Exmark 4500-540 Rev. B User manual

Brand: Exmark

Model: 4500-540 Rev. B

Category: Lawnmowers

Type: User manual

This manual is also suitable for

Turf Tracer HP

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.

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.......................................................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

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.

1-303508

1-303517

1-403005

1-403143

1-413206

36inchDecksOnly

1-413214

Safety

1-413327

48inchand52inchDecksOnly

1-413421

1-553049

98-5954

103-1798

103-1976

20HPKawasakiElectricStart

Safety

103-1977

16HPand18HPKawasakiManualStart

103–2076

103-2103

103–2242

103–2243

103-4935

Safety

109-3148

116-0404

117–2718

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.

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

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

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.

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

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.

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

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).

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.

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.

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Exmark 4500-540 Rev. B User manual

Brand: Exmark

Model: 4500-540 Rev. B

Category: Lawnmowers

Type: User manual

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