Page 2 - WARNING
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: IMPORTANT The engine in this product is not equipped with a spark arrestermuffler. It is a violati...
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; Clean Engine and Exhaust System
Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...
Page 5 - Safety; Safety Alert Symbol; Safe Operating Practices; Training
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 on level ground,in an open area, when the engine is cold.Wipe up any gasoline that spills. • Ne...
Page 7 - Operation; DO NOT; Slope Operation; Extreme
Safety Operation WARNING Operating engine parts, especially the muffler,become extremely hot. Severe burns can occuron contact and debris, such as leaves, grass,brush, etc. can catch fire. • Allow engine parts, especially the muffler, tocool before touching. • Remove accumulated debris from mufflera...
Page 8 - Do Not mow slopes when grass is wet.; Maintenance and Storage; Always shield eyes and face from battery.
Safety DANGER Operating on wet grass or steep slopes cancause sliding and loss of control. Loss of controland/or loss of operator’s footing could result in afall with an arm or leg getting under the moweror engine deck which may result in seriousinjury, death or drowning. • Mow across slopes, never ...
Page 9 - Do Not swallow electrolyte.; CAUTION
Safety 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 handling electrolyte. • Do N...
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: 850,000 and Higher Manual Start Models: THP16KA363; THP16KA483; THP18KA523; THP16KA363CA; THP16KA483CA Electric Start Models: THP20KAE483; THP20KAE523; THP20KAE483CA Systems Engine • Engine Specifications: See your Engine Owner’sManual • RPM: F...
Page 15 - Cutting Deck; Cutting Height Adjustment:; Dimensions; Weights will vary slightly depending on engine
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 - Determine the left and right sides of the; Controls; Drive Levers; Located on the control console’s right side.; Speed Control Lever; Located in middle of control console.
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 - Never use methanol, gasoline; Operating Instructions; Open the Fuel Shut-Off Valve; Do Not crank the engine
Operation Pre-Start Fill fuel tank on level ground. For best results useonly clean, fresh regular grade unleaded gasoline withan octane rating of 87 or higher. Important: Never use methanol, gasoline containing methanol, gasohol containing morethan 10% ethanol, premium gasoline, or whitegas because ...
Page 20 - PTO Engagement; Drive Lever/Neutral Lock Latch Operation
Operation PTO Engagement DANGER The rotating blades under the mower deck aredangerous. Blade contact can cause seriousinjury or kill you. Do Not put hands or feet under the mower ormower 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.; Be sure the fuel shut-off valve is closed.
Operation Figure 9 1. Spring disc washer(cone towards nut ) 3. 3/8 nyloc-torque to 30-35ft-lb (41-47 N-m) 2. Front right anti-scalpbracket shown 4. 3/8-16 whizlock nuttorque to 30-35 ft-lb(41-47 N-m) Transporting Transporting a Unit WARNING Loading the mower onto a trailer without strongenough or pr...
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 could seriouslyinjure you or other bystanders. Remove the key f...
Page 25 - Periodic Maintenance; Check Engine Oil Level; 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 - Service Interval: As required; Do Not lean over the batteries.
Maintenance Recommended JumpStarting Procedure (ElectricStart Units Only) Service Interval: As required 1. Check the weak battery for terminal corrosion (white, green, or blue “snow”), it must be cleanedoff prior to jump starting. Clean and tightenconnections as necessary. CAUTION Corrosion or loose...
Page 27 - Check Mower Blades; Lift deck and secure in raised position as stated in; Clean Grass Build-Up Under Deck; C. Apply lubricant to threads of blade bolt as; To remove a damaged or worn discharge
Maintenance Check Mower Blades Service Interval: Before each use or daily 1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake. 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 rep...
Page 28 - Check for Loose Hardware; Service Air Cleaner; Service Interval: Every 25 hours—Service
Maintenance Figure 13 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 29 - 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 need more often undersevere conditions. See theEngine Owner’s manualfor additional information.)Every 200 hours/Yearly(whichever comesfirst)—Replace the paperelement. 1. Stop engine, wait for all moving parts to stop, and remove key or spark plug wire(s). Engage parkingbrake. 2. See the ...
Page 30 - Check Spark Plugs; Service Interval: Every 160 hours; Change Fuel Filter
Maintenance 2. Lubricate fittings with NGLI grade #2 multi-purpose gun grease. Refer to the following chart for fitting locationsand lubrication schedule. Lubrication Chart Fitting Locations Initial Pumps Number of Places Service Interval 36 inch Deck 48 inch Deck 52 inch Deck 1. CasterWheelBearings...
Page 31 - Hydraulic System Air; Hydraulic System Air Purge; Check Hydraulic Oil
Maintenance Exmark Premium Hydro Oil is recommended.Refer to the chart for an acceptable alternative: Hydro Oil Change Interval Exmark Premium HydroOil (Preferred) 500 Hours Mobil 1 15W50 250 Hours 5. Loosen filter 1/2 turn and allow a small amount of oil to leak from the oil filter (this allows air...
Page 32 - Check the Hydraulic Oil Level; Thread Locking Adhesives
Maintenance 4. Thoroughly clean the area around each of the charge pump housings. 5. To “prime” charge pump, loosen two hex socket head capscrews (shown in Figure 14) 1 1/2 turns only. Make sure engine is not running. Lift the charge pump housing upward and wait fora steady flow of oil to flow out f...
Page 33 - Check Mower; Adjustments
Maintenance which could cause binding of the OPC levers anderratic operation. • Fuel tank studs, where studs are inserted into tank. 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 bear...
Page 34 - Adjust Neutral Control Linkages:; Adjust Hydro Control Linkages:
Maintenance speed control linkage (see Figure 16) until thetabs are positioned correctly. Figure 16 Viewed from Left Side of Unit 1. Neutral Safety Switch 3. 5/16 inch (7.9 mm) 2. Actuating Tab in neutralposition 3. Pull the speed control lever back to neutral. Check that the neutral safety switch a...
Page 35 - If inconsistent neutral occurs,
Maintenance disengaged whenever speed control levers aremoved out of the neutral position. Note: The neutral lock latches should be “unlocked” and in the forward position. 2. Loosen the front nut on left hydro control linkage as shown in Figure 17. Turn the rearcontrol linkage adjusting nut counterc...
Page 36 - Tracking Adjustment; Check the Tire; PTO Safety Switch
Maintenance Tracking Adjustment 1. Stop engine and wait for all moving parts to stop. 2. Check the drive tire pressures and tire circumferences as stated in Check the Tire Pressures section in Maintenance. 3. Run the unit and observe the tracking on a level, smooth, hard surface such as concrete or ...
Page 37 - Cleaning; Service Interval: Every 100 hours; Clean Debris From Machine; Waste Disposal; 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 cause engine,exhaust area, and hydraulic system to overheatw...
Page 39 - 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 41 - Schematics; Electrical Diagram
Schematics Schematics Electrical Diagram Electrical Diagram 41
Page 42 - Hydraulic Diagram
Page 43 - 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...
