Exmark 4500-528 User manual

Brand: Exmark

Model: 4500-528

Category: Lawnmowers

Type: User manual

TURFTRACER®

ForSerialNos.

850,000&Higher

PartNo.4500-528Rev.B

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:IMPORTANTTheengineinthis

productisnotequippedwithasparkarrester

mufer.ItisaviolationofCaliforniaPublic

ResourceCode(CPRC)Section4442touse

oroperatethisengineonanyforest-covered,

brush-covered,orgrass-coveredlandasdened

inCPRC4126.Otherstatesorfederalareasmay

havesimilarlaws.

Toacquireasparkarresterforyourunit,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

evidentintheactualspecicationsofitsproducts

andthestatementsanddescriptionscontained

inthispublication.

IndustrialParkBox808

Beatrice,NE68310

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,

maintainitsmaximumefciency,andpromotesafe

operation.

Ifadditionalinformationisneeded,orshouldyou

requiretrainedmechanicservice,contactyour

authorizedExmarkequipmentdealerordistributor.

Exmarkpartsmanualsareavailableonlineat

http://www.exmark.com/manuals.htm

AllExmarkequipmentdealersanddistributorsare

keptinformedofthelatestmethodsofservicing

andareequippedtoprovidepromptandefcient

serviceintheeldorattheirservicestations.They

carryamplestockofservicepartsorcansecurethem

promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected

beforeleavingthefactory,however,attentionis

requiredonyourpartifyouaretoobtainthefullest

measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,

oradditionalinformation,contactanAuthorized

ServiceDealerorExmarkCustomerServiceandhave

themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial

numbersontheproduct.Writethenumbersinthe

spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.....................10

Specications.......................................................12

ModelNumbers............................................12

Systems.........................................................12

Dimensions...................................................13

TorqueRequirements....................................14

ProductOverview................................................14

Operation.............................................................15

Controls........................................................15

Pre-Start........................................................16

OperatingInstructions..................................17

Transporting.................................................20

Maintenance.........................................................22

RecommendedMaintenanceSchedule(s)...........22

PeriodicMaintenance.......................................23

CheckEngineOilLevel.................................23

CheckBatteryCharge....................................23

CheckMowerBlades.....................................24

CheckSafetyInterlockSystem.......................25

CheckforLooseHardware............................26

ServiceAirCleaner........................................26

ChangeEngineOil........................................26

CheckHydraulicOilLevel.............................26

CheckTirePressures.....................................26

CheckConditionOfBelts..............................27

LubricateGreaseFittings...............................27

LubricateCasterWheelHubs........................27

RemoveEngineShroudsandCleanCooling

Fins...........................................................28

CheckSparkPlugs.........................................28

ChangeHydraulicSystemFilter.....................29

ThreadLockingAdhesives.............................30

MobilHTSGrease(OrFood-Grade

Anti-seize).................................................31

Copper-BasedAnti-seize..............................31

DielectricGrease...........................................31

Adjustments.....................................................31

DeckLeveling...............................................31

PumpDriveBeltTension...............................31

DeckBeltTension.........................................31

BladeDriveBeltTension..............................31

ParkBrakeAdjustment..................................31

HydroDriveLinkageAdjustment..................31

TrackingAdjustment.....................................33

HydroPumpSpringTensionSetting..............34

ElectricClutchAdjustment............................34

Cleaning...........................................................34

CleanGrassBuild-UpUnderDeck................34

WasteDisposal..............................................34

Troubleshooting...................................................35

Schematics...........................................................37

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.

•Onlyadultsandmatureteenagersshouldoperate

amower,andevenmatureteenagersshouldhave

adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator’s

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe

mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtohimselfor

herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories

andattachmentsareneededtoproperlyand

safelyperformthejob.Onlyuseaccessoriesand

attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses,

substantialfootwear,longtrousers,andhearing

protection.DoNotoperatewhenbarefootor

whenwearingopensandals.Longhair,loose

clothingorjewelrymaygettangledinmoving

parts.

CAUTION

Thismachineproducessoundlevelsinexcess

of85dBAattheoperator’searandcancause

hearinglossthroughextendedperiodsof

exposure.

Wearhearingprotectionwhenoperatingthis

machine.

•Inspecttheareawheretheequipmentistobe

usedandremoveallrocks,toys,sticks,wires,

bones,andotherforeignobjectswhichcanbe

thrownbythemachineandmaycausepersonal

injurytotheoperatororbystanders.

Safety

DANGER

Incertainconditionsgasolineisextremely

ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn

you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground,

inanopenarea,whentheengineiscold.

Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe

machineindoorsorinsideanenclosed

trailer.

•DoNotllthefueltankcompletelyfull.

Fillthefueltanktothebottomoftheller

neck.Theemptyspaceinthetankallows

gasolinetoexpand.Overllingmayresult

infuelleakageordamagetotheengineor

emissionsystem(ifequipped).

•Neversmokewhenhandlinggasoline,and

stayawayfromanopenameorwhere

gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer

andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never

removethecapofthefueltankoradd

fuelwhenengineisrunningorwhenthe

engineishot.

•Iffuelisspilled,DoNotattempttostart

theengine.Moveawayfromtheareaof

thespillandavoidcreatinganysourceof

ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust

systeminplaceandinproperworking

condition.

DANGER

Incertainconditionsduringfueling,static

electricitycanbereleasedcausingaspark

whichcanignitegasolinevapors.Areor

explosionfromgasolinecanburnyouand

othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe

groundawayfromyourvehiclebefore

lling.

•DoNotllgasolinecontainersinsidea

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.

Safety

Operation

WARNING

Operatingengineparts,especiallythemufer,

becomeextremelyhot.Severeburnscanoccur

oncontactanddebris,suchasleaves,grass,

brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to

coolbeforetouching.

•Removeaccumulateddebrisfrommufer

andenginearea.

•Installandmaintaininworkingordera

sparkarresterbeforeusingequipment

onforest-covered,grass-covered,or

brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide,

whichisanodorlessdeadlypoisonthatcankill

you.

DoNotrunengineindoorsorinasmallconned

areawheredangerouscarbonmonoxidefumes

cancollect.

•Operateonlyindaylightorgoodarticiallight,

keepingawayfromholesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake

isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

•Neveroperatethemowerwithdamagedguards,

shields,orcovers.Alwayshavesafetyshields,

guards,switchesandotherdevicesinplaceandin

properworkingcondition.

•Nevermowwiththedischargedeectorraised,

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.

•DoNotoperatethemowerundertheinuence

ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe

machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning

onslopesaslossoftractionand/ortip-overcould

occur.Theoperatorisresponsibleforsafeoperation

onslopes.

Safety

DANGER

Operatingonwetgrassorsteepslopescan

causeslidingandlossofcontrol.Lossofcontrol

and/orlossofoperator’sfootingcouldresultina

fallwithanarmorleggettingunderthemower

orenginedeckwhichmayresultinserious

injury,deathordrowning.

•Mowacrossslopes,neverupanddown.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan20degrees.

•Reducespeedanduseextremecautionon

slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•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

combustibleandmayresultinare.

•Letenginecoolbeforestoringanddonotstore

nearameoranyenclosedareawhereopenpilot

lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do

Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow

untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen

required.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Disconnectbatteryorremovesparkplugwire

beforemakinganyrepairs.Disconnectthe

negativeterminalrstandthepositivelast.

Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s)

orweargloves,andusecautionwhenservicing

them.Onlyreplacedamagedblades.Never

straightenorweldthem.

•Keephandsandfeetawayfrommovingparts.

Ifpossible,donotmakeadjustmentswiththe

enginerunning.

•Chargebatteriesinanopenwellventilatedarea,

awayfromsparkandames.Unplugcharger

beforeconnectingordisconnectingfrombattery.

Wearprotectiveclothinganduseinsulatedtools.

DANGER

Chargingorjumpstartingthebatterymay

produceexplosivegases.Batterygasescan

explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway

frombattery.

•Ventilatewhenchargingorusingbattery

inanenclosedspace.

•Makesureventingpathofbatteryis

alwaysopenoncebatteryislledwith

acid.

•Alwaysshieldeyesandfacefrombattery.

Safety

DANGER

Batteryelectrolytecontainssulfuricacid,

whichispoisonousandcancausesevere

burns.Swallowingelectrolytecanbefatalor

ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and

rubberglovestoprotectskinandclothing

whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith

waterandcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere

ispotentialforsparksandengagement

ofcomponents.Sparkscouldcausean

explosionormovingpartscouldaccidentally

engagecausingpersonalinjury

Besureignitionswitchisinthe“OFF”

positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin

placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper

tightness.

•Frequentlycheckforwornordeteriorating

componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipmentparts,

orusingnon-Exmarkreplacementpartsand

accessoriesmayalterthewarranty,traction,and

safetyofthemachine.Failuretouseoriginal

Exmarkpartscouldcauseseriousinjuryor

death.

Replaceallpartsincluding,butnotlimitedto

tires,belts,andbladeswithoriginalExmark

parts.

WARNING

Hydraulicuidescapingunderpressure

canpenetrateskinandcauseinjury.Fluid

accidentallyinjectedintotheskinmustbe

surgicallyremovedwithinafewhoursbyadoctor

familiarwiththisformofinjuryorgangrenemay

result.

•Ifequipped,makesureallhydraulicuid

hosesandlinesareingoodconditionandall

hydraulicconnectionsandttingsaretight

beforeapplyingpressuretohydraulicsystem.

•Keepbodyandhandsawayfrompinhole

leaksornozzlesthatejecthighpressure

hydraulicuid.

•Usecardboardorpaper,notyourhands,to

ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic

systembyplacingthemotioncontrollevers

inneutralandshuttingofftheenginebefore

performinganyworkonthehydraulicsystem.

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease,

dirtanddebrisfromsafetysignsandinstructional

labels.

•Replaceallworn,damaged,ormissingsafety

signs.

•Whenreplacementcomponentsareinstalled,be

surethatcurrentsafetysignsareafxedtothe

replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled,

makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom

yourauthorizedExmarkequipmentdealeror

distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe

backingtoexposetheadhesivesurface.Apply

onlytoaclean,drysurface.Smoothtoremove

anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns

andinstructionlabels.Theyarecriticaltothesafe

operationofyourExmarkcommercialmower.

1-303517

1-403143

1-413214

103–1541

Safety

103–2242

103–2243

103-4935

103-2432

116-0404

117–2718

Specications

ModelNumbers

SerialNos:850,000andHigher

TT20KCE,TT24KAE,TT24KAECA

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s

Manual

•RPM:FullSpeed:3600(NoLoad)

FuelSystem

•Capacity:5.0gal.(18.9L)

•TypeofFuel:Regularunleadedgasoline,87

octaneorhigher;containingnomorethan10%

methanolorethanol.

•FuelFilter:ReplaceableIn-line

•FuelShut-OffValve:1/4turnincrements

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:BCIGroupU1235amps0°F

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:Twobladetype,20amptochargingcircuit;

20amptoelectricclutch

SafetyInterlockSystem:

•OperatormusthaveOPC(OperatorPresence

Control)leversheldincontactwithhandle

grips,speedcontrolleverinneutral,andPTO

disengagedtostartengine.ReleaseofOPClevers

willcausetheenginetostopifspeedcontrollever

isnotinneutraland/orPTOisengaged.

•Parkbrakemustbedisengagedtomovespeed

controloutofneutralorenginewillkill.

OperatorControls

SteeringControl:Fingertipdrivecontrollevers

provideindependentspeedcontrol,brakingand

neutraltoeachdrivewheelformovingforwardor

reverse,stopping,andpowerturning.

Transmission

•TwoHydroGearvariabledisplacementpiston

pumpsindependentlycoupledtotwohigh

efciencyParkerwheeldrivemotors.

•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:

–0-6.75mph(10.9km/hr)forward.

–0-2.25mph(3.6km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe

movedwhenengineisnotrunning.

WheelDriveSystem

DrivewheelsaredirectcoupledtoParkerwheeldrive

motorswith1inch(25.4mm)taperedshaft.

Specications

Tires&Wheels

DriveFrontCaster

Pneumatic

(Air-Filled)

Pneumatic

(Air-Filled)

Semi-

Pneumatic

AllSerial

Nos.

SN599,999

&Lower

SN600,000

&Higher

Quantity

222

Tread

TurfMasterSmoothSmooth

Size18x8.50-811x4.00-511x4.00-5

PlyRating

Pressure

14psi(96

kPa)

16psi(110

kPa)

CuttingDeck

•ModelNumbers:

–FMD524

–FMD604

•CuttingWidth:

–52inch(132.1cm)

–60inch(152.4cm)

•Discharge:Side

•BladeSize:(3ea.)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

•BladeSpindles:Solidsteelspindleswith13/4

inch(4.45cm)I.D.bearings.

•DeckDrive:

–Electricclutchmountedonengineshaft.

–Bladesdrivenbytwobelts(w/self-tensioning

idlers).

•Deck:

Fulloatingdeckisattachedtoout-frontsupport

frame,removableforservice.Anti-scalprollers

providemaximumturfprotection.Deckdesign

allowsforbagging,mulchingorsidedischarge.

•DeckDepth:

–52inchDeck:5.5inches(14.0cm)

–60inchDeck:5.5inches(14.0cm)

•CuttingHeightAdjustment:

Adjustsfrom11/2inches(3.8cm)to41/2

inches(11.4cm)in1/2inch(1.3cm)increments.

•MulchingKit:Optional

•Bagger:Optional

Dimensions

OverallWidth:

52inchDeck60inchDeck

DeectorUp53.4inches

(135.6cm)

61.4inches

(156.0cm)

DeectorDown64.8inches

(164.6cm)

73.0inches

(185.4cm)

OverallLength:

52inchDeck60inchDeck

83.4inches(211.8cm)83.4inches(211.8cm)

OverallHeight:

52inchDeck60inchDeck

45inches(114.3cm)45inches(114.3cm)

TreadWidth:(OutsidetoOutsideof

Tires,Widthwise)

52inchDeck60inchDeck

45.8inches(116.3cm)45.8inches(116.3cm)

WheelBase:(CenterofCasterTireto

CenterofDriveTire)

52inchDeck60inchDeck

43.3inches(110.0cm)43.3inches(110.0cm)

CurbWeight:

52inchDeck60inchDeck

720lb(327kg)760lb(345kg)

ProductOverview

TorqueRequirements

BoltLocation

Torque

CutterHousingSpindle

Nut

140–145ft-lb(190–197

N-m)

BladeMountingBolt

(lubricatewithanti-seize)

55-60ft-lb(75-81N-m)

EngineDeck/Mower

DeckSupportMount

Bolts

30-35ft-lb(41-47N-m)

Type1Hardware

–Anti-ScalpRoller

WhizlockNutSeeFigure9

40-45ft-lb(54-61N-m)

Type2

Hardware–Anti-Scalp

RollerNylocNutSee

Figure9

30-35ft-lb(41-47N-m)

Type2&3Hardware

–Anti-ScalpRollerHex

CapscrewSeeFigure9

50-55ft-lb(68-75N-m)

Type3

Hardware–Anti-Scalp

RollerFlangedNylocNut

SeeFigure9

30-35ft-lb(41-47N-m)

Type4

Hardware–Anti-Scalp

RollerWhizlockNutSee

Figure9

30-35ft-lb(41-47N-m)

Type4

Hardware–Anti-Scalp

RollerNylocNutSee

Figure9

30-35ft-lb(41-47N-m)

EngineMountingBolts—

Kohler

15-20ft-lb(20-27N-m)

EngineMountingBolts—

Kawasaki

17–23ft-lb(23-31N-m)

WheelLugNuts

90-95ft-lb(122-129N-m)

WheelHubSlottedNutsminimum100ft-lb(136

N-m)

ClutchRetainingBolt

(securedwiththreadlocker)

55-60ft-lb(75-81N-m)

WheelMotorMounting

Bolts

30-35ft-lb(41-47N-m)

ProductOverview

Figure3

1.Controls

3.ParkBrakeLever

2.FuelCap4.Height-of-CutPins

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

OperatorPresenceControl(OPC)

Levers

Locatedontheupperhandleassemblydirectlyabove

thehandlegrips.

Whentheseleversaredepressed,theOPCsystem

sensesthattheoperatorisinthenormaloperator’s

position.Whentheleversarereleased,theOPC

systemsensesthattheoperatorhasmovedfromthe

normaloperatingpositionandwillkilltheengineif

eitherthespeedcontrolleverisnotintheneutral

positionorthePTOisengaged(see

Figure4).

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

Locatedonthecontrolconsolefrontrighthandside.

Chokeisusedtoaidinstartingacoldengine.The

chokecontrolispulledouttobeinthe“ON”position

andpushedintobeinthe“OFF”position.DoNot

runawarmenginewithchokeinthe“ON”position.

ThrottleControl

Locatedonthecontrolconsole’srightside.

Thethrottleisusedtocontrolenginespeed.Moving

thethrottlecontrolforwardwillincreaseengine

speedandmovingittotherearwilldecreaseengine

speed.Movingthethrottleforwardintothedetent

isfullposition.

SpeedControlLever

Locatedinmiddleofcontrolconsole.

Thespeedcontrollevercontrolsthemaximum

forwardspeedandisinnitelyvariablefromneutral

0–6.75mph(10.9km/hr).

Parkbrakemustbedisengagedtomovespeedcontrol

outofneutralorenginewillkill.

BrakeLever

Locatedontheleftsideoftheunitabovethe

hydraulictank.

Operation

Thebrakeleverengagestheparkbrakeonthedrive

wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe

brake.

Whenparkingonasteepslope,thewheelsmustbe

chockedorblockedinadditiontothebrakebeing

engaged.Theunitmustbetieddownandbrake

engagedwhentransporting.

Parkbrakemustbedisengagedtomovespeedcontrol

outofneutralorenginewillkill.

IgnitionSwitch

Locatedontheleftsideofthecontrolconsole.

Theignitionswitchisusedtostartandstopthe

engine.Theignitionswitchhasthreepositions,

“Off”,“On”and“Start”.Insertkeyintoswitch

androtateclockwisetothe“On”position.Rotate

clockwisetothenextpositiontoengagethestarter

(keymustbeheldagainstspringpressureinthis

position).Operatormusthavespeedcontrolleverin

neutral,OPCleversdepressedandPTOdisengaged

tostartengine.Whenenginestarts,releasekey.

HourMeter

Locatedonthefrontlefthandsideofconsolejust

abovethePTOswitch.

Thehourmeterisconnectedtoapressureswitch

installedintheengineblockanditrecordsthe

numberofhoursthattheenginehasrun.Ifignition

switchisleftonwithoutenginerunning,hourmeter

willnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot

alerttheoperatoriftheengineoilislow.

FuelShut-OffValve

Locatedinthefuellinemidwaybetweenthetank

andengine.

Thefuelshut-offvalveisusedtoshutoffthe

owoffuelwhenparkinginsideabuilding,during

transportationtoandfromthejobsites,andwhen

themachinewillnotbeusedforafewdays.

Rotatevalve1/4turnclockwisetoshutfueloff.

Rotatevalve1/4turncounterclockwisetoturnfuel

on.

DriveWheelReleaseValves

Locatedontheleftrearcornerofthehydrostatic

pumps.

Drivewheelreleasevalvesareusedtoreleasethe

hydro-staticdrivesystemtoallowthemachinetobe

movedbyhandwithouttheenginerunning.

Witha5/8wrench,turnbothvalvesoneturn

counterclockwisetoreleasethedrivesystem.

Turnclockwisetoresetthedrivesystem.DoNot

overtighten.

TrackingAdjustmentKnob

Locatedontheright-handsideoftherearofthefuel

tanksupport.

Theknobcanbeadjustedsothatmachinewill

“track”straightaheadwiththedriveleversreleased.

PTOEngagementSwitch

Switchislocatedonleftsideofcontrolconsole.

Theswitchmustbepulledouttothe“Rotate”

positiontoengagetheblades.Theswitchispushed

intothe“Stop”positiontostoptheblades.Operator

musthaveoperatorpresencecontrolleversdepressed

whenPTOisengagedorenginewillstop.

Pre-Start

Fillfueltankonlevelground.Forbestresultsuse

onlyclean,freshregulargradeunleadedgasolinewith

anoctaneratingof87orhigher.

Important:Neverusemethanol,gasoline

containingmethanol,gasoholcontainingmore

than10%ethanol,premiumgasoline,orwhite

gasbecausethefuelsystemcouldbedamaged.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe

tankallowsgasolinetoexpand.Overllingmayresult

infuelleakageordamagetotheengineoremission

system(ifequipped).

Makesureyouunderstandthecontrols,their

locations,theirfunctions,andtheirsafety

requirements.

RefertotheMaintenancesectionandperformallthe

necessaryinspectionandmaintenancesteps.

Operation

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethevalve1/4turncounterclockwisetoturn

fuelon.

StartingtheEngine

1.Onacoldengine,placethethrottlemidway

betweenthe“Slow”and“Fast”positionsand

placethechokeinthe“On”position.Onawarm

engine,placethethrottlelevermidwaybetween

“Slow”and“Fast”positionsandleavethechoke

inthe“Off”position.

2.Turnignitionswitchto“Start”position.Release

theswitchassoonastheenginestarts.

3.Onacoldengine,graduallyreturnchoketothe

“Off”positionafterenginestartsandwarmsup.

Important:Donotcranktheengine

continuouslyformorethantensecondsat

atime.Iftheenginedoesnotstart,allowa

60secondstartercool-downperiodbetween

startingattempts.Failuretofollowthese

guidelinescanburnoutthestartermotor.

Note:Itishelpfultohavetheleftandright

neutrallocklatcheslockedinneutralwhen

startingtheengine.RefertoNeutralLock

LatchessectioninControls.

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeckare

dangerous.Bladecontactcancauseserious

injuryorkillyou.

DoNotputhandsorfeetunderthemoweror

mowerdeckwhenthebladesareengaged.

DANGER

Anuncovereddischargeopeningwillallow

objectstobethrowninanoperator’sor

bystander’sdirection.Also,contactwiththe

bladecouldoccur.Thrownobjectsorblade

contactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththedischarge

deectorraised,removed,oralteredunlessthere

isagrasscollectionsystemormulchkitinplace

andworkingproperly.

ThePTOswitchengagesthecuttingblades.Besure

thatallpersonsareclearofmowerdeckanddischarge

areabeforeengagingthePTO.

1.Setthrottleto“MIDWAY”position.

2.PullthePTOswitchoutwardtothe“ROTATE”

positiontoengagetheblades.

3.Placethethrottleinthe“FAST”positiontobegin

mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushthePTOswitchintothe“STOP”position

todisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Lockdriveleversinneutral.

3.DisengagethePTO.

4.Movespeedcontrollevertoneutral.

5.Engagetheparkingbrake.

6.Placethethrottlemidwaybetweenthe“SLOW”

and“FAST”positions.

7.Allowtheenginetorunforaminimumof15

seconds,thenturntheignitionswitchtothe

“OFF”positiontostoptheengine.

8.Removethekeytopreventchildrenorother

unauthorizedpersonsfromstartingengine.

9.Closethefuelshut-offvalvewhenthemachine

willnotbeinuseforafewdays,when

transporting,orwhentheunitisparkedinside

abuilding.

Operation

DrivingtheMachine

DriveLever/NeutralLockLatchOperation

Tolockthedriveleversin“neutrallock”,squeezethe

driveleverstothe“neutral”position(DoNotsqueeze

thedriveleversallthewaybackasthiswillcausethe

drivewheelstogointofullreversedirection).See

Figure5position1.Placethumbsontheinnerlobe

oftheneutrallocklatchesandrotatethemunder

thedriveleversintothe“neutrallock”position.See

Figure5position2.Releasethedrivelevers.

CAUTION

Iftheneutrallocklatchesarenotcompletely

engagedthedriveleverscouldunexpectedlyslip

intotheforwarddriveposition.Ifthedrivelevers

slipintothedrivepositiontheunitcouldlurch

forwardandcauseinjuryorpropertydamage.

Besurethedriveleversarepasttherollerand

securelyseatedatthebottomoftheneutrallock

latches.

Toplacethedriveleversinthe“forward”position,

slightlysqueezethedriveleverswhileplacingthumbs

ontheouterthumblobeoftheneutrallocklatches

(ortheindexngeronthefrontlobe)androtatethem

fromunderthedrivelevers.Slowlyandcarefully

releasethedrivelevers.See

Figure5position3.

Toplacethedriveleversinthe“reverse”position,

squeezethedriveleverspasttheneutralposition.See

Figure5position4.

Figure5

1.DriveLeverinneutral

position

3.DriveLeverinforward

position

2.DriveLeverlockedin

neutralposition

4.DriveLeverinreverse

position

DrivingForward

1.Releasetheparkingbrake.

2.Withdriveleverslockedin“neutral”,shiftspeed

controllevertodesiredforwardspeed.

3.Slowlysqueezeandholdbothdriveleversin

theneutralpositionandrotatebothneutrallock

latchesfromtheneutrallockpositiontothe

forwardposition.

Note:DoNotsqueezebothdriveleversallthe

wayback.Thiswillcausethedrivewheelsto

engageinthereversedirection.

4.Tomoveforwardinastraightline,smoothly

releasebothdriveleverstoengagedrivewheels.

Toturnleftorright,squeezetherighthanddrive

levertoturnrightandthelefthanddrivelever

toturnleft.

Tomakea“zeroturn”,squeezeeithertheleft

handortherighthanddriveleverbackintothe

reversepositionwhiletheoppositedriveleverisin

aforwardpositionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine,

avoidquick,jerkymovementsofthedrivelevers.

Movethedriveleverssmoothlyanddeliberately.

Tostop,squeezedriveleversbacktothe“neutral”

position.Movetheneutrallocklatchesintothe

“neutrallock”positionandreleasedrivelevers.

Movethespeedcontrollevertotheneutral

position.

DrivinginReverse

Tomoverearwardinastraightline,squeezedrive

leversintothereverseposition.

Toturnleftorright,squeezetherighthanddrivelever

toturnleftandthelefthanddrivelevertoturnright.

Tomakea“zeroturn”,squeezeeitherthelefthand

ortherighthanddriveleverbackintothereverse

positionwhiletheoppositedriveleverisinaforward

positionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine,avoid

quick,jerkymovementsofthedrivelevers.Movethe

driveleverssmoothlyanddeliberately.

Tostop,squeezedriveleversbacktothe“neutral”

position.Movetheneutrallocklatchesintothe

“neutrallock”positionandreleasedrivelevers.Move

thespeedcontrollevertotheneutralposition.

Operation

AdjustingtheCuttingHeight

WARNING

Whenthetwofrontsupportrodhairpinsare

removedfromthemowerdeck,theweightofthe

tractorsectionmaycausethefrontframeofthe

unittorisesuddenly.Iftheunitrisessuddenly,

injurymayoccur.

Securelyholddownthefrontoftheunitwhenthe

frontsupportrodhairpinsareremoved.

Thecuttingheightofthemowerdeckisadjusted

from11/2to41/2inches(3.81cmto11.4cm)in

1/2inchincrements.

1.Stopthemachineandmovethedriveleverstothe

neutrallockedposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall

movingpartstostop.

5.Installhairpinclipsintheholesforthedesired

cuttingheight.SeeFigure6.

Important:Tomaintaincorrectcutting

heightandrake,checkthefollowingfor

properadjustment.

A.Thefrontandrearhairpinsareinthesame

holeswiththeproperspacersunderthehair

pins.SeeFigure6.

Figure6

1.Decksupportpin

2.CuttingHeight

B.ThetirepressuresaresetasdirectedinCheck

TirePressuresintheMaintenancesection.

C.Thelengthofthereardecksupportlink

assembliesaverage6.89inches(approximately

67/8inches)(175.01mm)fromthecenterof

theballjointtothecenterofthefarthesthole.

SeeFigure7.

Note:Allfourpinsmustequallysupportthe

weightofthedeck.Adjustmentinthelength

ofthereardecksupportassembliesmaybe

necessary.Ifonesideislongerthan6.89

inches(approximately67/8inches)(175.01

mm),thantheoppositesidemustbeshorter

bythesameamount.

Figure7

LeftHandSideShown

AdjustingtheAnti-ScalpRollers

Itisrecommendedtochangetheanti-scalproller

position,whentheheightofcuthaschanged.

1.Stopthemachineandmovethedriveleversto

theneutrallockposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall

movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe

anti-scalprollersbyremovingthespringdisc

washerandbolt(seestep7).

6.Adjustanti-scalprollersforNormalOperating

Conditions.Placerollersinoneofthepositions

shownin

Figure8.Rollerswillmaintain3/4

inches(19mm)clearancetothegroundto

minimizegougingandrollerwearordamage.

Note:ForMaximumDeckFlotation,place

rollersoneholepositionlower.Rollersshould

Operation

maintain1/4inch(6.35mm)clearancetoground.

DoNotadjustrollerstosupportthedeck.Be

surerollerboltsareinstalledwiththespringdisc

washerbetweenheadoftheboltandmounting

bracket.

Figure8

Forcuttingheightsabove3.5inches(38mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller

mountingbracket

2.Cuttingheight

7.Fourtypesofanti-scalprollerassembliesare

available.SeeFigure9todeterminewhich

assemblyhasbeeninstalledontheunit.Torque

hardwareasspecied,orlossofrollermayresult.

See

Figure9.

Figure9

Frontleftanti-scalpbracketshown

1.Type1hardware

2.Type2hardware

3.Type3hardware

4.Type4hardware

5.(Type1)3/8–16x4hexscrew

6.(Type2&3)3/8–24x2hexscrew—T orqueto50–55

ft-lb(68–75N-m)

7.(Type4)3/8whizlocknut—Torqueto30–35ft-lb

(41–47N-m)

8.Springdiscwasher(conetowardsbolthead)

9.(Type1)3/8whizlocknutandheavyatwasher—

Torqueto40–45ft-lb(54–61N-m)

10.(Type2)3/8nylocnutandheavyatwasher—T orque

to30–35ft-lb(41–47N-m)

11.(Type3)3/8angednylocnutwithoutwasher—Torque

to30–35ft-lb(41–47N-m)

12.(Type4)3/8nylocnut—Torqueto30–35ft-lb

(41–47N-m).

Transporting

TransportingaUnit

WARNING

Loadingthemowerontoatrailerwithoutstrong

enoughorproperlysupportedrampscouldbe

dangerous.Therampscouldcollapsecausing

theunittofall,whichcouldcauseinjury.

•Useproperrampsthataresecuredtothe

truckortrailer.

•Keepfeetandlegsoutfromundertheunit

whenloadingandunloading.

•Ifnecessary,useassistancewhenloading.

Besurethefuelshut-offvalveisclosed.

Useaheavydutytrailertotransportthemachine.

Engageneutrallocklatchesandparkbrake,then

blockwheels.

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Exmark 4500-528 User manual

Brand: Exmark

Model: 4500-528

Category: Lawnmowers

Type: User manual

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Exmark 4500-528 User manual

Exmark 4500-528 User manual

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