Exmark 4500-540 Rev. B manual

TURF TRACER ® HP For Serial Nos. 850,000 & Higher Part No. 4500-540 Rev . B[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals kno wn to the State of Califor nia to cause cancer , bir th defects, or other reproductiv e har m. Important: IMPORT ANT The engine in this product is not equipped with a spark ar rester mufer . It is a violation of Califor nia Public Resource Co[...]

Introduction CONGRATULATIONS on the purc hase of your Exmark Mo wer . This product has been carefully designed and man ufactured to gi ve you a maxim um amount of dependability and years of trouble-free operation. This manual contains operating, maintenance , adjustment, and safety instr uctions for your Exmark mow er . BEFORE OPERATING Y OUR MO WE[...]

Contents Introduction . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . 3 Safety .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. 5 Safety Alert Symbol . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. .[...]

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both in this manual and on the machine to identify impor tant safety messages whic h must be follo wed to a void accidents This symbol means: ATTENTION! BECOME ALERT! Y OUR SAFETY IS INV OL VED! Figure 2 1. Safety alert symbol The safety alert symbol appears abo v e infor[...]

Safety DANGER In certain conditions gasoline is extremely ammable and v apors are explosiv e. A re or explosion from gasoline can burn y ou, others, and cause proper ty dama ge. • Fill the fuel tank outdoors on lev el gr ound, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never rell the fuel tank or drai[...]

Safety Operation W ARNING Operating engine par ts, especially the mufer , become extremely hot. Sev ere bur ns can occur on contact and de bris, such as leav es, grass, br ush, etc. can catch re. • Allow engine par ts, especially the mufer, to cool before touching . • Remo ve accumulated de bris from mufer and engine area. • Insta[...]

Safety DANGER Operating on w et grass or steep slopes can cause sliding and loss of control. Loss of control and/or loss of operator’ s footing could result in a fall with an ar m or leg getting under the mower or engine deck which may result in serious injur y , death or drowning . • Mow across slopes, nev er up and do wn. • Do Not mow slope[...]

Safety DANGER Batter y electrolyte contains sulfuric acid, which is poisonous and can cause sev ere bur ns. Swallo wing electrolyte can be fatal or if it touches skin can cause sev ere bur ns. • W ear safety glasses to shield ey es, and r ub ber g lov es to protect skin and clothing when handling electrolyte. • Do Not s w allow electrolyte. •[...]

Safety Safety and Instructional Decals • Keep all safety signs legible. R emo ve all grease, dirt and debris from safety signs and instr uctional labels . • R eplace all w or n, damaged, or missing safety signs . • When replacement components are installed, be sure that current safety signs are afx ed to the replaced components . • If an[...]

Safety 1-413327 48 inch and 52 inch Decks Only 1-413421 1-553049 98-5954 103-1798 103-1976 20 HP Kawasaki Electric Start 1 1[...]

Safety 103-1977 16 HP and 18 HP Kawasaki Manual Start 103–2076 103-2103 103–2242 103–2243 103-4935 12[...]

Safety 109-3148 1 16-0404 1 17–2718 13[...]

Specications Specications Model Numbers Serial Nos: 850,000 and Higher Manual Start Models: THP16KA363; THP16KA483; THP18KA523; THP16KA363CA; THP16KA483CA Electric Star t Models: THP20KAE483; THP20KAE523; THP20KAE483CA Systems Engine • Engine Specications: See your Engine Owner’ s Manual • RPM: Full Speed: 3600 (No Load) Fuel System [...]

Specications Tires & Wheels Driv e Front Caster Pneumatic (Air-Filled) Pneumatic (Air-Filled) Semi- Pneumatic 36 48 & 52 All Decks Quantity 2 2 2 T read T urf Master T urf Master Smooth Size 16 x 6.50–8 16 x 7.50–8 9 x 3.50-4 Ply Rating 4 4 Pressure 14 psi (97 kP a) 14 psi (97 kP a) Cutting Deck • Cutting Width: – 36 inc h Deck: [...]

Product Overview T orque Requirements Bolt Location T orque Cutter Housing Spindle Nut 140-145 ft-lb (190-197 N-m) Blade Mounting Bolt (lubricate with anti-seize) 55-60 ft-lb (75-81 N-m) Engine Dec k/Mower Deck Suppor t Mount Bolts 30-35 ft-lb (41-47 N-m) Anti-Scalp R oller Nyloc Nut See Figure 9 30-35 ft-lb (41-47 N-m) Anti-Scalp R oller Whizlock [...]

Operation Operation Note: Deter mine the left and right sides of the machine from the nor mal operating position. Controls Operator Presence Control (OPC) Levers Located on the upper handle assembly directly abo ve the handle g rips . When these lev ers are depressed, the OPC system senses that the operator is in the nor mal operator’ s position.[...]

Operation Park Brake Lever Located on the left side of the unit abov e the hy draulic tank. The brake lev er engages the park brake on the dri ve wheels . Pull the lev er up and rearward to engage the brake. Push the lever forw ard and do wn to diseng age the brake . When parking on a steep slope, the wheels must be choc ked or blocked in addition [...]

Operation Pre-Start Fill fuel tank on lev el ground. F or best results use only clean, fresh regular g rade unleaded gasoline with an octane rating of 87 or higher . Important: Nev er use methanol, gasoline containing methanol, gasohol containing more than 10% ethanol, premium gasoline, or white gas because the fuel system could be damaged. Do Not [...]

Operation PTO Engagement DANGER The rotating blades under the mower deck are dangerous. Blade contact can cause serious injur y or kill y ou. Do Not put hands or feet under the mo wer or mower deck when the blades are engaged. DANGER An uncov ered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also,[...]

Operation Figure 5 1. Drive Lever in neutral position 3. Drive Lever in forward position 2. Drive Lever locked in neutral position 4. Drive Lever in reverse position Driving F orw ard 1. R elease the parking brak e. 2. With dri ve levers locked in “neutral”, shift speed control lev er to desired forward speed. 3. Slowly squeeze and hold both dr[...]

Operation Figure 6 1. Deck support pin 2. Cutting Height B . The tire pressures are set as directed in Check Tire Pressures in the Maintenance section. C. The length of the rear deck support link assemblies a v erage 6.89 inches (approximately 6 7/8 inches) (175.01 mm) from the center of the balljoint to the center of the farthest hole. See Figure [...]

Operation Figure 9 1. Spring disc washer (cone towards nut ) 3. 3/8 nyloc-torque to 30-35 ft-lb (41-47 N-m) 2. Front right anti-scalp bracket shown 4. 3/8-16 whizlock nut torque to 30-35 ft-lb (41-47 N-m) T ransporting T ransporting a Unit W ARNING Loading the mower onto a trailer without strong enough or properl y suppor ted ramps could be dangero[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the machine from the normal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental starting of the engine could seriously injure y ou or other bystander s. Remo ve the key from the ignition switch, engage parking b[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedure Every 500 hours • Chang e the h ydraulic lter (Every 250 hours/yearly if using Mobil 1 15W50) • Check wheel hub-slotted torque specication. Monthly • Check the batter y c harge. • Grease the PTO engag ement bellcrank. Periodic Maintenance Check Engine Oil Level Service [...]

Maintenance Recommended Jump Starting Procedure (Electric Start Units Only) Service Interval: As required 1. Check the weak batter y for ter minal corrosion (white, g reen, or blue “sno w”), it must be cleaned off prior to jump starting . Clean and tighten connections as necessary . CAUTION Cor rosion or loose connections can cause unw anted el[...]

Maintenance Check Mower Blades Service Interval: Before each use or daily 1. Stop engine, wait for all moving parts to stop , and remov e k ey . Eng age parking brak e. 2. Lift deck and secure in raised position as stated in the Clean Grass Build-Up Under Deck section. 3. Inspect blades and sharpen or replace as required. 4. R einstall the blades ([...]

Maintenance Figure 13 1. Rod 4. Mower deck 2. Spring 5. Discharge deector bracket 3. Discharge deector 6. Assembled view 3. Hook the bent end of the rod around the front discharge deector brac ket to retain it from sliding out. Place the leg of the spring with the loop in the notch in the discharge deector to hold the discharge deect[...]

Maintenance need more often under severe conditions. See the Engine Owner ’ s manual for additional information.) Every 200 hours/Y early (whichever comes rst)—Replace the paper element. 1. Stop engine, wait for all moving parts to stop , and remov e key or spark plug wire(s). Eng age parking brake . 2. See the Engine Owner’ s Manual for m[...]

Maintenance 2. Lubricate ttings with NGLI g rade #2 multi-purpose gun grease. R efer to the following chart for tting locations and lubrication sc hedule. Lubrication Chart Fitting Locations Initial Pumps Number of Places Ser vice Inter v al 36 inch Deck 48 inch Deck 52 inch Deck 1. Caster Wheel Bearings 12 2 2 2 Daily 2. Caster Piv ots 2 2 2[...]

Maintenance Exmark Premium Hy dro Oil is recommended. R efer to the chart for an acceptable alternativ e: Hydro Oil Change Inter v al Exmark Premium Hydro Oil (Preferred) 500 Hours Mobil 1 15W50 250 Hours 5. Loosen lter 1/2 tur n and allow a small amount of oil to leak from the oil lter (this allows air to be purged from the oil lter and s[...]

Maintenance 4. Thoroughly clean the area around each of the charge pump housings . 5. T o “prime” charge pump , loosen tw o hex sock et head capscrews (shown in Figure 14) 1 1/2 tur ns only . Make sure engine is not running . Lift the c harge pump housing upw ard and w ait for a steady o w of oil to o w out from under the housing . R etig[...]

Maintenance which could cause binding of the OPC levers and er ratic operation. • Fuel tank studs , where studs are inserted into tank. Mobil HTS Grease (Or Food-Grade Anti-seize) Mobil HTS grease (or food-grade anti-seize) is used in the follo wing locations: • Between the cutter housing spindle and bearings . • Between the cutter housing sp[...]

Maintenance speed control linkage (see Figure 16) until the tabs are positioned correctly . Figure 16 Viewed from Left Side of Unit 1. Neutral Safety Switch 3. 5/16 inch (7.9 mm) 2. Actuating T ab in neutral position 3. Pull the speed control lev er bac k to neutral. Check that the neutral safety switch actuating tab has depressed the plunger of th[...]

Maintenance disengag ed whenever speed control levers are mov ed out of the neutral position. Note: The neutral loc k latc hes should be “unlock ed” and in the forward position. 2. Loosen the front n ut on left hy dro control linkage as shown in Figure 17. T ur n the rear control linkage adjusting nut countercloc kwise until wheel rotates forwa[...]

Maintenance T racking Adjustment 1. Stop engine and wait for all mo ving par ts to stop . 2. Check the driv e tire pressures and tire circumferences as stated in Check the Tire Pressures section in Maintenance. 3. R un the unit and obser v e the tracking on a lev el, smooth, hard surface such as concrete or asphalt. 4. If the unit tracks to one sid[...]

Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) CAUTION Excessi v e de bris around engine cooling air intake and exhaust system area can cause engine, exhaust area, and h ydraulic system to o v erheat which can create a re hazard. Clean [...]

Maintenance If a batter y is being replaced or if the unit containing the batter y is no longer operating and is being scrapped, take the batter y to a local certied recycling center . If no local recycling is a vailable return the batter y to any certied battery reseller . 38[...]

T roubleshooting T roubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mow er use. When a problem occurs , do not o verlook the simple causes . F or example: star ting problems could be caused by an empty fuel tank. The following table lists some of the common causes [...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e 1. R educe the ground speed. 2. Oil lev el in the crankcase is lo w . 2. Add oil to the crankcase. Engine ov erheats 3. Cooling ns and air passages for the engine are plugg ed. 3. Remo ve the obstructions from the cooling ns and air passages . 1. T racki[...]

Schematics Schematics Electrical Diagram Electrical Diagram 41[...]

Schematics Hydraulic Diagram 42[...]

Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty Company , pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair , replace or adjust any part on these products and found by us (in the ex ercise of our reasonable discretion) to be defect i ve in factor[...]

Notes: 44[...]

Service Record Date: Description of W ork Done: Service Done By: 45[...]

46[...]

G01 1841 Figure 21 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 20 degrees . Use the slope indicator to determine the degree of slope of hills before operating. Do Not operate this machine on a slope greater than 20 degrees. Fold along the appropriate line to match the recommended slope. 2.[...]

MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF A CCESSORIES AND OPTIONS W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED[...]