Exmark 4500-528 manual

TURF TRACER ® For Serial Nos. 850,000 & Higher Part No. 4500-528 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 103–2242 103–2243 103-4935 103-2432 1 16-0404 1 17–2718 1 1[...]

Specications Specications Model Numbers Serial Nos: 850,000 and Higher TT20K CE, TT24KAE, TT24KAECA Systems Engine • Engine Specications: See your Engine Owner’ s Manual • RPM: Full Speed: 3600 (No Load) Fuel System • Capacity: 5.0 gal. (18.9 L) • T ype of Fuel: Regular unleaded gasoline, 87 octane or higher; containing no more t[...]

Specications Tires & Wheels Driv e Front Caster Pneumatic (Air-Filled) Pneumatic (Air-Filled) Semi- Pneumatic All Serial Nos . SN 599,999 & Lower SN 600,000 & Higher Quantity 2 2 2 T read T urf Master Smooth Smooth Size 18 x 8.50-8 11 x 4.00-5 11 x 4.00-5 Ply Rating 4 4 Pressure 14 psi (96 kP a) 16 psi (110 kP a) Cutting Deck • Mod[...]

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) T ype 1 Hardware –Anti-Scalp Roller Whizlock Nut See Figure 9 40-45 ft-lb (54-61 N-m) T [...]

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 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 to the brak e being engag ed. The unit m ust be tied do wn and brak e engag ed whe[...]

Operation Operating Instructions Open the Fuel Shut-Off V alve R otate the valv e 1/4 turn countercloc kwise to turn fuel on. Starting the Engine 1. On a cold engine, place the throttle midwa y between the “Slow” and “F ast” positions and place the c hoke in the “On” position. On a w ar m engine, place the throttle lev er midwa y betwee[...]

Operation Driving the Machine Driv e Lever/Neutral Lock Latch Operation T o lock the driv e lev ers in “neutral loc k”, squeeze the driv e lev ers to the “neutral” position (Do Not squeeze the dri ve levers all the wa y bac k as this will cause the driv e wheels to go into full rev erse direction). See Figure 5 position 1. Place thumbs on t[...]

Operation Adjusting the Cutting Height W ARNING When the two front suppor t rod hair pins are remov ed from the mow er deck, the weight of the tractor section may cause the front frame of the unit to rise suddenly . If the unit rises suddenly , injur y may occur . Securely hold down the front of the unit when the front suppor t rod hair pins are re[...]

Operation maintain 1/4 inch (6.35 mm) clearance to ground. Do Not adjust rollers to support the dec k. Be sure roller bolts are installed with the spring disc washer betw een head of the bolt and mounting brack et. Figure 8 For cutting heights above 3.5 inches (38 mm) use the bottom hole. The rollers will still be effective against scalping. 1. Ant[...]

Operation Securely fasten the mac hine to the trailer with straps , chains , cables , or ropes . Do Not rely solely on the parking brake to hold the machine on the trailer . Be sure that the trailer has all necessar y lighting and marking as required by law and use a safety chain. 21[...]

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 Periodic Maintenance Check Engine Oil Level Service Interval: Before each use or daily 1. Stop engine and wait for all moving parts to stop . Make sure unit is on a level surface . 2. Check with engine cold. 3. Clean area around dipstic k. R emov e dipstic k and wipe oil off . Reinsert the dipstic k and push it all the wa y do wn into t[...]

Maintenance 2. Make sure the booster is a good and fully charged lead acid battery at 12.6 v olts or greater . Use properly sized jumper cables (4 to 6 A W G) with short lengths to reduce voltage drop betw een systems . Mak e sure the cables are color coded or labeled for the correct polarity . CAUTION Connecting the jumper ca bles incorr ectly (wr[...]

Maintenance Figure 1 1 1. Install bushing in blade prior to installing bushing in spindle. B . Install bushing/blade combo into spindle . Figure 12 1. Use wrench here for blade installation. This nut has been torqued to 90–1 10 ft-lb (122–149 N-m) 2. T orque to 55-60 ft-lb (75-81 N-m) Apply lubricant to threads as needed to prevent seizing. Cop[...]

Maintenance Check for Loose Hardware 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. Visually inspect mac hine for any loose hardware or any other possible problem. Tighten hardware or correct the problem before operating . Service Air Cleaner Service Inter[...]

Maintenance Note: F ront caster tires hav e per manent tire sealant installed. F or Serial Nos. 600,000 and Higher: Semi-pneumatic caster tires do not need to be inated. Note: Do Not add an y type of tire liner or foam ll material to the tires. Ex cessiv e loads created by foam lled tires may cause failures to the hy dro drive system, fram[...]

Maintenance Figure 13 1. Seal guard 2. Spacer nut with wrench ats 2. R emov e caster wheel from caster forks . 3. R emov e seal guards from the wheel hub . 4. R emov e one of the spacer n uts from the axle assembly in the caster wheel. Note that thread locking adhesi v e has been applied to loc k the spacer n uts to the axle . R emov e the axle [...]

Maintenance Change Hydraulic System Filter Service Interval: After the rst 250 hours Every 500 hours/Y early (whichever comes rst) thereafter (Every 250 hours/Y early if using Mobil 1 15W50) Note: Use only Exmark P art No . 109-4180 for Summer use abov e 32°F (0°C) or P/N 1-523541 for Winter use below 32°F (0°C) (R efer to T ransmission s[...]

Maintenance Figure 14 1. Charge pump cap 2. Loosen 1 1/2 turns only 1. Stop engine and wait for all moving parts to stop . Raise the rear of the machine up onto jack stands high enough to raise the driv e wheels off the g round. 2. Check oil level as stated in Check Hydraulic Oil Level section. 3. Start engine and mo ve throttle control ahead to fu[...]

Maintenance • OPC lever hubs and cross-shaft Note: Care m ust be used not to bond the bearing, next to each OPC hub , to the cross-shaft 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-seiz[...]

Maintenance speed control linkage (see Figure 15) until the tabs are positioned correctly . Figure 15 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 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 16. T ur n the rear control linkage adjusting nut countercloc kwise until wheel rotates forward. T urn the rear nut of left control linkag e clockwise 1/4 of a tur n at a time[...]

Maintenance 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 side or the other , turn the quick track knob . T urn the knob right to “steer?[...]

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 excessi ve 1. R educe the ground speed. 2. Oil level in the crankcase is low . 2. Add oil to the crankcase . Engine ov erheats 3. Cooling ns and air passages for the engine are plugg ed. 3. R emov e the obstr uctions from the cooling ns and air passages . 1. T rac k[...]

Schematics Schematics Electrical Diagram 37[...]

Schematics Electrical Logic Schematic 38[...]

Schematics Hydraulic Diagram 39[...]

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[...]

Service Record Date: Description of W ork Done: Service Done By: 41[...]

42[...]

G01 1841 Figure 20 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[...]