Page 2 - IMPORTANT
ii WARNING POTENTIAL HAZARD ♦ This product is a piece of power equipment. WHAT CAN HAPPEN ♦ Failure to follow safe operating practices can result in serious operator injury or even death. HOW TO AVOID THE HAZARD ♦ Keep all shields, guards and safety devices (especially the grass discharge system) in...
Page 3 - iii; EXMARK PARTS PLUS
iii EXMARK PARTS PLUS PROGRAM EFFECTIVE DATE: September 1, 1995 Program If your Exmark dealer does not have the Exmark part in stock, Exmark will get the parts to the dealer the next business day or the part will be FREE* Guaranteed!! How the Program Works 1. If dealer does not have part in stock ...
Page 4 - iv; CONGRATULATIONS; on the purchase of your Exmark Mower. This product has been; BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL
iv CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. OPERATOR'S MANUAL This manual contains assembly, operating, maintenance, adjustment, and safety instru...
Page 6 - SAFETY ALERT SYMBOL; YOUR SAFETY IS INVOLVED!; CAUTION
- 1 - 1. SAFETY 1.1 SAFETY ALERT SYMBOL This SAFETY ALERT SYMBOL is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents. This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol appears above ...
Page 7 - DO NOT
- 2 - 1.3.4 Thoroughly inspect the area where the equipment is to be used and remove all stones, sticks, wires, bones and other foreign objects which may damage the equipment or cause personal injury to the operator or bystanders. WARNING POTENTIAL HAZARD ♦ Engine exhaust contains carbon monoxide, w...
Page 9 - Do Not; EXTREME; DANGER
- 4 - WARNING POTENTIAL HAZARD ♦ Operating engine parts, especially the muffler, become extremely hot. WHAT CAN HAPPEN ♦ Severe burns can occur on contact. ♦ Debris, such as leaves, grass, brush, etc. can catch fire. HOW TO AVOID THE HAZARD ♦ Allow engine parts, especially the muffler, to cool befor...
Page 10 - midway
- 5 - • See inside the back cover to determine the approximate slope angle of the area to be mowed. • Progressively greater care is needed as the slope increases. • Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope. • B...
Page 11 - MAINTENANCE AND STORAGE; Check all bolts frequently to maintain proper tightness.
- 6 - 1.4.16 This mower was designed for one operator only. Keep all others away from mower during operation. 1.4.17 Do Not mow with the grass deflector raised, removed, or altered unless there is a grass collection system or a mulch kit in place and working properly. 1.4.18 Be aware of the mower di...
Page 12 - WARNING; RIDING ATTACHMENTS; Exmark
- 7 - WARNING POTENTIAL HAZARD ♦ Hydraulic fluid escaping under pressure can penetrate skin and cause injury. WHAT CAN HAPPEN ♦ Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result. HOW TO AVOID T...
Page 16 - ELECTRICAL SYSTEM; speed control lever is; Front Caster
- 11 - 2. SPECIFICATIONS 2.1 MODEL NUMBER: Serial Nos. 440,000 & Higher: TT3615KAC; TT4817KAC; TT5217KAC; TT4817KAEC; TT5217KAEC 2.2 ENGINE 2.2.1 Engine Specifications: See your Engine Owner's Manual. 2.2.2 3600 RPM (No Load). 2.3 FUEL SYSTEM 2.3.1 Capacity: 5.0 gal.(18.9 L.) 2.3.2 Type of Fuel:...
Page 17 - Discharge: Right Side; Discharge chute down; TORQUE REQUIREMENTS; BOLT LOCATION; ASSEMBLY INSTRUCTIONS
- 12 - 2.10 DECK 2.10.1 Cutting Width: Model 36 in. ........................................ 35.25 in. (89.5 cm) Model 48 in. ........................................ 47.25 in. (120.0 cm) Model 52 in. ........................................ 52.00 in. (132.1 cm) 2.10.2 Discharge: Right Side 2.10.3 B...
Page 18 - The machine is shipped with a filled lead acid battery.; Wash
- 13 - 3.2 Service Battery : The machine is shipped with a filled lead acid battery. 3.2.1 Remove battery cover from the machine. DANGER POTENTIAL HAZARD ♦ Charging the battery may produce explosive gasses WHAT CAN HAPPEN ♦ Battery gasses can explode causing serious injury. HOW TO AVOID THE HAZARD ♦...
Page 19 - FIGURE 1; left
- 14 - NOTE: If the positive cable is also disconnected, connect the positive (red) cable to the positive terminal on the battery first , then connect the negative (black) cable to the negative terminal on the battery. Reinstall battery cover. NOTE: If time does not permit charging the battery, or i...
Page 22 - OPERATION INSTRUCTIONS; Familiarize yourself with the controls and operation of the unit.; FIGURE 5
- 17 - 3.19 Follow pre-start instructions as outlined in Section 4.2. NOTE: After starting the engine and engaging the hydro drive, if either of the drive wheels acts sluggish or will not rotate at all, stop engine and refer to Section 5.1.10 on the Hydraulic System Air Purge procedure. 3.20 Perform...
Page 24 - OPERATING INSTRUCTIONS; For a 15 & 17 HP Kawasaki manual start engine
- 19 - 4.1.14 Cold Start Kit: (Manual start units only) Located on the right hand side of engine deck, below the hydro control shield. The cold start kit is used to ease the starting of the unit in cold weather or when the unit has not been operated for a period of time. The cold start kit moves the...
Page 25 - neutral
- 20 - IMPORTANT: For electric start models, do not crank the engine continuously for more than ten (10) seconds at a time. If the engine does not start, allow a 60 second starter cool-down period between starting attempts. Failure to follow these guidelines can burn out the starter motor. On a warm...
Page 26 - For straight ahead motion:
- 21 - FIGURE 6 DRIVE LEVER, NEUTRAL LOCK LATCH OPERATION 4.3.5 Drive Wheel Engagement/Turning: With drive levers locked in “neutral”, shift speed control lever to desired forward speed. Note: The park brake must be disengaged before the speed control lever is moved out of neutral or the engine will...
Page 27 - For manual start engines:; Do not rely solely on parking brake
- 22 - DANGER POTENTIAL HAZARD ♦ An uncovered discharge opening will allow objects to be thrown in an operator’s or bystander’s direction. Also, contact with the blade could occur. WHAT CAN HAPPEN ♦ Thrown objects or blade contact can cause serious injury or death. HOW TO AVOID THE HAZARD ♦ Never op...
Page 28 - PERIODIC MAINTENANCE; See Engine Owner's Manual; operate the engine with oil level below the “LOW”
- 23 - 5. MAINTENANCE & ADJUSTMENTS WARNING POTENTIAL HAZARD ♦ While maintenance or adjustments are being made, someone could start the engine. WHAT CAN HAPPEN ♦ Accidental starting of the engine could seriously injure you or other bystanders. HOW TO AVOID THE HAZARD ♦ Remove the key from the ig...
Page 31 - Do not; After First 250 hrs, then yearly thereafter.
- 26 - 5.1.6 Service pre-cleaner element and air cleaner. Service Interval: See Engine Owner's Manual a) Stop engine and wait for all moving parts to stop. Remove key or spark plug wire(s). b) See engine owner’s manual for cleaning instructions. 5.1.7 Change engine oil. Service Interval: See Engine ...
Page 32 - Changing; Hydraulic system air purge procedure.
- 27 - IMPORTANT : Before re-installing new filter, fill it completely with Mobil 1 15W- 50 and apply a thin coat of oil on the surface of the rubber seal. Turn filter clockwise until rubber seal contacts the filter adapter. Do not tighten yet. d) Fill reservoir as stated in Section 5.1.8. e) Loosen...
Page 33 - Make sure engine is not running; Semi-pneumatic Caster Tires – No maintenance
- 28 - FIGURE 8 CHARGE PUMP LOCATION e) To “prime” charge pump, loosen two hex socket head capscrews (shown in Figure 11) 1-1/2 turns only. Make sure engine is not running . Lift charge pump housing upward and wait for a steady flow of oil to flow out from under housing. Retighten capscrews . Do thi...
Page 34 - PIVOT POINT
- 29 - b) Engage PTO lever. c) Look through the round hole in the left rear corner of the engine deck to inspect blade clutching belt tension. Bolt on blade engagement linkage bellcrank and indicator arm should align within 1/16” (.16 cm) (See Figure 13). Refer to section 5.2.2 for adjustment. 5.1.1...
Page 35 - not; to bond the bearing, next to each OPC hub,
- 30 - a) Stop engine and wait for all moving parts to stop. Remove ignition key or spark plug wire(s). b) Remove cooling shrouds from engine and clean cooling fins. Also clean dust, dirt, and oil from external surfaces of engine, which can cause improper cooling. c) Make sure cooling shrouds are pr...
Page 36 - Monthly
- 31 - 5.1.24 Check battery charge: (Electric start units only) Service Interval: Monthly Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in st...
Page 38 - BLADE ENGAGEMENT LINKAGE; DOES NOT; NEUTRAL SAFETY SWITCH ADJUSTMENT
- 33 - b) With PTO engaged, adjust the linkage length by loosening the locknut on the turnbuckle and adjusting the turnbuckle so that the bolt on the bellcrank and the indicator arm align with each other within 1/16” (.16 cm). See Figure 11. Tighten locknut against turnbuckle. FIGURE 11 BLADE ENGAGE...
Page 40 - HYDRO CONTROL LINK/SWIVEL ADJUSTMENT; Repeat above adjustments if necessary.; DRIVE LEVER AND LATCH IN NEUTRAL POSITION
- 35 - FIGURE 14 HYDRO CONTROL LINK/SWIVEL ADJUSTMENT After adjusting the left hydro control linkage, move the speed control lever to the mid-speed position and then back to the neutral position. Recheck the left drive wheel rotation to see if further adjustment is necessary - be sure the speed cont...
Page 41 - HYDRO PUMP SPRING TENSION SETTING; MOTOR OIL DISPOSAL
- 36 - 3. Make this adjustment for both sides. e) Tracking Adjustment 1. Stop engine and wait for all moving parts to stop. Raise the rear of the machine, remove jack stands and carefully lower the machine to the ground. (Check the drive tire pressure and tire circumference. (See 5.1.11.) 2. Run the...
Page 42 - BATTERY DISPOSAL; NOTE: Kawasaki engines may need to be choked even when warm.
- 37 - 6.2 BATTERY DISPOSAL DANGER POTENTIAL HAZARD ♦ Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns WHAT CAN HAPPEN ♦ Swallowing electrolyte can be fatal or if it touches skin can cause severe burns. HOW TO AVOID THE HAZARD ♦ Wear safety glasses to shield ...
Page 43 - ENGINE TROUBLESHOOTING; The following table lists some of the common causes of trouble.; Engine Service Dealer.; ENGINE TROUBLESHOOTING TABLE; PROBLEM
- 38 - g) Check that there is fuel in the tank and that the fuel valve is open. h) Check that the spark plug wire(s) are properly connected. i) Check for loose or faulty wiring connections. If it is necessary to disconnect wire connectors, Do Not pull on the wires while disconnecting. j) Check for c...
Page 45 - HYDRAULIC DIAGRAM
Page 48 - INDUSTRIAL PARK BOX 808; ALL RIGHTS RESERVED
SEE EXMARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z ® LAZER Z ® HP LAZER Z ® XP LAZER Z ® CT TURF RANGER ® VIKING HYDRO TURF TRACER ® TURF TRACER ® HP METRO ® METRO ® HP ULTRA VAC ™ ULTRA VAC ™ QDS GRASS CATCHER SELF STEERING SULKY MICRO-MULCH ™ ACCESSORY WARNING The engine exhaust from thi...
