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
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
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; DO NOT; Slope Operation; Extreme
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 - Do Not mow slopes when grass is wet.; Maintenance and Storage
Safety DANGER Operating on wet grass or steep slopes cancause sliding and loss of control. Loss ofcontrol and/or loss of operator’s footingcould result in a fall with an arm or leggetting under the mower or engine deckwhich may result in serious injury, death ordrowning. • Mow across slopes, never u...
Page 10 - 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 14 - Specifications; Model Numbers
Specifications Specifications 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 Specifications: See your Engine Owner’sManual • RPM: F...
Page 15 - Cutting Deck; Dimensions
Specifications Tires & Wheels Drive Front Caster Pneumatic(Air-Filled) Pneumatic(Air-Filled) Semi-Pneumatic 36 48 & 52 All Decks Quantity 2 2 2 Tread Turf Master Turf 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 kPa) 14 psi(97 kPa) Cutting Deck • Cu...
Page 16 - Torque Requirements; Product Overview
Product Overview Torque Requirements Bolt Location Torque Cutter Housing SpindleNut 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/MowerDeck Support MountBolts 30-35 ft-lb (41-47 N-m) Anti-Scalp Roller NylocNut See Figure 9 30-35 ft-lb (...
Page 17 - Controls; Drive Levers; Speed Control Lever
Operation Operation Note: Determine 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 abovethe handle grips. When these levers are depressed, the OPC systemsenses that the operator ...
Page 18 - Do Not; Tracking Adjustment Knob; Starting
Operation Park Brake Lever Located on the left side of the unit above thehydraulic tank. The brake lever engages the park brake on the drivewheels. Pull the lever up and rearward to engage the brake. Push the lever forward and down to disengage thebrake. When parking on a steep slope, the wheels mus...
Page 19 - Operating Instructions; Open the Fuel Shut-Off Valve; Do Not crank the engine
Operation Pre-Start Fill fuel tanks. For best results use only clean, freshregular grade unleaded gasoline with an octane ratingof 87 or higher. Regular grade leaded gasoline mayalso be used; however, combustion chamber andcylinder head will require more frequent service. SeeEngine Owner’s Manual. D...
Page 20 - PTO Engagement; Disengaging the PTO; Drive Lever/Neutral Lock Latch Operation
Operation PTO Engagement DANGER The rotating blades under the mower deckare dangerous. Blade contact can causeserious injury or kill you. Do Not put hands or feet under the moweror mower deck when the blades are engaged. DANGER An uncovered discharge opening will allowobjects to be thrown in an oper...
Page 21 - Driving Forward; Adjusting the Cutting Height; To maintain correct cutting
Operation Figure 5 1. Drive Lever in neutralposition 3. Drive Lever in forwardposition 2. Drive Lever locked inneutral position 4. Drive Lever in reverseposition Driving Forward 1. Release the parking brake. 2. With drive levers locked in “neutral”, shift speed control lever to desired forward speed...
Page 22 - Check; Adjusting the Anti-Scalp Rollers; For Maximum Deck Flotation
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 average 6.89 inches (approximately6 7/8 inches) (175.01 mm) from the center ofthe balljoint to...
Page 23 - Transporting; Transporting a Unit; If necessary, use assistance when loading.
Operation Figure 8 For cutting heights above 3.5 inches (38 mm) use the bottom hole. The rollers will still be effective against scalping. 1. Anti-scalp rollermounting bracket 2. Cutting height 7. Torque the 3/8–16 whizlock nut to 30-35 ft-lb (41-47 N-m) (Figure 9). 8. If the 3/8 nyloc nut has been ...
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; Check Mower Blades; Service Interval: Before each use or daily
Maintenance Maintenance Service Interval Maintenance Procedure Every 500 hours • Change the hydraulic filter (Every 250 hours/yearly if using Mobil 1 15W50)• Check wheel hub-slotted torque specification. Monthly • Check the battery charge.• Grease the PTO engagement bellcrank. Periodic Maintenance C...
Page 26 - Clean Grass Build-Up Under Deck; Service Interval: As required
Maintenance 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. Reinstall the blades (if they were removed) in the following order: A. Install bushing through blade with bushing flange on bottom...
Page 27 - Check for Loose Hardware
Maintenance Figure 12 1. Rod 4. Mower deck 2. Spring 5. Discharge deflectorbracket 3. Discharge deflector 6. Assembled view 3. Hook the bent end of the rod around the front discharge deflector bracket to retain it fromsliding out. Place the leg of the spring with theloop in the notch in the discharg...
Page 28 - Change Engine Oil; Service Interval: After the first 5 hours; Check Hydraulic Oil Level; Check Tire Pressures; Service Interval: Every 40 hours; Check Condition Of Belts; Service Interval: Every 40 hours; Lubricate Grease Fittings; See chart for service intervals.
Maintenance 1. Stop engine, wait for all moving parts to stop, and remove key or spark plug wire(s). Engage parkingbrake. 2. See the Engine Owner’s Manual for cleaning instructions. Change Engine Oil Service Interval: After the first 5 hours Every 100 hours (Mayneed more often undersevere conditions...
Page 29 - Check Spark Plugs; Service Interval: Every 160 hours; Change Fuel Filter
Maintenance Lubrication Chart Fitting Locations Initial Pumps Number of Places Service Interval 36 inch Deck 48 inch Deck 52 inch Deck 1. CasterWheelBearings 12 2 2 2 Daily 2. CasterPivots 2 2 2 2 Daily 3. PTOEngagementBellcrank 1 1 1 1 40 hours 4. PumpDrive IdlerPivot 2 1 1 1 Yearly 5. ClutchArm Pi...
Page 30 - Hydraulic System Air; Hydraulic System Air Purge; Check Hydraulic Oil
Maintenance 5. Loosen filter 1/2 turn and allow a small amount of oil to leak from the oil filter (this allows air tobe purged from the oil filter and supply hose fromthe hydraulic reservoir). Turn filter clockwiseuntil rubber seal contacts the filter adapter. Thentighten the filter an additional 2/...
Page 31 - Check the Hydraulic Oil Level; Thread Locking Adhesives
Maintenance a steady flow of oil to flow out from under thehousing. Retighten the capscrews. Do this forboth pumps. Note: Hydraulic reservoir can be pressurized up to 5 psi to speed this process. 6. If either drive wheel still does not rotate, stop and repeat steps 4 and 5 above for the respectivepu...
Page 32 - Check Mower; Dielectric Grease; Adjustments; Deck Leveling; Pump Drive Belt Tension; Inspect PTO Clutching Belt Tension; Park Brake Adjustment
Maintenance Mobil HTS Grease (OrFood-Grade Anti-seize) Mobil HTS grease (or food-grade anti-seize) is usedin the following locations: • Between the cutter housing spindle and bearings. • Between the cutter housing spindle and sheave. • Under top cutter housing bearing guard. Copper-Based Anti-seize ...
Page 35 - Check the Tire Pressures; PTO Safety Switch
Maintenance the machine, remove jack stands and carefullylower the machine to the ground. (Check thedrive tire pressure and tire circumference see Check the Tire Pressures section.) 2. Run the unit and observe the tracking on a level, smooth, hard surface such as concreteor asphalt. 3. If the unit t...
Page 36 - Cleaning; Service Interval: Every 80 hours; Clean Debris From Machine; Motor Oil Disposal
Maintenance Cleaning Clean Engine and ExhaustSystem Area Service Interval: Before each use or daily (May be required moreoften in dry or dirtyconditions.) CAUTION Excessive debris around engine cooling airintake and exhaust system area can causeengine, exhaust area, and hydraulic systemto overheat w...
Page 37 - Battery Disposal; Do Not swallow electrolyte.
Maintenance Battery Disposal DANGER Battery electrolyte contains sulfuric acid,which is poisonous and can cause severeburns. Swallowing electrolyte can be fatal orif it touches skin can cause severe burns. • Wear safety glasses to shield eyes, andrubber gloves to protect skin and clothingwhen handli...
Page 38 - Troubleshooting; 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 be causedby an empty fuel tank. The followi...
Page 40 - Schematics; Electrical Diagram; Electrical Diagram; 9 HP KAWASAKI
Schematics Schematics Electrical Diagram 15 & 17 HP KAWASAKI SAFETY INTERLOCK MODULE TRANSMISSION SWITCH N.O. PARK BRAKE SWITCH N.O. BLADE SWITCH N.O. OPC SWITCH N.O. KEY SWITCH ENGINE GROUND ENGINE KILL CONNECTORS ARE VIEWED FROM WIRE ENDN.C. = NORMALLY CLOSEDN.O. = NORMALLY OPEN GREEN BLUE ORA...
Page 41 - Hydraulic Diagram
Page 42 - 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 45 - Service Record
Service Record Date: Description of Work Done: Service Done By: 45
Page 48 - 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...
