Exmark Turf Tracer HP 4500-358 User Manual

TURFTRACER®HP
ForSerialNos. 790,000&Higher
PartNo.4500-358Rev.A
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct containschemicalsknowntotheStateof Californiatocausecancer,birthdefects,or otherreproductiveharm.
Important:Whenthemowerisusedoroperated onanyCaliforniaforest,brushorgrasscovered land,aworkingsparkarrestermustbeattached tothemufer.Ifnot,theoperatorisviolating statelaw,Section4442PublicResourceCode.To acquireasparkarresterforyourunit,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.
©2008—ExmarkMfg.Co.,Inc. IndustrialParkBox808 Beatrice,NE68310
Contactusatwww.Exmark.com.
2
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.
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.....................................25
CheckSafetyInterlockSystem.......................27
CheckforLooseHardware............................27
ServicePre-CleanerElementandAir
Cleaner......................................................27
ChangeEngineOil........................................28
CheckHydraulicOilLevel.............................28
CheckTirePressures.....................................28
CheckConditionOfBelts..............................28
LubricateGreaseFittings...............................28
CheckSparkPlugs.........................................29
ChangeHydraulicSystemFilter.....................29
WheelHub-SlottedNutTorque
Specication..............................................31
InspectPTOClutchingBeltTension..............31
ThreadLockingAdhesives.............................31
MobilHTSGrease(OrFood-Grade
Anti-seize).................................................32
Copper-BasedAnti-seize...............................32
DielectricGrease...........................................32
Adjustments.....................................................32
DeckLeveling...............................................32
PumpDriveBeltTension...............................32
PTOClutchingBeltTension..........................32
MowerDeckDriveBeltTension....................32
ParkBrakeAdjustment..................................32
HydroDriveLinkageAdjustment..................32
HydroPumpSpringTensionSetting..............35
PTOSafetySwitch........................................35
Cleaning...........................................................36
CleanEngineandExhaustSystem
Area..........................................................36
RemoveEngineShroudsandCleanCooling
Fins...........................................................36
CleanDebrisFromMachine..........................36
CleanGrassBuild-UpUnderDeck................36
WasteDisposal..............................................36
Troubleshooting...................................................38
Schematics...........................................................40
4
Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER, WARNING,orCAUTION.
Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.
Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.
Preparation
Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.
Wearappropriateclothingincludingsafetyglasses, substantialfootwear,longtrousers,andhearing protection.DoNotoperatewhenbarefootor whenwearingopensandals.Longhair,loose clothingorjewelrymaygettangledinmoving parts.
CAUTION
DANGER:Whitelettering/Redbackground. Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Y ellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)can notreadEnglishitistheowner’sresponsibilityto explainthismaterialtothem.
Thismachineproducessoundlevelsin excessof85dBAattheoperator’searand cancausehearinglossthroughextended periodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
Inspecttheareawheretheequipmentistobe usedandremoveallrocks,toys,sticks,wires, bones,andotherforeignobjectswhichcanbe thrownbythemachineandmaycausepersonal injurytotheoperatororbystanders.
Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.
Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.
5
Safety
DANGER
Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.
Fillthefueltankoutdoorsinanopen area,whentheengineiscold.Wipeup anygasolinethatspills.
Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.
DoNotllthefueltankcompletely full.Addgasolinetothefueltankuntil thelevelis1/4to1/2inch(6–13mm) belowthebottomofthellerneck.This emptyspaceinthetankallowsgasoline toexpand.
Neversmokewhenhandlinggasoline, andstayawayfromanopenameor wheregasolinefumesmaybeignitedby spark.
Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.
Addfuelbeforestartingtheengine. Neverremovethecapofthefueltankor addfuelwhenengineisrunningorwhen theengineishot.
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,especiallythe mufer,becomeextremelyhot.Severeburns canoccuroncontactanddebris,suchas leaves,grass,brush,etc.cancatchre.
Allowengineparts,especiallythemufer, tocoolbeforetouching.
Removeaccumulateddebrisfrommufer andenginearea.
Installandmaintaininworkingordera sparkarresterbeforeusingequipment onforest-covered,grass-covered,or brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcan killyou.
DoNotrunengineindoorsorinasmall connedareawheredangerouscarbon monoxidefumescancollect.
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.Lossof controland/orlossofoperator’sfooting couldresultinafallwithanarmorleg gettingunderthemowerorenginedeck whichmayresultinseriousinjury,deathor drowning.
Mowacrossslopes,neverupanddown.
DoNotmowslopeswhengrassiswet.
DoNotmowneardrop-offsornearwater.
DoNotmowslopesgreaterthan20 degrees.
Reducespeedanduseextremecaution onslopes.
Avoidsuddenturnsorrapidspeed changes.
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.
Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.
Checkallboltsfrequentlytomaintainproper tightness.
Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.
Allreplacementpartsmustbethesameas orequivalenttothepartssuppliedasoriginal equipment.
8
WARNING
Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbya doctorfamiliarwiththisformofinjuryor gangrenemayresult.
Makesureallhydraulicuidhoses andlinesareingoodconditionand allhydraulicconnectionsandttings aretightbeforeapplyingpressureto hydraulicsystem.
Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.
Usecardboardorpaper,notyourhands, tondhydraulicleaks.
Safety
Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrol leversinneutralandshuttingoffthe enginebeforeperforminganyworkon thehydraulicsystem.
9
Safety
SafetyandInstructionalDecals
Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.
Replaceallworn,damaged,ormissingsafety signs.
Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.
Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.
1-303508
Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.
Safetysignsmaybeafxedbypeelingoffthe backingtoexposetheadhesivesurface.Apply onlytoaclean,drysurface.Smoothtoremove anyairbubbles.
Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.
1-403143
1-303517
1-413206
36inchDecksOnly
1-413214
1-403005
10
1-413327
48inchand52inchDecksOnly
1-413421
Safety
103-1798
1-513747
19HPKawasakiElectricStartOnly
1-553049
98-5954
103-1976
19HPKawasakiElectricStart
11
Safety
103-1977
15HPand17HPKawasakiManualStart
103-2242
103-2076
103-2243
103-2103
103-4935
12
Safety
109-3148
116-0404
13
Specications
Specications
ModelNumbers
SerialNos:790,000andHigher
ManualStartModels:THP15KA363;THP17KA483;THP17KA523;THP17KA363CA;THP17KA483CA
ElectricStartModels:THP19KAE483;THP19KAE523;THP19KAE483CA
Systems
Engine
EngineSpecications:SeeyourEngineOwner’s Manual
RPM:FullSpeed:3600±50RPM(NoLoad)
FuelSystem
Capacity:5.0gal.(18.9L)
TypeofFuel:Regularunleadedgasoline,87 octaneorhigher.
FuelFilter:ReplaceableIn-line
FuelShut-OffValve:1/4turnincrements
ElectricalSystem(ElectricStart)
ChargingSystem:FlywheelAlternator
ChargingCapacity:15amps
BatteryType:BCIGroupU1
BatteryVoltage:12Volt
Polarity:NegativeGround
Fuses:Two20ampbladetype
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.
SafetyInterlockSystem
Operatormusthavespeedcontrolleverinneutral, PTOdisengaged,(andOPCleversdepressedfor electricstart)tostartengine.ReleaseofOPC leverswillcausetheenginetostopifspeedcontrol leverisnotinneutraland/orPTOisengaged.
Parkbrakemustbeengagedtomovespeed controloutofneutralorenginewillkill.
OperatorControls
SteeringControl:Fingertipdrivecontrollevers provideindependentspeedcontrol,brakingand
WheelDriveSystem
DrivewheelsaredirectcoupledtoParkerwheeldrive motorswith1inch(25.4mm)taperedshaft.
14
Specications
Tires&Wheels
DriveFrontCaster
Pneumatic (Air-Filled)
3648&52
Quantity
Tread
Size16x6.50–816x7.50–89x3.50-4
PlyRating
Pressure
222
TurfMasterTurfMasterSmooth
44
14psi (97kPa)
Pneumatic (Air-Filled)
14psi (97kPa)
CuttingDeck
CuttingWidth:
–36inchDeck:35.25inches(89.5cm)
–48inchDeck:47.25inches(120.0cm)
–52inchDeck:52.00inches(132.1cm)
Discharge:Side
Semi­Pneumatic
AllDecks
Dimensions
OverallWidth:
36inch Deck
Deector Up
Deector Down
36.1inches (91.7cm)
46.25inches (117.5cm)
OverallLength:
36inchDeck48inchDeck52inchDeck
77.3inches (196.3cm)
73.7inches (187.2cm)
OverallHeight:
36inchDeck48inchDeck52inchDeck
44.1inches (112.0cm)
44.1inches (112.0cm)
48inch Deck
48.1inches (122.2cm)
58.25inches (148.0cm)
52inch Deck
53.0inches (134.6cm)
62.6inches (159.0cm)
75.9inches (192.8cm)
44.1inches (112.0cm)
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
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.
MulchingKit:Optional
Bagger:Optional
15
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