TURFTRACER®HP
ForSerialNos.
790,000&Higher
PartNo.4500-358Rev.A
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.
Important:Whenthemowerisusedoroperated
onanyCaliforniaforest,brushorgrasscovered
land,aworkingsparkarrestermustbeattached
tothemufer.Ifnot,theoperatorisviolating
statelaw,Section4442PublicResourceCode.To
acquireasparkarresterforyourunit,seeyour
EngineServiceDealer.
ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada
TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.
KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2008—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
2
Contactusatwww.Exmark.com.
PrintedintheUSA
AllRightsReserved
Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3
Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.....................10
Specications.......................................................14
ModelNumbers............................................14
Systems.........................................................14
Dimensions...................................................15
TorqueRequirements....................................16
ProductOverview................................................16
Operation.............................................................17
Controls........................................................17
Pre-Start........................................................19
OperatingInstructions..................................19
Transporting.................................................23
Maintenance.........................................................24
RecommendedMaintenanceSchedule(s)...........24
PeriodicMaintenance.......................................25
CheckEngineOilLevel.................................25
CheckBatteryCharge(ElectricStartUnits
Only).........................................................25
CheckMowerBlades.....................................25
CheckSafetyInterlockSystem.......................27
CheckforLooseHardware............................27
ServicePre-CleanerElementandAir
Cleaner......................................................27
ChangeEngineOil........................................28
CheckHydraulicOilLevel.............................28
CheckTirePressures.....................................28
CheckConditionOfBelts..............................28
LubricateGreaseFittings...............................28
CheckSparkPlugs.........................................29
ChangeHydraulicSystemFilter.....................29
WheelHub-SlottedNutTorque
Specication..............................................31
InspectPTOClutchingBeltTension..............31
ThreadLockingAdhesives.............................31
MobilHTSGrease(OrFood-Grade
Anti-seize).................................................32
Copper-BasedAnti-seize...............................32
DielectricGrease...........................................32
Adjustments.....................................................32
DeckLeveling...............................................32
PumpDriveBeltTension...............................32
PTOClutchingBeltTension..........................32
MowerDeckDriveBeltTension....................32
ParkBrakeAdjustment..................................32
HydroDriveLinkageAdjustment..................32
HydroPumpSpringTensionSetting..............35
PTOSafetySwitch........................................35
Cleaning...........................................................36
CleanEngineandExhaustSystem
Area..........................................................36
RemoveEngineShroudsandCleanCooling
Fins...........................................................36
CleanDebrisFromMachine..........................36
CleanGrassBuild-UpUnderDeck................36
WasteDisposal..............................................36
Troubleshooting...................................................38
Schematics...........................................................40
4
Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.
CAUTION
Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.
Wearhearingprotectionwhenoperatingthis
machine.
•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
5
Safety
DANGER
Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.
•Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anygasolinethatspills.
•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.
•DoNotllthefueltankcompletely
full.Addgasolinetothefueltankuntil
thelevelis1/4to1/2inch(6–13mm)
belowthebottomofthellerneck.This
emptyspaceinthetankallowsgasoline
toexpand.
•Neversmokewhenhandlinggasoline,
andstayawayfromanopenameor
wheregasolinefumesmaybeignitedby
spark.
•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.
•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.
•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
DANGER
Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.
•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.
•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.
•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.
•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.
•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.
WARNING
Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgas
tank/containeropening.
•Keepawayfromeyesandskin.
•Neversiphonbymouth.
•Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
6
Safety
Operation
WARNING
Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,
tocoolbeforetouching.
•Removeaccumulateddebrisfrommufer
andenginearea.
•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.
DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.
•Neverraisedeckwithbladesrunning.
•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.
•DoNotchangetheenginegovernorsettingor
overspeedtheengine.
•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:
–Beforerefueling.
–Beforedumpingthegrasscatcher.
–Beforemakingheightadjustments.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.
•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
•DONOToperatethemowerwhenpeople,
especiallychildren,orpetsareinthearea.
•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.
•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
7
Safety
DANGER
Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Lossof
controland/orlossofoperator’sfooting
couldresultinafallwithanarmorleg
gettingunderthemowerorenginedeck
whichmayresultinseriousinjury,deathor
drowning.
•Mowacrossslopes,neverupanddown.
•DoNotmowslopeswhengrassiswet.
•DoNotmowneardrop-offsornearwater.
•DoNotmowslopesgreaterthan20
degrees.
•Reducespeedanduseextremecaution
onslopes.
•Avoidsuddenturnsorrapidspeed
changes.
•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.
•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.
•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.
MaintenanceandStorage
•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.
•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.
•Letenginecoolbeforestoringanddonotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.
•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.
•Keephandsandfeetawayfrommovingparts.
Ifpossible,donotmakeadjustmentswiththe
enginerunning.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.
8
Safety
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.
•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.
•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.
•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.
9
Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
1-303508
1-303517
1-403005
1-403143
1-413206
36inchDecksOnly
1-413214
10
Safety
1-413327
48inchand52inchDecksOnly
1-413421
1-513747
19HPKawasakiElectricStartOnly
1-553049
98-5954
103-1798
103-1976
19HPKawasakiElectricStart
11
Safety
103-1977
15HPand17HPKawasakiManualStart
103-2076
103-2103
103-2242
103-2243
103-4935
12
Safety
109-3148
116-0404
13
Specications
Specications
ModelNumbers
SerialNos:790,000andHigher
ManualStartModels:THP15KA363;THP17KA483;THP17KA523;THP17KA363CA;THP17KA483CA
ElectricStartModels:THP19KAE483;THP19KAE523;THP19KAE483CA
Systems
Engine
•EngineSpecications:SeeyourEngineOwner’s
Manual
•RPM:FullSpeed:3600±50RPM(NoLoad)
FuelSystem
•Capacity:5.0gal.(18.9L)
•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher.
•FuelFilter:ReplaceableIn-line
•FuelShut-OffValve:1/4turnincrements
ElectricalSystem(ElectricStart)
•ChargingSystem:FlywheelAlternator
•ChargingCapacity:15amps
•BatteryType:BCIGroupU1
•BatteryVoltage:12Volt
•Polarity:NegativeGround
•Fuses:Two20ampbladetype
SafetyInterlockSystem
•Operatormusthavespeedcontrolleverinneutral,
PTOdisengaged,(andOPCleversdepressedfor
electricstart)tostartengine.ReleaseofOPC
leverswillcausetheenginetostopifspeedcontrol
leverisnotinneutraland/orPTOisengaged.
•Parkbrakemustbeengagedtomovespeed
controloutofneutralorenginewillkill.
OperatorControls
SteeringControl:Fingertipdrivecontrollevers
provideindependentspeedcontrol,brakingand
neutraltoeachdrivewheelformovingforwardor
reverse,stopping,andpowerturning.
Transmission
TwinHydrostaticDrive
•TwoHydroGearvariabledisplacementhigh
efciencypumpsindependentlycoupledtotwo
highefciencyParker/Rosswheeldrivemotors.
•HydraulicOil:UseExmarkPremiumHydroOil.
•HydraulicOilCapacity:2.4qt.(2.2L)
•HydraulicFilterisreplaceablecartridgetype.
P/N109-4180:25microns,10psibypass
(Summeruseabove32°F(0°C))
P/N1-523541:40microns,18psibypass(Winter
usebelow32°F(0°C))
•Speeds:
–0-6.2mph(10.0km/hr)forward.
–0-2.2mph(3.5km/hr)reverse.
•Drivewheelsreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
WheelDriveSystem
DrivewheelsaredirectcoupledtoParkerwheeldrive
motorswith1inch(25.4mm)taperedshaft.
14
Specications
Tires&Wheels
DriveFrontCaster
Pneumatic
(Air-Filled)
Pneumatic
(Air-Filled)
Semi-
Pneumatic
3648&52
AllDecks
Quantity
222
Tread
TurfMasterTurfMasterSmooth
Size16x6.50–816x7.50–89x3.50-4
PlyRating
44
Pressure
14psi
(97kPa)
14psi
(97kPa)
CuttingDeck
•CuttingWidth:
–36inchDeck:35.25inches(89.5cm)
–48inchDeck:47.25inches(120.0cm)
–52inchDeck:52.00inches(132.1cm)
•Discharge:Side
•BladeSize:
–36inchDeck:18.00inches(45.7cm)—
Quantity:2
–48inchDeck:16.25inches(41.3cm)—
Quantity:3
–52inchDeck:18.00inches(45.7cm)—
Quantity:3
•DeckDrive:Manualengagementofbeltwith
over-centerlock.Bladebelttensionisadjustable
viaturnbuckle.
•DeckMounting:Fulloatingdeckisattachedto
out-frontsupportframe,removableforservice.
•DeckDepth:
–36inchDeck:5.0inches(12.7cm)
–48inchDeck:5.0inches(12.7cm)
–52inchDeck:5.0inches(12.7cm)
•CuttingHeightAdjustment:
Adjustsfrom11/2inches(3.8cm)to41/2
inches(11.4cm)in1/2inch(1.3cm)increments
•MulchingKit:Optional
•Bagger:Optional
Dimensions
OverallWidth:
36inch
Deck
48inch
Deck
52inch
Deck
Deector
Up
36.1inches
(91.7cm)
48.1inches
(122.2cm)
53.0inches
(134.6cm)
Deector
Down
46.25inches
(117.5cm)
58.25inches
(148.0cm)
62.6inches
(159.0cm)
OverallLength:
36inchDeck48inchDeck52inchDeck
77.3inches
(196.3cm)
73.7inches
(187.2cm)
75.9inches
(192.8cm)
OverallHeight:
36inchDeck48inchDeck52inchDeck
44.1inches
(112.0cm)
44.1inches
(112.0cm)
44.1inches
(112.0cm)
TreadWidth:(OutsidetoOutsideof
Tires,Widthwise)
36inchDeck48inchDeck52inchDeck
35.0inches
(88.9cm)
39.4inches
(100.1cm)
39.4inches
(100.1cm)
CurbWeight:
36inchDeck48inchDeck52inchDeck
565lb(211kg)610lb(277kg)644lb(292kg)
Note:Weightswillvaryslightlydependingonengine
andelectricstartoptions.
15
ProductOverview
TorqueRequirements
BoltLocation
Torque
CutterHousingSpindle
Nut
140-145ft-lb
(190-197N-m)
BladeMountingBolt
(lubricatewithanti-seize)
55-60ft-lb(75-81N-m)
EngineDeck/Mower
DeckSupportMount
Bolts
30-35ft-lb(41-47N-m)
Anti-ScalpRollerNyloc
NutSeeFigure9
30-35ft-lb(41-47N-m)
Anti-ScalpRollerWhizlock
NutSeeFigure9
30-35ft-lb(41-47N-m)
EngineMountingBolts
15-20ft-lb(20-27N-m)
WheelLugNuts
90-95ft-lb(122-129N-m)
WheelHubSlottedNutsminimum100ft-lb
(136N-m)
WheelMotorMounting
Bolts
30-35ft-lb(41-47N-m)
ProductOverview
Figure3
1.ParkBrakeLever
3.FuelCap
2.Controls4.Height-of-CutPins
16
Operation
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
OperatorPresenceControl(OPC)
Levers
Locatedontheupperhandleassemblydirectlyabove
thehandlegrips.
Whentheseleversaredepressed,theOPCsystem
sensesthattheoperatorisinthenormaloperator’s
position.Whentheleversarereleased,theOPC
systemsensesthattheoperatorhasmovedfromthe
normaloperatingpositionandwillkilltheengineif
eitherthespeedcontrolleverisnotintheneutral
positionorthePTOisengaged.
Figure4
1.OPCLever
3.NeutralLockLatch
2.Rotateneutrallocklatch
downwardforneutral
lockposition
4.DriveLeverinneutral
position
DriveLevers
Locatedoneachsideoftheupperhandleassembly
aheadofandbelowthehandlegrips.
Theseleversindividuallycontrolthespeedand
directionofeachdrivewheel.Whenthespeedcontrol
leverismovedoutoftheneutralpositionandthe
neutrallocklatchesaremovedintothedriveposition,
asshowninFigure4,andthedriveleversarereleased,
thedrivewheelsareengagedintheforwarddirection.
Squeezingthelefthandand/orrighthandlever
causesthelefthandand/orrighthanddrivewheel
respectivelytoslowdown,stop,orreverse,depending
onhowfareachdriveleveris“squeezed”.Squeezing
thedriveleversbeyondtheneutralpositioncauses
thedrivewheelstoengageinthereversedirection
regardlessofthepositionoftheneutrallocklatches
andthespeedcontrollever.
NeutralLockLatches
Locatedontheupperhandleassemblyontheends
ofthehandlegrips.
Theselatchesallowtheoperatortolockthedrive
leversina“neutral”positionwherethedrivewheels
arenotengagedineitheraforwardorreverse
direction.
ChokeControl
Locatedonthefrontleftcornerofthefueltank
support.
Chokeisusedtoaidinstartingacoldengine.The
chokecontrolispulledouttobeinthe“ON”position
andpushedintobeinthe“OFF”position.DoNot
runawarmenginewithchokeinthe“ON”position.
ThrottleControl
Locatedontherightsideofthecontrolconsole.
Thethrottleisusedtocontrolenginespeed.Moving
thethrottlecontrolforwardwillincreaseengine
speedandmovingittotherearwilldecreaseengine
speed.Movingthethrottleforwardintothedetent
isfullposition.
SpeedControlLever
Locatedinmiddleofthecontrolconsole.
Thespeedcontrollevercontrolsthemaximum
forwardspeedandisinnitelyvariablefromneutral
0–6.2mph(10.0km/hr).
Parkbrakemustbedisengagedtomovespeedcontrol
outofneutralorenginewillkill.
17
Operation
ParkBrakeLever
Locatedontheleftsideoftheunitabovethe
hydraulictank.
Thebrakeleverengagestheparkbrakeonthedrive
wheels.
Pulltheleverupandrearwardtoengagethebrake.
Pushtheleverforwardanddowntodisengagethe
brake.
Whenparkingonasteepslope,thewheelsmustbe
chockedorblockedinadditiontothebrakebeing
engaged.Theunitmustbetieddownandbrake
engagedwhentransporting.
Theparkbrakemustbedisengagedtomovespeed
controloutofneutralorenginewillkill.
Formanualstartengines:Theparkbrakemustbe
disengagedbeforethePTOisengagedortheengine
willkill.
“Off-Run”Switch(ManualStartOnly)
Locatedontheconsole.
Turnkeytothe“Run”positiontoallowtheengine
tobestarted.Turnkeytothe“Off”positiontoshut
engineoff.
Operatormusthavespeedcontrolleverinneutral
andthePTOdisengagedtostartengine.
IgnitionSwitch(ElectricStartOnly)
Locatedonthecontrolconsole.
Theignitionswitchisusedtostartandstopthe
engine.Theignitionswitchhasthreepositions,
“Off”,“On”and“Start”.Insertkeyintoswitch
androtateclockwisetothe“On”position.Rotate
clockwisetothenextpositiontoengagethestarter
(keymustbeheldagainstspringpressureinthis
position).Operatormusthavespeedcontrolleverin
neutral,OPCleversdepressedandPTOdisengaged
tostartengine.Whenenginestarts,releasekey.
FuelShut-OffValve
Locatedinthefuellinemidwaybetweenthetank
andengine.
Thefuelshut-offvalveisusedtoshutoffthe
owoffuelwhenparkinginsideabuilding,during
transportationtoandfromthejobsites,andwhen
themachinewillnotbeusedforafewdays.
Rotatevalve1/4turnclockwisetoshutfueloff.
Rotatevalve1/4turncounterclockwisetoturnfuel
on.
DriveWheelReleaseValves
Locatedontheleftrearcornerofthehydrostatic
pumps.
Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
movedbyhandwithouttheenginerunning.
Witha5/8wrench,turnbothvalvesoneturn
counterclockwisetoreleasethedrivesystem.
Turnclockwisetoresetthedrivesystem.DoNot
overtighten.
TrackingAdjustmentKnob
Locatedontheright-handsideoftherearofthefuel
tanksupport.
Theknobcanbeadjustedsothatmachinewill
“track”straightaheadwiththedriveleversreleased.
PTOEngagement
Locatedontheleftsideoftheupperhandle.
Toengagetheblades,pushtheleverforward,oraway
fromtheoperator,untilthelinkagelocksover-center.
Todisengagetheblades,pullthelevertotherear,
ortowardstheoperator.
Formanualstartengines:Theparkbrakemustbe
disengagedbeforethePTOisengagedortheengine
willkill.
ColdStartKit(ManualStartOnly)
Locatedbelowthehydrocontrolshield.
Thecoldstartkitisusedtoeasethestartingofthe
unitincoldweatherorwhentheunithasnotbeen
operatedforaperiodoftime.Thecoldstartkit
movestheidlerpulleyawayfromthepumpbelt,
releasingthetensiononthebeltwhichallowsthe
enginetoturnoverwithlessresistance(seeStarting
theEngine(ManualStart)sectioninOperation).
18
Operation
Pre-Start
Fillfueltanks.Forbestresultsuseonlyclean,fresh
regulargradeunleadedgasolinewithanoctanerating
of87orhigher.Regulargradeleadedgasolinemay
alsobeused;however,combustionchamberand
cylinderheadwillrequiremorefrequentservice.See
EngineOwner’sManual.
DoNotaddoiltogasoline.
DoNotoverllfueltank.Neverllthefueltankso
thatthefuellevelrisesabovealevelthatis1/2inch
belowthebottomofthellernecktoallowforfuel
expansionandpreventfuelspillage.
Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.
RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.
Note:Afterstartingtheengineandengagingthe
hydrodrive,ifeitherofthedrivewheelsactssluggish
orwillnotrotateatall,stopengineandreferto
theHydraulicSystemAirPurgeProcedurein
Maintenance.
OperatingInstructions
OpentheFuelShut-OffValve
Rotatethevalve1/4turncounterclockwisetoturn
fuelon.
StartingtheEngine(ManualStart)
Note:OperatormusthavePTOdisengagedand
speedcontrolleverinneutralpositionwhenstarting
theengine.
1.Lockdriveleversinneutralandengagepark
brake.
Note:Acoldweatherstartingkithasbeenadded
foreaseofstartingineithercoldweatherorwhen
theunithasnotbeenrunforaperiodoftime.
•Tousecoldstartkit:
A.Pullsplitringstraightoutthesideofthe
unit,andhooktheringoverthelowerrear
hydrocontrolshieldbolt.
B.Startengine.Refertothefollowing
guidelinesforfurtherstartingsuggestions.
•Toengagepumpdrive(disengagecoldstart
kit):
A.Pullchainstraightoutfromthesideofthe
unituntilthesplitringcanberemoved
fromthebolt.
B.Slowlyreleasetensiononchain.
2.Pulloutthechokecontrol.Placethethrottle
controlmidwaybetweenthe“Slow”and“Fast”
positions.
3.Turnthekeyswitchtothe“Run”position.
4.Pullrecoilropetostartengine.
5.Afterenginewarmsup,graduallypushinthe
chokecontrol.DoNotrunwarmenginewiththe
chokeinthe“ON”position.
Note:Kawasakienginesgenerallyneedtobe
“choked”evenwhenwarm.
StartingtheEngine(ElectricStart)
Note:OperatormusthavePTOdisengaged,speed
controlleverinneutralposition,andOPClevers
depressedwhenstartingtheengine.
1.Lockdriveleversinneutralandengagepark
brake.
2.Pulloutthechokecontrol.Placethethrottle
controlmidwaybetweenthe“Slow”and“Fast”
positions.
3.Turntheignitionswitchtothe“Start”position.
Releasetheswitchassoonastheenginestarts.
Important:DoNotcranktheengine
continuouslyformorethantensecondsat
atime.Iftheenginedoesnotstart,allowa
60secondstartercool-downperiodbetween
startingattempts.Failuretofollowthese
guidelinescanburnoutthestartermotor.
4.Afterenginewarmsup,graduallypushinthe
chokecontrol.DoNotrunwarmenginewiththe
chokeinthe“ON”position.
Note:Kawasakienginesgenerallyneedtobe
“choked”evenwhenwarm.
19
Operation
PTOEngagement
DANGER
Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.
DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.
DANGER
Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryordeath.
Neveroperatethemowerwiththedischarge
deectorraised,removed,oralteredunless
thereisagrasscollectionsystemormulch
kitinplaceandworkingproperly.
ThePTOswitchengagesthecuttingblades.Besure
thatallpersonsareclearofmowerdeckanddischarge
areabeforeengagingthePTO.
1.Setthrottleto“MIDWAY”position.
2.PushthePTOengagementarmforwardand
downtoengageblades.
3.Placethethrottleinthe“FAST”positiontobegin
mowing.
Formanualstartengines:Theparkbrakemust
bedisengagedbeforethePTOisengagedorthe
enginewillkill.
DisengagingthePTO
1.Setthrottleto“MIDWAY”position.
2.PullupwardandbackcompletelyonthePTO
engagementarmtodisengagetheblades.
StoppingtheEngine
1.Bringtheunittoafullstop.
2.Lockdriveleversinneutral.
3.DisengagethePTO.
4.Movespeedcontrollevertoneutral.
5.Engagetheparkingbrake.
6.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.
7.Allowtheenginetorunforaminimumof15
seconds,thenturnthekeytothe“OFF”position
tostoptheengine.
8.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.
9.Closethefuelshut-offvalvewhenthemachine
willnotbeinuseforafewdays,when
transporting,orwhentheunitisparkedinside
abuilding.
DrivingtheMachine
DriveLever/NeutralLockLatchOperation
Tolockthedriveleversin“neutrallock”,squeezethe
driveleverstothe“neutral”position(DoNotsqueeze
thedriveleversallthewaybackasthiswillcausethe
drivewheelstogointofullreversedirection).See
Figure5position1.Placethumbsontheinnerlobe
oftheneutrallocklatchesandrotatethemunder
thedriveleversintothe“neutrallock”position.See
Figure5position2.Releasethedrivelevers.
CAUTION
Iftheneutrallocklatchesarenotcompletely
engagedthedriveleverscouldunexpectedly
slipintotheforwarddriveposition.Ifthe
driveleversslipintothedrivepositionthe
unitcouldlurchforwardandcauseinjuryor
propertydamage.
Besurethedriveleversarepasttherollerand
securelyseatedatthebottomoftheneutral
locklatches.
Toplacethedriveleversinthe“forward”position,
slightlysqueezethedriveleverswhileplacingthumbs
ontheouterthumblobeoftheneutrallocklatches
(ortheindexngeronthefrontlobe)androtatethem
fromunderthedrivelevers.Slowlyandcarefully
releasethedrivelevers.SeeFigure5position3.
Toplacethedriveleversinthe“reverse”position,
squeezethedriveleverspasttheneutralposition.See
Figure5position4.
20
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