Exmark VH3615KA Operator'S Manual Download Page 12

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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 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

2.4 SAFETY INTERLOCK SYSTEM

Operator must have transmission in neutral and blade clutch disengaged to start
engine. Release of OPC levers will cause the engine to stop if

hydro transmission is

not in neutral

and/or

blade clutch is engaged

2.5 STEERING/BRAKE CONTROL:

Fingertip drive control levers provide independent speed control, braking and neutral
to each drive wheel for moving forward or reverse, stopping and power turning.

2.6 TRANSMISSION:

Twin Hydrostatic Drive

2.6.1

Two Hydro Gear BDP-10L series variable displacement pumps independently
coupled to two high efficiency Parker/Ross wheel drive motors.

PART NO. 403005
LOCATION: Front Corners of
Mower Deck

PART NO. 303508
LOCATION: On Top Rear Right Hand
Surface of Mower Deck

PART NO. 513746
LOCATION: On Engine Blower
Housing Next to Muffler

PART NO. 303102
LOCATION: Upper
Handle

PART NO. 303293
LOCATION: On Top Right
Side of Fuel Tank

PART NO. 513890
LOCATION: On Top of
Hydraulic Tank

Summary of Contents for VH3615KA

Page 1: ......

Page 2: ...justing servicing or performing maintenance If mower deck becomes clogged stop engine and remove spark plug wire s or remove key and wait for all moving parts to stop before cleaning blockage Keep hands feet and clothing away from power driven parts Keep off mower unless seat platform is provided Keep others off mower WARNING POTENTIAL HAZARD Gasoline is harmful or fatal if swallowed Long term exp...

Page 3: ...ubmitting the Exmark Parts Plus order to Exmark by 3 00 p m central time the Distributor pays for the part and freight 3 Exmark being unable to ship the part and the Exmark parts order is received by 3 00 p m central time Exmark pays for the part and freight 4 If the part does not arrive overnight due to the shipper UPS the shipper pays for the freight and Exmark pays for the part The following re...

Page 4: ...wer maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact your authorized Exmark equipment dealer or distributor All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service st...

Page 5: ...8 2 8 Tires 8 2 9 Deck 8 2 10 Dimensions 8 2 11 Torque Requirements 9 3 ASSEMBLY INSTRUCTIONS 3 1 to 3 23 Assembly 9 11 4 OPERATION INSTRUCTIONS 4 1 Controls 12 13 4 2 Pre Start 13 14 4 3 Operation Instructions 14 17 4 4 Transporting 17 5 MAINTENANCE ADJUSTMENTS 5 1 Periodic Maintenance 18 24 5 2 Adjustments 24 32 6 TROUBLE SHOOTING 6 1 Mower Tacks Left or Right 32 6 2 Mower Cuts Unevenly 32 6 3 B...

Page 6: ...URY IF PROPER PRECAUTIONS ARE NOT TAKEN 1 2 TRAINING 1 2 1 Regard the Exmark mower as a piece of power equipment and teach this regard to all who operate this unit 1 2 2 Read the instructions carefully Familiarize yourself with the controls and the proper use of the equipment 1 2 3 Never allow children teenagers or people unfamiliar with these instructions to use the mower 1 2 4 Avoid mowing while...

Page 7: ...O AVOID THE HAZARD DO NOT smoke while refueling and stay away from an open flame or where gasoline fumes may be ignited by spark Refuel only in a well ventilated area or refuel outdoors Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is ho...

Page 8: ...pon the awareness concern prudence and proper training of the personnel involved in the operation transport maintenance and storage of the equipment It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing 1 4 1 Give complete undivided attention to the job at hand 1 4 2 Mow only in daylight or good artificial light Do Not operate the mower...

Page 9: ...gine return the throttle control to the idle position for 30 seconds to allow the engine to cool down 1 4 14 The fuel system is provided with a shut off valve The fuel shut off valve is used to shut off the fuel when The machine will not be used for a few days During transport to and from the job When parking inside a building 1 4 15 This mower was designed for one operator only Keep all others aw...

Page 10: ...uid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Safely relieve all pressure in the hydraulic system before performing any work on the hydraulic system 1 6 RIDING ATT...

Page 11: ...ON Left Side of Rear Surface on Engine Deck PART NO 403143 LOCATION Right Side of Rear Surface on Engine Deck PART NO 413214 LOCATION Right Side of Hydro Control Crank Arm PART NO 603845 LOCATION Rear Center of Top Surface of Engine Deck PART NO 403170 LOCATION 48 Deck PART NO 323427 LOCATION 36 Deck ...

Page 12: ... engine to stop if hydro transmission is not in neutral and or blade clutch is engaged 2 5 STEERING BRAKE CONTROL Fingertip drive control levers provide independent speed control braking and neutral to each drive wheel for moving forward or reverse stopping and power turning 2 6 TRANSMISSION Twin Hydrostatic Drive 2 6 1 Two Hydro Gear BDP 10L series variable displacement pumps independently couple...

Page 13: ...in 16 25 in 41 3 cm Qty 3 2 9 4 Type of Drive Manual engagement of belt with over center lock Belt tension is adjustable via turnbuckle 2 9 5 Blade Brake When the blade engagement control is move to the disengaged position a friction brake pad stops the rotation of the blades 2 9 6 Deck Mounting Bolted directly to the engine deck 2 9 7 Cutting Height Adjusts in 1 4 63 cm increments from 1 2 5 cm t...

Page 14: ...ds going through the slots in the support Install two 5 16 x 3 4 screws with a 5 16 SAE flatwasher and 5 16 lockwasher into the threaded holes in the right side of the fuel tank Do not over tighten Place a 5 16 SAE flatwasher then a spring over each of the studs and fasten with a 5 16 nyloc nut Tighten the 5 16 nylock nut fully than back off a 1 2 turn This is to allow for normal fuel expansion an...

Page 15: ...is not a STOP position The engine will continue to run when the throttle control is moved past the rear detent Turn the ignition switch to the off position to stop the engine e Secure fuel line to throttle control cable with a small wire tie from the bolt bag approximately 2 ahead of filter to keep fuel line away from hydraulic lines to prevent vapor lock 3 11 Install the blade engagement linkage ...

Page 16: ...h terminals underneath 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 3 17 The unit is shipped with the muffler installed onto the engine exhaust manifold but rotated rearward to fit the crate Loosen the clamp rotate...

Page 17: ...right hand drive wheel respectively to slow down stop or reverse depending on how far each drive lever is squeezed Squeezing the drive levers beyond the neutral position causes the drive wheels to engage in the reverse direction regardless of the position of the neutral lock latches and the speed control lever 4 1 4 Neutral Lock Latch Located directly above the drive levers These latches allow the...

Page 18: ...arting of the unit in cold weather or when the unit has not been operated for a period of time The cold start kit moves the idler pulley away from the pump belt releasing the tension on the belt which allows the engine to turn over with less resistance See Section 4 3 2 4 1 11 Tracking Adjustment Knob Located on the right hand side of the rear of the fuel tank support Can be adjusted so that machi...

Page 19: ...rpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle ...

Page 20: ... chain On a cold engine place the throttle in the full forward Choke position Turn the key switch to the Run position Pull recoil rope to start engine With a cold engine gradually return choke to the full throttle position after the engine starts and warms up NOTE Kawasaki engines generally need to be choked even when warm NOTE It is helpful to have the left and right neutral lock latches applied ...

Page 21: ...on smoothly release both drive levers to engage drive wheels Squeeze the right hand drive lever to turn right and the left hand drive lever to turn left To make a zero turn squeeze either the left hand or the right hand drive lever back into the reverse position while the opposite drive lever is in a forward position at an equal but opposite speed To back up squeeze both drive levers into the reve...

Page 22: ...ecurely fasten the machine to the trailer with straps chains cables or ropes Use a safety chain and be sure that the trailer has all necessary lighting and marking as required by law 5 MAINTENANCE ADJUSTMENTS WARNING POTENTIAL HAZARD If you leave the key in the ignition switch someone could start the engine WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or other bysta...

Page 23: ... under deck and check mower blades Service Interval Daily 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 misfunction allowing the unit to fall which could cause injury HOW TO AVOID THE HAZARD DO NOT rely solely on mechanic...

Page 24: ...clutch and releaseOPC levers engine MUST stop c If machine does not pass any of these tests DO NOT operate Contact your authorized EXMARK SERVICE DEALER IMPORTANT It is essential that all Operator Safety Mechanisms be connected and in proper operating condition prior to the use of the mower 5 1 5 Check for loose hardware Service Interval Daily a Stop engine and remove spark plug wire s b Visually ...

Page 25: ...octor familiar with this form of injury or gangrene may result HOW TO AVOID THE HAZARD Make sure all hydraulic fluid hoses and lines are in good condition an all hydraulic connections and fittings are tight before applying pressure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Safel...

Page 26: ...c components including oil filter are removed or any of the hydraulic lines are disconnected The critical area for purging air from the hydraulic system is between the oil reservoir and each charge pump located on the top of each variable displacement pump See Figure 7 Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is primed a Stop engine Ra...

Page 27: ...s 22 psi b Inflate tires to pressures stated above Measure circumference of each drive tire Adjust tire pressures within above range to try to make the circumferences match as closely as possible NOTE Front caster tires have permanent tire sealant installed 5 1 12 Inspect Belt wear Service Interval 40 hrs a Stop engine and remove spark plug wire s b Remove cutter deck belt shield to check mower pr...

Page 28: ...ng c Make sure cooling shrouds are properly reinstalled Operating the engine without cooling shrouds will cause engine damage due to overheating 5 1 16 Change fuel filter Service Interval As Required a A fuel filter is installed in the fuel line between the fuel tank and the engine Replace when necessary 5 1 17 Refer to Engine Operators Manual for detailed maintenance regarding the engine 5 1 18 W...

Page 29: ...or ease of removal of the pulley b Between the cutter housing spindles and the sheaves 5 1 21 Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact 5 2 ADJUSTMENTS WARNING POTENTIAL HAZARD If you leave the key in the ignition switch someone could start the engine WHAT CAN HAPPEN Accidental starting of the engine could seriously injure you or ot...

Page 30: ...on See Section 5 2 2 below 5 2 2 Axle height and caster spacer position Desired cutting height range can be obtained by adjusting the rear axle and placing caster spacers above or below the caster arm See Figure 8 To adjust rear axle a Stop engine and remove spark plug wire s b Raise the rear of the machine up onto jack stands and remove the drive wheels CAUTION POTENTIAL HAZARD Raising the mower ...

Page 31: ...1 1 1 7 8 2 1 8 2 3 8 2 5 8 2 7 8 C 2 0 2 1 8 2 3 8 2 5 8 2 7 8 3 1 8 C 2 1 2 1 4 2 1 2 2 3 4 3 3 1 4 C 3 0 2 1 2 2 3 4 3 3 1 4 3 1 2 D 2 1 2 3 8 2 5 8 2 7 8 3 1 8 3 3 8 D 3 0 2 1 2 2 3 4 3 3 1 4 3 1 2 D 3 1 2 3 4 3 3 1 4 3 1 2 3 3 4 D 4 0 3 3 1 4 3 1 2 3 3 4 4 E 3 1 2 7 8 3 1 8 3 3 8 3 5 8 3 7 8 E 4 0 3 1 8 3 3 8 3 5 8 3 7 8 4 1 8 E 4 1 3 1 4 3 1 2 3 3 4 4 4 1 4 IMPORTANT To achieve the highest q...

Page 32: ...tter Deck Belt a Stop engine and remove spark plug wire s b Check belt guides under rear engine and front mower deck to see that they are properly set See Section 5 2 6 c Belt must be tight enough so it does not slip during heavy loads while cutting grass Over tensioning will reduce belt and spindle bearing life To adjust belt tension loosen the 5 16 whizlock nut on turnbuckle and rotate the turn ...

Page 33: ...ng mounting bolts to properly align the pad on the sheave See Figure 11 d Check the distance between the spacer and the nut at the end of the blade brake rod The distance should be between 1 8 and 3 16 See figure 11 e Engage the blade control and check to make sure the blade brake pad clears the sheave FIG 11 BLADE BRAKE ADJUSTMENT 5 2 7 Belt Guide Adjustment a Stop engine and remove spark plug wi...

Page 34: ...peed control lever back to neutral Check that the neutral safety switch actuating tab has depressed the plunger of the switch so that there is about 5 16 between the tab and the switch See fig 14 If necessary move the switch fore and aft FIG 14 NEUTRAL SAFETY SWITCH ADJUSTMENT b Adjust Neutral Control Linkages 1 Raise the rear of the machine up onto jack stands high enough to raise the drive wheel...

Page 35: ...stment procedure 6 Make this adjustment on both sides 7 After adjustments are made and the wheels stop when the drive levers are in the neutral position tighten the nuts against the yokes c Adjust Hydro Control Linkages 1 Place the speed control lever in the neutral position This adjustment is again made with rear of machine on jack stands and engine running at full throttle OPC levers will have t...

Page 36: ...djustment 1 With rear of machine still on jack stands and engine running at full throttle move the speed control lever to the midway position Move the respective drive lever upward until it reaches the neutral position and engage neutral lock latches See fig 17 If the tire rotates in either direction the length of the drive lever link will need to be adjusted 2 Adjust the linkage length by releasi...

Page 37: ...h the mower needs to be adjusted Turn the knob in 1 4 turn increments until the mower tracks correctly 6 2 MOWER CUTS UNEVENLY a Check the drive tire pressures and circumferences See 5 1 11 A more uniform cutting height may be obtained with higher tire pressure on rough terrain A lower tire pressure provides more flotation b Check blade spacers they must be equal on each blade c Check caster mount...

Page 38: ...e 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 The following table lists some of the common causes of trouble Do not attempt to service or replace major items or any items that call for special timing or adjustment procedures such as valves governor etc Have this work done by your Engine Se...

Page 39: ... 34 8 WIRING DIAGRAM ...

Page 40: ... 35 9 HYDRAULIC DIAGRAM ...

Page 41: ...t back to the owner after repair or replacement will be paid for by the owner Exmark s responsibility in respect to claims is limited to making the required repairs or replacements and no claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower Proof of purchase may be required by the dealer to substantiate any warranty claim All warrant...

Page 42: ...loss or damage to person or property other than that covered by the terms of this warranty vii any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty or viii attorney s fees There are no representations or warranties which have been authorized and provided to the buyer of the turf equipment other than as set forth in this warranty Any and all statem...

Page 43: ...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 COMPARE SLOPE WITH FOLDED EDGE FOLD ALONG APPROPRIATE LINE T H I S I S A 2 0 S L O P E ...

Page 44: ...GER 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 INDUSTRIAL PARK BOX 808 FAX 402 223 5489 BEATRICE NE 68310 ALL RIGHTS RESERVED PRINTED IN U S A ...

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