Exmark 4500-540 Rev. B User manual

Category
Lawnmowers
Type
User manual

This manual is also suitable for

TURFTRACER®HP
ForSerialNos.
850,000&Higher
PartNo.4500-540Rev.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.
©2010ExmarkMfg.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,
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.
3
Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals.....................10
Specications.......................................................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.....................................27
CheckSafetyInterlockSystem.......................28
CheckforLooseHardware............................28
ServiceAirCleaner........................................28
ChangeEngineOil........................................29
CheckHydraulicOilLevel.............................29
CheckTirePressures.....................................29
CheckConditionOfBelts..............................29
LubricateGreaseFittings...............................29
CheckSparkPlugs.........................................30
ChangeHydraulicSystemFilter.....................30
WheelHub-SlottedNutTorque
Specication..............................................32
InspectPTOClutchingBeltTension..............32
ThreadLockingAdhesives.............................32
MobilHTSGrease(OrFood-Grade
Anti-seize).................................................33
Copper-BasedAnti-seize...............................33
DielectricGrease...........................................33
Adjustments.....................................................33
DeckLeveling...............................................33
PumpDriveBeltTension...............................33
PTOClutchingBeltTension..........................33
DeckBeltTension.........................................33
ParkBrakeAdjustment..................................33
HydroDriveLinkageAdjustment..................33
TrackingAdjustment.....................................36
HydroPumpSpringTensionSetting..............36
PTOSafetySwitch........................................36
Cleaning...........................................................37
CleanEngineandExhaustSystem
Area..........................................................37
RemoveEngineShroudsandCleanCooling
Fins...........................................................37
CleanDebrisFromMachine..........................37
CleanGrassBuild-UpUnderDeck................37
WasteDisposal..............................................37
Troubleshooting...................................................39
Schematics...........................................................41
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.
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.
5
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.
6
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.
7
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.
8
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.
9
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.
1-303508
1-303517
1-403005
1-403143
1-413206
36inchDecksOnly
1-413214
10
Safety
1-413327
48inchand52inchDecksOnly
1-413421
1-553049
98-5954
103-1798
103-1976
20HPKawasakiElectricStart
11
Safety
103-1977
16HPand18HPKawasakiManualStart
103–2076
103-2103
103–2242
103–2243
103-4935
12
Safety
109-3148
116-0404
117–2718
13
Specications
Specications
ModelNumbers
SerialNos:850,000andHigher
ManualStartModels:THP16KA363;THP16KA483;THP18KA523;THP16KA363CA;THP16KA483CA
ElectricStartModels:THP20KAE483;THP20KAE523;THP20KAE483CA
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(ElectricStart)
ChargingSystem:FlywheelAlternator
ChargingCapacity:15amps
BatteryType:BCIGroupU1
BatteryVoltage:12Volt
Polarity:NegativeGround
Fuses:Two20ampbladetype
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
TwinHydrostaticDrive
TwoHydroGearvariabledisplacementhigh
efciencypumpsindependentlycoupledtotwo
highefciencyParker/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
Specications
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:Fulloatingdeckisattachedto
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
Deector
Up
36.1inches
(91.7cm)
48.1inches
(122.2cm)
53.0inches
(134.6cm)
Deector
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
NutSee
Figure9
30-35ft-lb(41-47N-m)
EngineMountingBolts
17-23ft-lb(23-31N-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(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
Locatedonthefrontleftcornerofthefueltank
support.
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
0–6.2mph(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“Offpositiontoshut
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
hydro-staticdrivesystemtoallowthemachinetobe
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
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.
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
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.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,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.
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
engagedthedriveleverscouldunexpectedlyslip
intotheforwarddriveposition.Ifthedrivelevers
slipintothedrivepositiontheunitcouldlurch
forwardandcauseinjuryorpropertydamage.
Besurethedriveleversarepasttherollerand
securelyseatedatthebottomoftheneutrallock
latches.
Toplacethedriveleversinthe“forward”position,
slightlysqueezethedriveleverswhileplacingthumbs
ontheouterthumblobeoftheneutrallocklatches
(ortheindexngeronthefrontlobe)androtatethem
fromunderthedrivelevers.Slowlyandcarefully
releasethedrivelevers.SeeFigure5position3.
Toplacethedriveleversinthe“reverse”position,
squeezethedriveleverspasttheneutralposition.See
Figure5position4.
20
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Exmark 4500-540 Rev. B User manual

Category
Lawnmowers
Type
User manual
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