATION 48" BELT GUIDE LOCATION 5.2.8 Pump Drive Belt Tension Adjustment: No adjustment necessary . 5.2.9 Hydro Drive Linkage Adjustment: a) Adjust Speed Control Linkage and neutral safety ...

Page 36 - neutral; DRIVE LEVER AND LATCH IN NEUTRAL POSITION

- 31 - After adjusting the left hydro control linkage, move the speed controllever to the mid-speed position and then back to the neutral position.Recheck the left drive wheel rotation to see if further adjustment isnecessary - be sure the speed control lever is in the neutral position. If inconsist...

Page 37 - Turn the knob right to “steer” right, turn the knob left to “steer” left.; HYDRO PUMP SPRING TENSION SETTING; Check blade spacers, they must be equal on each blade.; NOTE: Kawasaki engines may need to be choked even when warm.

- 32 - 4. If the unit tracks to one side or the other, turn the quick track knob . Turn the knob right to “steer” right, turn the knob left to “steer” left. 5.2.10 Hydro Pump Spring Tension Setting: a) For medium or heavy duty drive conditions such as operation with a sulkyon steep slopes, a higher ...

Page 38 - ENGINE TROUBLESHOOTING; Engine Service Dealer.; ENGINE TROUBLESHOOTING TABLE; PROBLEM; MOWER DECK BELT ROUTING

- 33 - e) Check that there is fuel in the tank and that the fuel valve is open. f) Check that the spark plug wire(s) are properly connected. g) Check for loose or faulty wiring connections. If it is necessary todisconnect wire connectors, Do Not pull on the wires while disconnecting. h) Check for co...

Page 43 - IS

- 38 - T H IS IS A 1 5 ° S L O P E T H IS IS A 1 0 ° S L O P E T H IS IS A 5 ° S L O P E ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) EXAMPLE: CO MP A R E SLOPE WI T H FOLDED EDGE. FOLD AL ONG APP R OPRI A T E L INE T HI S IS A 2 0 ° S L O P E

Page 44 - INDUSTRIAL PARK BOX 808

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 STEERING SULKY GRASS CATCHER MICRO-MULCH ™ ACCESSORY ® MFG . CO. INC. ©1997,1998, 1999 PART NO. 850654 EXMARK MFG. CO. INC. (402) 223-6300 IND...