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 working spark arrester must be attached to the muffler. If not, the operator is violating state law, Section 442 Public Resource Code. To acquire a spark arrester for your unit, see your Engine Service Dealer.
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 the part will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in stock for a "down" unit at the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus shipment of six (6) line items or less. 2.
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 of trouble-free operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment and safety instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
TABLE OF CONTENTS 1. SAFETY 1.1 1.2 1.3 1.4 1.5 1.6 1.7 PAGE Safety Alert Symbol ............................................................................... 1 Training ................................................................................................. 1 Preparation......................................................................................... 1-3 Operation ........................................................................................... 3-4 Maintenance & Storage .....
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 information which alerts you of unsafe actions or situations and will be followed by the word DANGER, WARNING, or CAUTION.
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 area where dangerous carbon monoxide fumes can collect. DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive.
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, and cause property damage. HOW TO AVOID THE HAZARD ♦ Purchase and store gasoline only in an approved container. ♦ Always place gasoline containers on the ground away from your vehicle before filling.
is responsible for safe operation on slopes. See inside back cover to determine the approximate slope angle of the area to be mowed. 1.4.5 Stop the blades when crossing surfaces other than grass, if mower must be tilted for transportation, and when transporting the mower to and from the area to be mowed. 1.4.6 Never operate the mower with defective guards, shields, or covers. Always have safety shields, guards, switches, and other devices in place and in proper working condition. 1.4.
1.5.4 Store fuel in a container specifically designed for this purpose. Store the fuel container in a cool, dry place. 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 are present. 1.5.
KOHLER, 13 HP KAW, & 10.5 B&S PART NO. 323688 LOCATION: Console 15 & 17 HP KAW PART NO. 323699 LOCATION: Console PART NO. 403143 LOCATION: Right Rear of Engine Deck 15 & 17 hp KAW PART NO. 323691 LOCATION: RH Side of Console 12.5 HP KAW, KOHLER & 10.5 HP B&S PART NO.
PART NO. 323427 LOCATION: 32” & 36” Decks PART NO. 403170 LOCATION: 48” Decks PART NO. 303518 LOCATION: Transmission Shifter Plate PART NO. 303508 LOCATION: Right Rear Corner of Deck 2. SPECIFICATIONS 2.1 MODEL NUMBER: Serial Nos. 220,000 & Higher M3211B; M3213KA; M3613KA; M3613KC; M3615KA; M4815KC; M4815KA; M4817KA 2.2 ENGINE 2.2.1 Engine Specifications: See your engine owner's manual. 2.2.2 RPM (No Load): 3600 rpm 2.3 FUEL SYSTEM 2.3.1 Capacity: 5 gal. (18.9 liter) 2.3.
2.6.2 Speed range: 1st 2.0 mph (3.22 km/h) 2nd 2.7 mph (4.35 km/h) 3rd 3.5 mph (5.63 km/h) 4th 4.1 mph (6.60 km/h) 5th 6.2 mph (9.98 km/h) Rev 3.1 mph (4.99 km/h) 2.7 WHEEL DRIVE SYSTEM Banded double A-Section V-belts, single top-side idlers and replaceable bolt-on drive sheaves and brake drums. (Single B-Section V-belts for the 32" Model) 2.8 TIRES Drive Tires Size Qty. Tread Ply 4 Pressure Bearings 36” & 48” Models 13 x 6.
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. Engine Mounting Bolts 15 & 17 HP Kawasaki & Briggs & Stratton..........15-20 ft-lbs. Kohler & 12.5 HP Kawasaki................................25-30 ft-lbs. Transmission Shifter Lever ...........................
IMPORTANT: If the mower has been completely assembled and the handle position is changed, it will be necessary to readjust the drive and brake linkage. FIG. 2 UPPER HANDLE HEIGHT ADJUSTMENT 3.8.1 Attach throttle cable to engine. For Kohler, Kawasaki, and B&S 10.5 hp Engines with "positive" detents in throttle cable for both idle and full throttle positions. a) Position the throttle control lever (on console) in the full throttle (but not choke) position.
FIG 4 12.5 HP KAWASAKI SPEED CONTROL (THROTTLE CABLE HOOK-UP) FIG 5 B&S 10.5 HP SPEED CONTROL (THROTTLE CABLE HOOK-UP) Choke Link Control Plate Lever Control Alignment Holes Clamp Choke Adjusting Control Cable FIG 6 15 & 17 HP KAWASAKI SPEED CONTROL (THROTTLE CABLE HOOK-UP) d) Pull cable upward for 12.5 HP Kawasaki and Kohler units (rearward for B&S or to the right when facing the control plate on the 15 & 17 HP Kawasaki units) until alignment holes in control plate lever and control plate line up.
e) Check that the choke adjusting screw just comes in contact with the choke lever when throttle control is in the full throttle position. (B&S 10.5 hp does not have a choke adjusting screw.) Choke link should not move when throttle control is moved to the full throttle position. Be sure choke is fully closed when throttle lever is moved fully forward to the "CHOKE" position. f) This step needs to be done after the unit has been assembled and the engine has been started.
FIG. 8 THIS CLEARANCE SHOULD BE EQUAL FIG. 7 SHIFTER LEVER TO TRANSMISSION FIG. 9 THIS CLEARANCE SHOULD BE EQUAL 3.8.5 Install and adjust wheel drive linkages. a) Screw threaded end of drive linkages into swivels in wheel drive idler arms. b) Insert clevis pin from bolt bag through drive linkage, lever and slot in the neutral lock/park brake latches (See Figure 10). Make proper adjustments before adding hairpins. Neutral Lock/Park Brake Clevis Pin Drive Linkage Drive Lever FIG.
3/16” TO 1/4” Neutral Lock / Park Brake Latch Drive Linkage FIG. 11 NEUTRAL LOCK LEVER CLEARANCE NOTE: Neutral lock/park brake latch clearance should be checked when there is a slight upward force placed on the drive levers to remove any "slack" in the linkage. After clevis pin has been inserted, install hairpin into hole on the clevis pin between the neutral lock/park brake latch and drive lever (See Figure 12). Repeat procedure on opposite side of unit.
3.8.8 3.9 Route the long, unattached wiring harness lead up the left hand side of the handle and connect the two leads, in any order, to the operator presence control switch terminals on the inside of the control console. Fasten the lead to the handle with two large wire ties, from bolt bag, one at the upper end of the handle next to the console and one at the very lower end of the handle where it attaches to the fuel tank support.
Rotate Forward for Park Brake Position Rotate Back for Neutral Lock Position Latch is in the drive position Park Brake Full Speed Forward Neutral Lock NETURAL – Hold in this position FORWARD – Release Drive Lever REVERSE – Squeeze Drive Lever FIG. 13 DRIVE LEVER, NEUTRAL LOCK/PARK BRAKE LATCH OPERATION 4.1.4 Operator Presence Control (OPC) Levers: Located on the upper handle assembly directly above the handle grips.
4.1.8 Transmission Shift Lever: Located under the control console and behind the fuel tank. It shifts the 5-speed transmission into five forward gears, neutral and reverse. Shift transmission only when drive levers are in the neutral position. Shifting without drive levers in neutral may cause damage to the transmission. NOTE: Reverse is "reverse assist" only, meaning when the transmission is in reverse, the operator has to pull the unit backward to "assist" with the movement of the unit. 4.1.
Do not add oil to gasoline. Do not overfill fuel tank. Never fill the fuel tank so that the fuel level rises above a level that is ½” below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage. 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, and cause property damage.
4.3 OPERATING INSTRUCTIONS 4.3.1 Read the Engine Owner's Manual carefully for detailed operating instructions and maintenance regarding the engine. Before attempting to operate the unit, refer to Section 1 (Safety) and follow all safety, operating, and preparation guidelines as stated in that section. 4.3.2 Starting Engine Position mower on a level surface. Disengage blade drive and place transmission in neutral. Open fuel shut-off valve.
4.3.4 Drive Lever/Neutral Lock/Park Brake Latch Operation: To lock the drive levers in “neutral” squeeze the drive levers back to the neutral position. Place thumbs on the upper portion of the neutral lock/park brake latches and move them to the rear. Release drive levers (See Figure 13). To lock the levers in “park brake”, squeeze the drive levers back to the brake position. Place thumbs on the upper portion of the neutral lock/park brake latches and move them to the front.
4.4 TRANSPORTING WARNING POTENTIAL HAZARD ♦ Loading the mower onto a trailer without strong enough or properly supported ramps could be dangerous. WHAT CAN HAPPEN ♦ The ramps could collapse causing the unit to fall, which could cause injury. HOW TO AVOID THE HAZARD ♦ Use proper ramps that are secured to the truck or trailer. ♦ Keep feet and legs out from under the unit when loading and unloading. ♦ If necessary, use assistance when loading. Be sure fuel shut-off valve is closed.
WARNING POTENTIAL HAZARD ♦ The engine can become very hot. WHAT CAN HAPPEN ♦ Touching a hot engine can cause severe burns. HOW TO AVOID THE HAZARD ♦ Allow the engine to cool completely before service or making repairs around the engine area. 5.1.1 Check engine oil level. Service Interval: See Engine Owner's Manual a) b) c) Make sure engine is stopped and on a level surface. Check with engine cold. Clean area around dipstick. Remove dip stick and wipe off oil.
a) b) c) d) Disengage blades. Stop engine and remove spark plug wire(s). Raise deck, support properly using safety precautions. Clean out any grass build-up from underside of deck and in deck discharge chute. e) Inspect blades and sharpen or replace as required. f) If blade removal is necessary, be careful for the sharp cutting edges of the blades. g) Re-install the blades (if they were removed) and torque blade bolts to 75-80 ft/lbs.
5.1.6 5.1.7 5.1.8 Check for loose hardware. Service Interval: Daily a) Stop engine and remove spark plug wire(s). b) Visually inspect machine for any loose hardware or any other possible problem. Tighten or replace any hardware before operating. Service pre-cleaner element and air cleaner. Service Interval: See Engine Owners Manual a) Stop engine and remove spark plug wire(s). b) See engine owners manual for cleaning instructions. Change engine oil.
f) 5.1.11 Check for side play caused by bearing wear on the input and output shafts of the transmission. Replace bearings if necessary. g) Remove the six bolts that fasten the upper case to the lower case and carefully remove the upper case half. h) Check the grease level in the lower case. The grease level should be approximately 1-1/2" to 1-3/4" from the gearbox bottom. If necessary, fill to proper level with Peerless grease (Part No. 788067).
c) Replace 5-speed gearbox grease yearly. Use 18 oz. Of Peerless grease (Part No. 788067). See Section 5.1.10. d) Lubricate pivot points with a spray penetrating lubricant as directed below. SPRAY LUBRICANT CHART PIVOT POINTS 1. Blade Engagement Bellcrank 5.1.13 NO. of PLACES 32" 36" 48" 1 1 1 SERVICE INTERVAL Weekly Remove engine shrouds and clean cooling fins. Service Interval: See Engine Owner's Manual a) Stop engine and remove spark plug wire(s). 5.1.14 5.1.
5.1.20 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact. 5.2 ADJUSTMENTS 5.2.1 Adjusting cutting height with blade spacers. Blades may be adjusted for cutting height by using the four 1/4" spacers found on the blade spindle bolts (factory setting is two above and two below). This allows a 1" range in 1/4" increments of cutting height in any axle position.
Axle Pivot Bolt Place Jack Here Axle Adjustment Holes Pos. A Pos. B Pos. C Pos. D Pos. E Axle Adjustment Holes are actually in the side of the rear deck. FIG. 15 CASTER HEIGHT ADJUSTMENT FIG. 16 AXLE HEIGHT ADJUSTMENT These models have five (5) axle positions; four (4) 1/2" caster spacers; one (1) 3/16" caster spacer, and four (4) blade spacers. NOTE: The axle positions are in 1/2" increments and the large caster spacers are 1/2" thick.
b) To tighten transmission belt, loosen the 3/8" nyloc nut on transmission belt idler pulley. Slide bolt inward in slot and retighten nyloc nut. c) When properly adjusted, the belt should have 1/2" of deflection with three pounds of pressure on the belt midway between the transmission and engine pulley. 5.2.4 Wheel drive belts and scrapers. a) If wheel traction appears to be slipping, drive lever rods may be touching bottom of neutral lock/park brake latch slot. To adjust, refer to Section 3.8.5.
e) Check belt guide under the engine deck to see that it is properly set. (See Section 5.2.7). Also check the blade brake adjustment. (See Section 5.2.6) 5.2.6 Blade Brake Adjustment: a) Stop engine and remove spark plug wire(s). b) Disengage blades. c) Make sure the blade brake pad rests against the sheave. Adjust the spring mounting bolts to properly align the pad on the sheave. See Figure 18. d) Check the distance between the spacer and the nut at the end of the blade brake rod.
5.2.11 Shifter detent adjustment - Transmission shifter detent can be adjusted by adjusting the setscrew on the back side of transmission located just behind the neutralstart switch. Turn setscrew in (clockwise) to hold the transmission shifter more positively in each gear and to increase the force on the lever required to shift gears. Turn setscrew out (counterclockwise) to decrease force on lever required to shift gears. Factory setting is to turn setscrew all the way in then back out 1-1/2 turns.
5.2.15 Adjust throttle lever tension (B&S Engines only). a) Stop engine. b) Tension in throttle levers can be increased or decreased by adjusting 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 arm pulleys and drive sheaves for mud and/or grass buildup. Check for proper scraper position. See 5.2.4. b) Check to be sure idler arms pivot freely, if not, lubricate idler pivots. c) Check for worn drive belts.
NOTE: After carefully checking the previous steps, attempt to start the engine. If it does not start, contact your authorized Exmark service dealer. ENGINE TROUBLESHOOTING When a problem occurs, do not overlook the simple causes. For example, starting problems could be caused by an empty fuel tank, key switch not "ON" etc. The following tables list some common causes of troubles.
8.
9. WARRANTY Limited Warranty Exmark Commercial Turf Equipment Exmark Mfg. Co. Inc. ("Exmark") warrants on the terms and conditions herein, that it will repair, replace or adjust any part manufactured by Exmark and found by Exmark(in the exercise of its reasonable discretion)to be defective in factory material or workmanship.
As a condition to this warranty, customer shall have read the operator's manual and shall have returned to Exmark, within the prescribed time, the enclosed warranty registration card. The sole liability of Exmark with respect to this warranty shall be repair and replacement as set forth herein. Exmark shall have no liability for any other cost, loss or damage, including but not limited to, any incidental or consequential loss or damage.
SERVICE RECORD Date Description of Work Done - 37 - Service Done By
ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) THI S IS THIS I A2 0 ° SLO PE 10° SL OPE SA 1 5 ° SL OPE THIS IS A THIS IS A 5° SLOPE FOLD ALONG APPROPRIATE LINE EXAMPLE: COMPARE SLOPE WITH FOLDED EDGE.
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 ©1997,1998, 1999 EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 BEATRICE, NE 68310 ALL RIGHTS RESERVED PART NO. 850651 Rev B. (402) 223-6300 FAX (402) 223-5489 PRINTED IN U.S.A. ® M F G . C O . IN C .
