For Serial Nos. 440,000 & Higher Part No.
WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards, and safety devices (especially the grass discharge system) in place and in proper working condition. ♦ Stop engine and wait for all moving parts to stop. Remove spark plug wire(s) or remove key before adjusting, servicing, or performing maintenance.
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 .............................................................................................PAGE 1.1 Safety Alert Symbol........................................................................................ 1 1.2 Training .......................................................................................................... 1 1.3 Preparation.................................................................................................. 1-3 1.4 Operation ..................
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 to unsafe actions or situations and will be followed by the word DANGER, WARNING, or CAUTION. DANGER: White lettering/Red background.
1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones, and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, which is an odorless deadly poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you. 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. 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.
WARNING POTENTIAL HAZARD ♦ Operating engine parts, especially the muffler, become extremely hot. WHAT CAN HAPPEN ♦ Severe burns can occur on contact. ♦ Debris, such as leaves, grass, brush, etc. can catch fire. HOW TO AVOID THE HAZARD ♦ Allow engine parts, especially the muffler, to cool before touching. ♦ Remove accumulated debris from muffler and engine area. ♦ Install and maintain in working order a spark arrester before using equipment on forest-covered, grass-covered, or brush-covered unimproved land.
• See inside the back cover to determine the approximate slope angle of the area to be mowed. • Progressively greater care is needed as the slope increases. • Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope. • Be aware that loss of traction may occur going downhill. Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering.
1.4.17 Do Not mow with the grass deflector raised, removed or altered unless there is a grass collection system or mulch kit in place and working properly. 1.4.18 Be aware of the mower discharge and direct discharge away from others. 1.4.19 Do NOT operate the mower under the influence of alcohol or drugs. 1.4.20 Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. 1.5 MAINTENANCE AND STORAGE 1.5.
PART NO. 1-303508 LOCATION: Front of Mower Deck, Top Surface PART NO. 1-303517 LOCATION: LH Side of Rear Surface of Mower Deck PART NO. 1-303518 LOCATION: Transmission Shifter Plate PART NO. 1-403005 LOCATION: RH & LH Corners of Mower Deck PART NO. 1-403143 LOCATION: RH Side of Rear Surface of Engine Deck PART NO. 1-413206 LOCATION: Top of Cutter Deck, Under Center Belt Shield (36”) PART NO. 1-413327 LOCATION: Top of Cutter Deck, Under Belt Shield (48” & 52” Decks) PART NO.
PART NO. 1-553049 LOCATION: Front of Mower Deck Top Surface PART NO. 103-1798 LOCATION: RH Side of Console PART NO. 103-1077 LOCATION: On Top LH Side of Mower Deck PART NO. 103-2244 LOCATION: LH Side of Console PART NO. 103-2245 LOCATION: RH Side of Console PART NO. 103-1623 LOCATION: Console PART NO.
2. SPECIFICATIONS 2.1 MODEL NUMBER: MHP3615KAC; MHP4815KAC 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 or higher. In countries using the research method, it should be a 90 octane minimum. 2.3.3 Fuel Filter: Replaceable in-line 2.3.4 Fuel Shut-Off Valve: 1/4 turn 2.
2.10 DIMENSIONS 2.10.1 Overall Width: Discharge chute down Discharge chute up (Transport only) 2.10.2 Overall Length: 2.10.3 Curb Weight: 36” 46.25” (117.5 cm) 36.1” (91.7 cm) 36” 77.0” (196 cm) 48” 73.0” (185 cm) 36” 517 lbs. (234 kg) 48” 565 lbs. (256 kg) 48” 58.25” (148.0 cm) 48.1” (122.2 cm) ∗ Weights will vary slightly depending on engine option. 2.10.4 Overall Height: 36” 44.1” (112 cm) 48” 44.1” (112 cm) 2.10.5 Tread Width (to outside of tires): 36” 35.2” (89.4 cm) 48” 35.2” (89.
3.8 3.9 FIGURE 1 UPPER HANDLE MOUNTING Route the throttle cable along the right side of the upper handle, through the clip, under the fuel tank support, and position the cable on the left side of the engine. Attach throttle cable to engine: a) Position the throttle control lever (located on console) ¼” (6mm) from the upper end of the slot. b) Attach inner wire of the throttle cable to the top hole in the throttle control lever as shown in Figure 2.
3.10 Install and adjust shifter lever. a) Remove the 3/8” nyloc nut and spring disc washer from the stud on top of the transmission. Install the shifter lever through slot in shifter lever plate and onto the stud on top of transmission. Be sure the square-hole washer remains between the lever and transmission. Replace the spring disc washer and nyloc nut (see figure 4). Torque the 3/8” nut to 35ft-lbs. (47N.M). b) Shift lever to second gear and check alignment of lever in slot of shifter plate.
b) The bend in the drive lever linkages should be positioned downward and slightly outward. If adjustment is needed, loosen jam nut below balljoint and rotate linkage. Tighten jam nut. Shift transmission lever to fifth gear. Insure that bend in right hand linkage is rotated outward enough that linkage clears shifter lever. If linkage is rotated too far out, ball joint may bind when drive lever is released into the “drive” position. Insure that this does not happen.
3.12 Route the long unattached wiring harness lead, up the left hand side of the handle and connect the connector on the end of the shorter lead to the key switch. Connect the two flag terminals that are on the longer lead (in any order) to the operator presence control switch terminals underneath the control console.
FIGURE 9 NEUTRAL LOCK/PARK BRAKE LATCH 4.1.5 4.1.6 4.1.7 4.1.8 4.1.9 PTO Engagement: Located on the left side of the upper handle. To engage the blades, push the lever forward, or away from the operator, until the linkage locks over-center. To disengage the blades, pull the lever to the rear, or towards the operator. Choke Control: Choke is used to aid in starting a cold engine.
Do not add oil to gasoline. 4.2.3 Do not overfill fuel tank. Never fill the fuel tank so that the fuel level rises above a level that is 1/2” (1.3 cm) below the bottom of the filler neck to allow for fuel expansion and prevent fuel spillage. Make sure you understand the controls, their locations, their functions and their safety requirements. 4.3 OPERATING INSTRUCTIONS 4.3.1 Refer to Engine Owner’s Manual for detailed operating instructions regarding the engine. 4.3.
(a) (b) (c) (d) FIGURE 10 DRIVE LEVER, NEUTRAL LOCK/PARK BRAKE LATCH OPERATION 4.3.5 Drive Wheel Engagement and Turning: With drive levers in “neutral” or “park brake” position, shift transmission into desired gear. Squeeze both drive levers and move both neutral lock/park brake latches from the “neutral” or “park brake” position to the “drive” position. For straight ahead motion: Smoothly release both drive levers to engage drive wheels.
DANGER POTENTIAL HAZARD ♦ An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with the blade could occur. WHAT CAN HAPPEN ♦ Thrown objects or blade contact can cause serious injury or death. HOW TO AVOID THE HAZARD ♦ Never operate the mower with the discharge deflector raised, removed, or altered unless there is a grass collection system or mulch kit in place and working properly.
5. MAINTENANCE & ADJUSTMENTS WARNING POTENTIAL HAZARD ♦ While maintenance or adjustments are being made, someone could start the engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD ♦ Remove the key from the ignition switch and/or pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).
CAUTION POTENTIAL HAZARD ♦ Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury. HOW TO AVOID THE HAZARD ♦ DO NOT rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support. a) Disengage PTO. b) Stop engine and wait for all moving parts to stop.
5.1.4 FIGURE 11 BLADE BOLT INSTALLATION Check safety interlock system. Service Interval: Daily a) For your safety, your Exmark mower is equipped with Operator Presence Controls (OPC). When either the PTO is engaged, or the transmission shift lever is not in neutral and both hands are removed from the handles, the mower engine MUST stop. b) Check OPC circuits. Clear the area.
a) Stop engine and wait for all moving parts to stop. Remove key or spark plug wire(s). b) Drain oil while engine is warm from operation. c) The oil drain valve is located on left hand side of engine. Place pan under machine to catch oil and turn valve counter clockwise with a 10 mm wrench to open valve. Allow oil to drain, then turn valve clockwise to close. 5.1.9 d) Replace the oil filter as per Engine Owner's Manual. Clean around oil filter and unscrew filter to remove.
b) Remove deck support belt shield to check mower deck drive belt condition. c) Look under engine deck to check the transmission drive and clutching belt condition. d) Inspect wheel drive belt conditions e) Check all idler arms to be sure they pivot freely. Disassemble, clean and grease pivot bushings if necessary. 5.1.12 Inspect PTO Clutching Belt Tension. Service Interval: Check every 2 hrs. for first 8 hrs. operation then check every 40 hrs. thereafter.
d) Lubricate drive wheel hubs once a year. First remove wheel, then remove hub cap. Lubricate the grease fitting on each wheel hub with an NGLI grade no. 2 multipurpose gun grease, until grease appears through outer bearing. Reinstall hub caps and wheels. e) Replace 5-speed gearbox grease yearly. Use 18 oz. of Peerless grease (Part No. 788067). See Section 5.1.9. 5.1.14 Check spark plugs. Service Interval: 160 hrs. a) Remove spark plugs, check condition and adjust plug gap or replace with new plugs.
5.1.20 Mobil HTS grease (or food-grade antisieze) is used in the following locations: a) Between the cutter housing spindle and bearings. b) Between the cutter housing spindle and sheave. c) Under top cutter housing bearing guard. 5.1.21 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact. 5.2 ADJUSTMENTS 5.2.1 Cutting height and anti-scalp roller adjustment.
FIGURE 13 ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT c) Adjust anti-scalp rollers for Normal Operating Conditions. Stop engine and wait for all moving parts to stop. Place rollers in one of the positions shown in Figure 13. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize gouging and roller wear or damage. For Maximum Deck Flotation, place rollers one hole position lower. Rollers should maintain 1/4 in. (6.4 mm) minimum clearance to ground.
5.2.4 Engine to Cutter Deck Belt: No adjustment necessary. 5.2.5 5.2.6 Transmission Belt Adjustment: a) Stop engine and wait for all moving parts to stop. Remove key or spark plug wire(s). 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” (12 mm) of deflection with three pounds (13.
FIGURE 15 DRIVE BELT TENSION ADJUSTMENT POSITIONS 6. WASTE DISPOSAL 6.1 MOTOR OIL DISPOSAL Engine oil is a pollutant to the environment. Dispose of used oil at a certified recycling center or according to your state and local regulations. 7. TROUBLE SHOOTING 7.1 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 5.2.6. b) Check to be sure idler arms pivot freely, if not lubricate idler pivots.
f) Check that the spark plug wire(s) are properly connected. g) Check for loose or faulty wiring connections. If it is necessary to disconnect wire connectors, Do Not pull on the wires while disconnecting. h) Check for corrosion at all wiring connections. Even minor corrosion may cause a faulty connection. Clean connector terminals thoroughly with electrical contact cleaner, apply dielectric grease and reconnect.
8.
9. Limited Warranty Exmark Turf Equipment Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part manufactured by Exmark and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship. This warranty applies to Exmark turf equipment sold in the US or Canada.
NOTES - 32 -
SERVICE RECORD Date Description of Work Done Service Done By - 33 -
ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) S THI S IS THIS I A2 0 ° S LOP E 10° SL OP E A 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 LAZER Z® XP LAZER Z® CT TURF RANGER® VIKING HYDRO TURF TRACER® TURF TRACER® HP METRO® METRO® HP ULTRA VAC™ ULTRA VAC™ QDS GRASS CATCHER SELF STEERING SULKY MICRO-MULCH ™ ACCESSORY WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. ©1997 – 2003 EXMARK MFG. CO. INC.
