Exmark Turf Tracer HP 4500-358 manual

TURF TRACER ® HP For Serial Nos. 790,000 & Higher Part No. 4500-358 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer, bir th defects, or other reproductiv e har m. Important: When the mower is used or operated on any Califor nia forest, br ush or grass co vered land, a w orking spark arr ester must be attached to t[...]

Introduction CONGRATULATIONS on the purchase of y our Exmark Mow er . T his product has been carefully designed and manufactured to giv e you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for y our Exmark mow er . BEFORE OPERATING Y OUR MO WER[...]

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

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both in this man ual and on the machine to identify important safety messages which m ust be follow ed to av oid 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 ve inform[...]

Safety DANGER In certain conditions gasoline is extremely ammable and v apors are explosi ve. A re or explosion from gasoline can bur n y ou, others, and cause proper ty damage. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never rell the fuel tank or drain the machine indoo[...]

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

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 mow er or engine deck which may result in serious injur y , death or drowning . • Mow across slopes, never up and do wn. • Do Not mow slope[...]

Safety W ARNING Hydraulic uid escaping under pressure can penetrate skin and cause injur y . F luid accidentally injected into the skin must be surgically remov ed within a few hours by a doctor familiar with this for m of injur y or gangr ene may result. • Make sure all h y draulic uid hoses and lines are in good condition and all h y drau[...]

Safety Safety and Instructional Decals • Keep all safety signs legible . Remo 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 cur rent safety signs are afx ed to the replaced components . • If a[...]

Safety 1-413327 48 inch and 52 inch Decks Only 1-413421 1-513747 19 HP Kawasaki Electric Start Only 1-553049 98-5954 103-1798 103-1976 19 HP Kawasaki Electric Start 1 1[...]

Safety 103-1977 15 HP and 17 HP Kawasaki Manual Start 103-2076 103-2103 103-2242 103-2243 103-4935 12[...]

Safety 109-3148 1 16-0404 13[...]

Specications Specications Model Numbers Serial Nos: 790,000 and Higher Manual Start Models: THP15KA363; THP17KA483; THP17KA523; THP17KA363CA; THP17KA483CA Electric Start Models: THP19KAE483; THP19KAE523; THP19KAE483CA Systems Engine • Engine Specications: See y our Engine Owner’ s Manual • RPM: Full Speed: 3600 ±50 RPM (No Load) Fue[...]

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 inch Deck: 3[...]

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 Deck/Mo wer Deck Support 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 N[...]

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

Operation Park Brake Lever Located on the left side of the unit abo ve the hy draulic tank. The brak e lever engag es the park brak e on the dri ve wheels . Pull the lev er up and rearward to engage the brak e. Push the lev er forw ard and down to disengag e the brake . When parking on a steep slope , the wheels m ust be choc ked or block ed in add[...]

Operation Pre-Start Fill fuel tanks . F or best results use only clean, fresh regular grade unleaded g asoline with an octane rating of 87 or higher . Regular grade leaded gasoline ma y also be used; ho wev er, combustion c hamber and cylinder head will require more frequent ser vice . See Engine Owner’ s Man ual. Do Not add oil to gasoline. Do N[...]

Operation PTO Engagement DANGER The rotating blades under the mow er deck are dangerous. Blade contact can cause serious injur y or kill y ou. Do Not put hands or feet under the mow er or mower deck when the blades are engaged. DANGER An unco v ered discharge opening will allo w objects to be thrown in an operator’s or bystander’s direction. Al[...]

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 driv e lev ers loc ked in “neutral”, shift speed control lev er to desired forw ard speed. 3. Slowly squeeze and hold both[...]

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 dec k support link assemblies a verage 6.89 inc hes (appro ximately 6 7/8 inches) (175.01 mm) from the center of the balljoint to the center of the farthest hole . See Figu[...]

Operation Figure 8 For cutting heights above 3.5 inches (38 mm) use the bottom hole. The rollers will still be ef fective against scalping. 1. Anti-scalp roller mounting bracket 2. Cutting height 7. T or que the 3/8–16 whizloc k n ut to 30-35 ft-lb (41-47 N-m) (Figure 9). 8. If the 3/8 nyloc nut has been remo v ed, reinstall and tor que to 30–3[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the machine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystanders. Remo ve the k ey from the ignition s witch, engage parkin[...]

Maintenance Maintenance Ser vice Inter val Maintenance Procedure Every 500 hours • Chang e the h ydraulic lter (Every 250 hours/yearly if using Mobil 1 15W50) • Check wheel hub-slotted tor que specication. Monthly • Check the battery c harge. • Grease the PTO engagement bellcrank. Periodic Maintenance Check Engine Oil Level Service In[...]

Maintenance 2. Lift dec k 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 (if they were remo ved) in the following order: A. Install bushing through blade with bushing ange on bottom (grass) side of blade . Figure 10 1. Install [...]

Maintenance Figure 12 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 brack et to retain it from sliding out. Place the leg of the spring with the loop in the notch in the disc harge deector to hold the discharge deec[...]

Maintenance 1. Stop engine, wait for all mo ving par ts to stop , and remov e k ey or spark plug wire(s). Engag e parking brake . 2. See the Engine Owner’ s Manual for cleaning instr uctions . Change Engine Oil Service Interval: After the rst 5 hours Every 100 hours (May need more often under severe conditions.) 1. Stop engine, wait for all mo[...]

Maintenance Lubrication Chart Fitting Locations Initial Pumps Number of Places Ser vice Inter val 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 2 Daily 3. PTO Engag ement Bellcrank 1 1 1 1 40 hours 4. Pump Driv e Idler Piv ot 2 1 1 1 Y early 5. Clutch Ar m Pi vot 1 1 1 1 40 hours 6. Pump Cont[...]

Maintenance 5. Loosen lter 1/2 turn and allow a small amount of oil to leak from the oil lter (this allo ws air to be purged from the oil lter and supply hose from the hy draulic reser voir). T urn lter cloc kwise until rubber seal contacts the lter adapter . Then tighten the lter an additional 2/3 to 3/4 turn. 6. Raise the rear o[...]

Maintenance a steady ow of oil to o w out from under the housing . R etighten the capscrews . Do this for both pumps . Note: Hydraulic reser voir can be pressurized up to 5 psi to speed this process . 6. If either dri ve wheel still does not rotate , stop and repeat steps 4 and 5 abo ve for the respectiv e pump . If wheels rotate slowly , the[...]

Maintenance Mobil HTS Grease (Or Food-Grade Anti-seize) Mobil HTS grease (or food-grade anti-seize) is used in the following locations: • Between the cutter housing spindle and bearings . • Between the cutter housing spindle and shea ve . • Under top cutter housing bearing guard. Copper-Based Anti-seize Copper-based anti-seize is used in the [...]

Maintenance Adjust the threaded yok e at the bottom of the 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 (.76 cm) 2. Actuating T ab in neutral position 3. Pull the speed control lever bac k to neutral. Check that the neutral safety switc [...]

Maintenance disengag ed whenev er speed control lev ers are mov ed out of the neutral position. Note: The neutral lock latches should be “unlock ed” and in the forw ard position. 2. Loosen the front nut on left h ydro control linkage as sho wn in Figure 16. T urn the rear control linkage adjusting n ut countercloc kwise until wheel rotates forw[...]

Maintenance the mac hine, remov e jac k stands and carefully low er the mac hine to the g round. (Chec k the driv e tire pressure and tire circumference see Check the Tire Pressures section.) 2. R un the unit and obser v e the trac king on a level, smooth, hard surface such as concrete or asphalt. 3. If the unit tracks to one side or the other , tu[...]

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 ve de bris around engine cooling air intake and exhaust system area can cause engine, exhaust area, and h y draulic system to o verheat which can create a re hazard. Clean a[...]

Maintenance Battery Disposal DANGER Batter y electrolyte contains sulfuric acid, which is poisonous and can cause severe bur ns. Sw allowing 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 ubber g lov es to protect skin and clothing when handling electrolyte. • Do Not sw all[...]

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 ov erlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The follo wing table lists some of the common causes [...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. T racking needs adjustment. 1. Adjust the trac king by turning knob on the right hydro control linkage in the direction that the mow er needs to be adjusted to . T urn the knob in 1/4 turn increments until the mower tracks correctly . Mower pulls left or right (with lev ers fully forwar[...]

Schematics Schematics Electrical Diagram 15 & 17 HP KA W ASAKI SAFETY INTERLOCK MODULE TRANSMISSION SWITCH N.O . P ARK BRAKE SWITCH N.O . BLADE SWITCH N.O . OPC SWITCH N.O . KEY SWITCH ENGINE GROUND ENGINE KILL CONNECT ORS ARE VIEWED FROM WIRE END N.C. = NORMALL Y CLOSED N.O . = NORMALL Y OPEN GREEN BLUE ORANGE GREEN YELLOW RED BLACK RED BLACK [...]

Schematics Hydraulic Diagram 41[...]

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 defective in factory [...]

Notes: 43[...]

Notes: 44[...]

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

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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[...]