Exmark 4500-497 - Manuals - manualsarea.com

Page 2 - WARNING; CALIFORNIA

WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects, orother reproductive harm. Important: When the mower is used or operated on any California forest, brush or grass coveredland, a working sp...

Page 3 - Introduction; CONGRATULATIONS; on the purchase of your

Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation. This manual contains operating, maintenance,adjustment, and safety instructions for your Exmark...

Page 4 - Contents; Remove Engine Shrouds and Clean Cooling

Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...

Page 5 - Safety; Safety Alert Symbol; Safe Operating Practices; Training; CAUTION

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both inthis manual and on the machine to identify importantsafety messages which must be followed to avoidaccidents This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Figure 2 1. Safety alert symbol The s...

Page 6 - DANGER; Avoid prolonged breathing of vapors.

Safety DANGER In certain conditions gasoline is extremelyflammable and vapors are explosive. A fire or explosion from gasoline can burnyou, others, and cause property damage. • Fill the fuel tank outdoors in an openarea, when the engine is cold. Wipe upany gasoline that spills. • Never refill the fu...

Page 7 - Operation

Safety Operation WARNING Operating engine parts, especially themuffler, become extremely hot. Severe burnscan occur on contact and debris, such asleaves, grass, brush, etc. can catch fire. • Allow engine parts, especially the muffler,to cool before touching. • Remove accumulated debris from mufflera...

Page 8 - Slope Operation; Use; Extreme; caution when mowing and/or turning; Do Not mow slopes when grass is wet.

Safety • Stop the blades, slow down, and use caution whencrossing surfaces other than grass and whentransporting the mower to and from the area tobe mowed. • Be aware of the mower discharge path and directdischarge away from others. • Do Not operate the mower under the influenceof alcohol or drugs. ...

Page 9 - Drive slowly and carefully.; Maintenance and Storage

Safety WARNING There is no rollover protection when the rollbar is down. Wheels dropping over edges,ditches, steep banks, or water can causerollovers, which may result in serious injury,death or drowning. • Keep the roll bar in the raised and lockedposition and use seat belt. • Lower the roll bar on...

Page 11 - Safety and Instructional Decals

Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease,dirt and debris from safety signs and instructionallabels. • Replace all worn, damaged, or missing safetysigns. • When replacement components are installed, besure that current safety signs are affixed to there...

Page 15 - Specifications; Model Numbers

Specifications Specifications Model Numbers Serial Nos: 790,000 and Higher FR27KC; FR31BV Systems Engine • Engine Specifications: See your Engine Owner’sManual • RPM: Full Speed: 3750 ±50 RPM (No Load)Idle: 1500 RPM Fuel System • Capacity: 8.5 gal. (32 L) • Type of Fuel: Regular unleaded gasoline, 8...

Page 16 - Hydrostatic Ground Drive System; Hydraulic Filter: Replaceable cartridge type.; Cutting Deck

Specifications • Mounting: Hinged to tilt up for access tohydraulic pumps, battery and other components.The seat is held in the tilted position with alinkage. Adjustable fore and aft seat track. • Armrests: Standard seat: foam padded flip-uparmrests. Optional suspension seat: moldedadjustable flip-u...

Page 17 - Mulching Kit: Optional; Dimensions; Minimum Turning Radius; Torque Requirements

Specifications • Cutting Height Adjustment: Adjusts from 1 1/2inches (3.8 cm) to 5 inches (12.7 cm) infinitelyvariable. • Mulching Kit: Optional • Bagger: Optional Dimensions Overall Width: 52 inchDeck 60 inchDeck 72 inchDeck WithoutDeck 49.0 inches(124.5 cm) 49.0 inches(124.5 cm) 53.0 inches(135 cm...

Page 18 - Product Overview; Determine the left and right sides of the; Controls; Motion Control Levers; Throttle Control; Located on right fuel tank console.; Park Brake Lever; Pull the lever up and rearward to engage the brake.

Operation Product Overview Figure 4 1. Fuel Cap 4. Seat Belt 2. Roll Bar 5. Motion Control Lever 3. Controls 6. Parking Brake Lever Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control levers located o...

Page 19 - Do Not overtighten. Do

Operation Push the lever forward and down to disengage thebrake. The unit must be tied down and brake engaged whentransporting. Ignition Switch Located on right fuel tank console. The ignition switch is used to start and stop theengine. The switch has three positions “OFF”, “ON”and “START”. Insert k...

Page 20 - Operating Instructions; Lower the roll bar only when; Open the Fuel Shut-Off Valve; Do Not crank the engine; Engaging the PTO

Operation Refer to the Maintenance section and perform all thenecessary inspection and maintenance steps. Operating Instructions Raise the Rollover Protection System(ROPS) Important: Lower the roll bar only when absolutely necessary. 1. Remove the hairpin cotter pins and remove the two roll bar pins...

Page 21 - Operator must be in seat before the; Disengaging the PTO; Use caution when making turns.; Driving Forward

Operation DANGER An uncovered discharge opening will allowobjects to be thrown in an operator’s orbystander’s direction. Also, contact with theblade could occur. Thrown objects or bladecontact can cause serious injury or death. Never operate the mower with the dischargedeflector raised, removed, or ...

Page 22 - Driving in Reverse; Transporting; Transporting a Unit; Do Not transport FrontRunner

Operation 3. To move forward in a straight line apply equal forward pressure to both levers. To turn left or right, pull the motion control leverback toward neutral in the direction desired. The machine will move faster the farther themotion control levers are moved away fromneutral. 4. To stop, pul...

Page 23 - Loading a Unit; Do Not attempt to turn the unit; Avoid sudden acceleration when driving on a ramp.

Operation Loading a Unit Use extreme caution when loading units on trailersor trucks. One full width ramp is required. If it isnot possible to use one full width ramp, use enoughindividual ramps to simulate a full width continuousramp. Ramp should be long enough so that the anglesbetween the ramp an...

Page 24 - Maintenance

Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are beingmade, someone could start the engine.Accidental starting of the engine couldseriously injure you or other bystanders. Remove the key f...

Page 25 - Periodic Maintenance; Check Engine Oil Level; Service Interval: Before each use or daily; Check Battery Charge; Service Interval: Monthly

Maintenance Maintenance Service Interval Maintenance Procedure Every 500 hours • Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)• Check the wheel hub locknuts torque specification. Monthly • Check the battery charge. Yearly • Grease the fold lock pin.• Grease the rear cas...

Page 27 - EXMARK; Check Seat Belt; Check for Loose Hardware; Service Air Cleaner; Do Not; Change Engine Oil; Service Interval: After the first 5 hours; Check Hydraulic Oil Level; Service Interval: Every 40 hours

Maintenance Note: If machine does not pass any of these tests, Do Not operate. Contact your authorized EXMARK SERVICE DEALER. Important: It is essential that operator safety mechanisms be connected and in properoperating condition prior to use for mowing. Check Rollover ProtectionsSystems (Roll Bar)...

Page 28 - Service Interval: As required; Check Tire Pressures; Check Condition Of Belts; Lubricate Grease Fittings; See chart for service intervals.

Maintenance 2. Tilt seat up. 3. Clean area around hydraulic reservoir cap and remove cap. Oil level should be to the top of thebaffle inside the tank. If not, add oil. Use ExmarkPremium Hydro oil. Replace hydraulic reservoircap and tighten until snug. Do Not overtighten. Note: The baffle is labeled ...

Page 29 - Lubricate Rear

Maintenance Lubrication Chart Fitting Locations Initial Pumps Number of Places Service Interval 1. Hitchand CylinderPivots 2 4 40 Hours 2. FoldPivot Pin 2 2 100 Hours 3. FoldLock Pin 2 2 Yearly 4. RearCaster Pivot *0 1 *Yearly 5. BeltIdlers 1 2 Yearly 6. MotionControlPivots 1 2 Yearly 7. TransferSpr...

Page 30 - To prevent seal and bearing damage,; Lubricate Brake Handle Pivot

Maintenance 10. With the open end of the wheel facing up, fill the area inside the wheel around the axle full ofNGLI grade #1 multi-purpose grease. 11. Insert the second bearing and new seal into the wheel. 12. Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the w...

Page 31 - Service Interval: After the first 250 hours; Service Interval: After the first 100 hours; Thread Locking Adhesives

Maintenance Replacement Filters Kohler Kohler P/N 2405010–15 Micron Briggs & Stratton Briggs & Stratton P/N 695327– 30 Micron Change Hydraulic SystemFilter Service Interval: After the first 250 hours Every 500 hours/Yearly(whichever comesfirst) thereafter(Every 250 hours/Yearly ifusing Mobil...

Page 32 - Dielectric Grease; Adjustments; Pump Drive Belt Tension

Maintenance • Pump drive sheave set screws. • Line shaft sheave setscrews. • Square head setscrews on Hydro pump controlarms. • Sheave retaining bolt in the end of enginecrankshaft. • Caster wheel spacer nuts. • Fuel tank bulkhead fitting nuts. • Motion control tab retaining bolt. Adhesives such as ...

Page 33 - Temporarily

Maintenance Figure 12 1. Park brake engaged 3. Thin nyloc nut 2. Yoke 4. 1/8 inch (3 mm) gapbetween nut and yoke. 5. If park brake does not fully disengage when the lever is disengaged check the brake rod linkageassembly. The assembly should measure 7 3/8inch (18.7 cm) from the center of the ball jo...

Page 35 - For additional weight transfer adjustment, repeat; Clutch Shim; Using a pneumatic line, blow out any debris

Maintenance Figure 16 Right-Hand Side of Unit Shown 1. Re-install spring in outerholes to reduce springtension. 3. Remove e-ring andwasher. 2. Weight transfer spring. 7. Re-install the left fender. 8. For additional weight transfer adjustment, repeat steps 4 through 7 on the right side of the unit. ...

Page 36 - Troubleshooting

Maintenance 3. Check the condition of the wire harness leads, connectors, and terminals. Clean or repair asnecessary. 4. Verify that 12V is present at the clutch connector when the PTO switch is engaged. 5. Measure the gap between the rotor and armature. If the gap is greater than .04 inch (1 mm), p...

Page 37 - c. Engage and disengage the PTO switch; Cleaning; Clean all debris from rotating engine air intake; Remove front panel from engine and clean around; Do Not use water to clean engine.

Maintenance If the clutch does not disengage,reinstall the shim and reference the Troubleshooting section. c. Engage and disengage the PTO switch ten consecutive times to ensure the clutchis functioning properly. If the clutchdoes not engage properly, reference the Troubleshooting section. Cleaning ...

Page 38 - Service Interval: Every 80 hours; Remove cooling shroud clean-out covers from; Waste Disposal; Motor Oil Disposal; Do Not swallow electrolyte.

Maintenance Remove Engine Shrouds andClean Cooling Fins Service Interval: Every 80 hours 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 2. Remove cooling shroud clean-out covers from engine and clean cooling fins. Also clean dust,dirt, and oil from external ...

Page 39 - condition prior to mower use.

Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use. When a problem occurs, Do Not overlook the simple causes. For example: starting problems could becaused by an empty fuel tank. The followi...

Page 41 - Schematics; Electrical Diagram —27HP Kohler

Schematics Schematics Electrical Diagram —27HP Kohler BA TT (POS) CIRCUIT BREAKER BA TT (NEG) BL ACK BL ACK ORANGE ORANGE M OT OR (FWD) M OT OR (REV) RED RED BLACK BLACK GREY / BLACK GREY L T BLUE YELL OW / BL ACK ORANGE ORANGE YELL OW / BL ACK ORANGE PINK / BLACK GREY GREY RED BL ACK DK GREEN DK GR...

Page 42 - Electrical Diagram – 31HP Briggs & Stratton

Schematics Electrical Diagram – 31HP Briggs & Stratton 3 I A S B X Y SE AT DEL AY MODULE CONT ROL SE AT DEL AY MODULE INPUT SE AT SWITCH P TO CLUTCH P TO SWITCH G ROUND FUSE 20 AMP KILL REL AY ST A RT REL AY BRAKE SWITCH LH M O TION CONT RO L RH M O TION CONT ROL IGNITION SWITCH HOUR METER FUSE ...

Page 43 - Electrical Logic Schematic – 27HP Kohler

Schematics Electrical Logic Schematic – 27HP Kohler DK. GREEN FUEL SOLENOID REGUL AT OR ENGINE KILL OIL PRESSURE ST A RTER SOLENOID DK. GREEN DK. GREEN T AN BLACK BLACK WHITE DK. GREEN / WHITE BLACK BLACK DK. GREEN / WHITE ORANGE / BLACK YELL OW PINK / BLACK DK. GREEN DK. GREEN DK. GREEN DK. GREEN L...

Page 44 - Electrical Logic Schematic – 31HP Briggs & Stratton

Schematics Electrical Logic Schematic – 31HP Briggs & Stratton ST A RT SOLENOID 5 1 2 4 3 RED ORANGE RED 40 AMP CIRCUIT BREAKER BL ACK YELL O W / BL ACK BL ACK AUX 15A - 12V OUTLET AC C Y PL U G (HEADLIGHT) BLUE / BL AC K WHITE / BL ACK BL ACK ORANGE / BL ACK DK GREEN TA N WHITE DK BLUE GREY GRE...

Page 45 - Hydraulic Diagram

Schematics Hydraulic Diagram CASE DRAIN CHARGE PUMP HIGH PRESSURE G007220 BYPASS VALVE BYPASS VALVE HIGH PRESSUREREVERSE HIGH PRESSUREFORWARD HIGH PRESSUREREVERSE HIGH PRESSUREFORWARD 45

Page 46 - Exmark Commercial Turf Equipment

Conditions and Products Covered Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty 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 exercise of our reason...

Page 49 - Service Record

Service Record Date: Description of Work Done: Service Done By: 49

Page 52 - M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S; SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS; WALK-BEHIND ACCESSORIES AND OPTIONS

M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS WALK-BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO-MULCH SYSTEM TURF STRIPER STANDON CUSTOM RIDE SEAT SUSPENSION SYSTEM FULL SUSPENSION SEAT DECK LIFT ASSIST KIT HITCH KI...