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 place and in proper working condition. ♦ Stop engine and wait for all moving parts to stop. Remove spark plug wire(s) or remove key before adjusting, servicing, or performing maintenance.
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 for a "down" unit at the time of request by customer, the dealer contacts his distributor by 1:00 p.m., local time, and requests Exmark Parts Plus shipment of six (6) line items or less. 2.
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 instructions for your Exmark mower. BEFORE OPERATING YOUR MOWER, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY.
TABLE OF CONTENTS 1. SAFETY ............................................................................................PAGE 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Safety Alert Symbol ................................................................................... 1 Training ..................................................................................................... 1 Preparation............................................................................................. 1-3 Operation ....................
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 information, which alerts you to unsafe actions or situations and will be followed by the word DANGER, WARNING, or CAUTION.
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, which is an odorless deadly poison. WHAT CAN HAPPEN ♦ Carbon monoxide can kill you. HOW TO AVOID THE HAZARD ♦ Do not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect.
DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A static charge can ignite gasoline vapors. A fire or explosion from gasoline can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD ♦ Purchase and store gasoline only in an approved container. ♦ Always place gasoline containers on the ground away from your vehicle before filling.
1.4 OPERATION Although hazard control and accident prevention are partially dependent upon the design and configuration of the equipment, these factors are also dependent upon the awareness, concern, prudence and proper training of the personnel involved in the operation, transport, maintenance and storage of the equipment. It is essential that all Operator Safety Mechanisms be connected and in operating condition prior to use for mowing.
1.4.4 Use EXTREME caution when mowing and/or turning on slopes as loss of traction and/or control could occur. Mow across slopes with walk behind mowers, never up and down. Loss of control and/or loss of operator’s footing could result in a fall with an arm or leg getting under the mower or engine deck and sustaining serious injury. Drive slower on slopes. Progressively greater care is needed as the slope increases. DO NOT operate on slopes greater than 20 degrees.
1.5 1.4.17 Be aware of the mower discharge direction and do not point it at anyone. 1.4.18 Do NOT operate the mower under the influence of alcohol or drugs. 1.4.19 Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. 1.4.
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 THE HAZARD ♦ Make sure all hydraulic fluid hoses and lines are in good condition an all hydraulic connections and fittings are tight before applying pressure to hydraulic system.
PART NO. 1-303517 LOCATION: Left Side of Rear Surface of Engine Deck PART NO. 1-413421 LOCATION: Left Rear on Top of Engine Deck 17 HP Kawasaki Electric Start Only PART NO. 1-513747 LOCATION: Battery Cover PART NO. 1-603845 LOCATION: Rear Center of Top Surface of Engine Deck PART NO. 1-413214 LOCATION: Right Side of Hydro Control Crank Arm Standard Pistol Grip Handles PART NO. 1-303102 LOCATION: Upper Handle PART NO. 1-303293 LOCATION: On Top RH Side of Fuel Tank PART NO.
Standard Pistol Grip Handles 15 & 17 HP Kawasaki Manual Start PART NO. 103-1974 LOCATION: Console PART NO. 103-1798 LOCATION: RH Side Console 36” Decks PART NO. 1-413206 LOCATION: Top of Cutter Deck Under Center Belt Shield ECS Handles 17 HP Kawasaki Electric Start PART NO. 103-1976 LOCATION: Console PART NO.
48” & 52” Decks PART NO. 1-413327 LOCATION: Top Center of Cutter Deck Under Center Belt Shield ECS Handles 15 & 17 HP Kawasaki Manual Start PART NO. 103-1977 LOCATION: Console PART NO. 98-5954 LOCATION: Under Mower Deck Belt Shield(s) PART NO. 1-323540 LOCATION: Front of Mower Deck Top Surface ECS Handles PART NO. 103-2242 LOCATION: LH Side of Console ECS Handles PART NO.
2. SPECIFICATIONS 2.1 MODEL NUMBER: Serial Nos. 320,000 & Higher: TT3615KA; TT4817KA; TT5217KA; 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: Regular unleaded gasoline, 87 octane or higher. In countries using the research method, it should be a 90 octane minimum. 2.3.3 Fuel Filter: Replaceable in-line 2.3.
2.9 TIRES Size Quantity Tread Ply Rating Pressure 36” Drive Pneumatic (Air-Filled) 16 x 6.50-8 2 Turf Master 4 14 psi (97 kPa) 48” & 52” Drive Pneumatic (Air-Filled) 16 x 7.50-8 2 Turf Master 4 14 psi (97 kPa) Front Caster Semi-Pneumatic 9 x 3.50-4 2 Smooth 2.10 DECK 2.10.1 2.10.2 Cutting Width: Model 36 in. ........................................ 35.25 in. (89.5 cm) Model 48 in. ........................................ 47.25 in. (120.0 cm) Model 52 in. ........................................ 52.
2.12 TORQUE REQUIREMENTS BOLT LOCATION TORQUE Blade Mounting Bolt .................................................... 115-120 ft-lbs. Cutter Housing Spindle Nut .............................................. 75-80 ft-lbs. Anti-Scalp Roller Bolts...................................................... 40-45 ft-lbs. Mower Deck Support/Engine Deck Mount ........................ 30-35 ft-lbs. Engine Mounting Bolts 15 &17 HP Kawasaki ........................................ 15-20 ft-lbs. 3.
CAUTION POTENTIAL HAZARD ♦ If the ignition is in the “ON” position there is potential for sparks and engagement of components. WHAT CAN HAPPEN ♦ Sparks could cause an explosion or moving parts could accidentally engage causing personal injury. HOW TO AVOID THE HAZARD ♦ Be sure ignition switch is in the “OFF” position before charging the battery. 3.2.3 Connect the negative battery cables.
3.9 Route the throttle cable along the right side of the upper handle, under the fuel tank support, and position the cable on the left side of the engine. Attach throttle cable to engine: a) Position the throttle control lever (located on console) ¼” (6mm) from the upper end of the slot. b) Attach inner wire of the throttle cable to the top hole in the throttle control lever as shown in Figure 2.
3.12 Connect the lower end of the speed control linkage to the speed control crank located at the top rear of the fuel tank support. Secure with clevis pin and hairpin from the bolt bag. 3.13 Install drive lever linkages. For Standard Pistol Grip Handles: Refer to figures 4 and 5. Position speed control lever in neutral. Locate two long clevis pins and two hairpin cotters in bolt bag and temporarily install through drive levers and neutral lock latches, but not through the drive lever linkages.
FIGURE 6 ECS HANDLES DRIVE LEVER LINKAGE INSTALLATION 3.14 Connect wiring harness. For recoil start models: Route the long unattached portion of the wiring harness up the left handle and under the console. Connect the connector on the end of the shorter lead to the keyswitch. Connect the two flag terminals that are in the longer lead to the OPC switch in any order. Continue routing this lead down the right side of the handle and connect the connector on the end of it to the park brake switch.
4. OPERATION INSTRUCTIONS 4.1 Controls 4.1.1 4.1.2 4.1.3 Operator Presence Control (OPC) Levers: Located on the upper handle assembly directly above the handle grips. When these levers are depressed, the OPC system senses that the operator is in the normal operator's position.
4.1.7 4.1.8 4.1.9 4.1.10 4.1.11 4.1.12 4.1.13 4.1.14 Throttle Control: Located on the control console’s right side. The throttle is used to control engine speed. Moving the throttle control forward will increase engine speed and moving it to the rear will decrease engine speed. “Off-Run” Switch (15 & 17 HP Kawasaki Manual Start only): Located on the console. Turn key to the “Run” position to allow the engine to be started. Turn key to the “Off” position to shut engine off.
DANGER POTENTIAL HAZARD ♦ In certain conditions gasoline is extremely flammable and highly explosive. WHAT CAN HAPPEN ♦ A fire or explosion from gasoline can burn you, others, and cause property damage. HOW TO AVOID THE HAZARD ♦ DO NOT smoke while refueling, and stay away from an open flame or where gasoline fumes may be ignited by spark. ♦ Refuel only in a well ventilated area, or refuel outdoors. ♦ Store gasoline in an approved container and keep it out of the reach of children.
4.2.2 Refer to Maintenance and Adjustment Section 5 and perform all of the necessary inspection and maintenance steps. 4.2.3 Familiarize yourself with the controls and operation of unit. See Controls section 4.1 and Operating Instructions section 4.3. 4.3 OPERATING INSTRUCTIONS 4.3.1 Refer to Engine Owner’s Manual for detailed operating instructions regarding the engine. 4.3.2 Starting Engine: Operator must have PTO disengaged and speed control lever in neutral.
CAUTION POTENTIAL HAZARD ♦ If the neutral lock latches are not completely engaged the drive levers could unexpectedly slip into the forward drive position. WHAT CAN HAPPEN ♦ If the drive levers slip into the drive position, the unit could lurch forward and cause injury or property damage. HOW TO AVOID THE HAZARD ♦ Be sure the pins protruding through the slots of each neutral lock latch are completely engaged in the rear slot of each latch.
4.3.6 To Stop: Squeeze drive levers back to the neutral position. Move neutral lock latches into the neutral lock position and release drive levers. Move the speed control lever to the neutral position. 4.3.7 PTO Engagement: DANGER POTENTIAL HAZARD ♦ The rotating blades under the mower deck are dangerous. WHAT CAN HAPPEN ♦ Blade contact can cause serious injury or kill you. HOW TO AVOID THE HAZARD ♦ DO NOT put hands or feet under the mower or mower deck when the PTO is engaged.
5. MAINTENANCE & ADJUSTMENTS 5.1 PERIODIC MAINTENANCE WARNING POTENTIAL HAZARD ♦ If you leave the key in the ignition switch, 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 ignition switch and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).
5.1.3 Clean grass build-up under deck and check mower blades. Service Interval: Daily CAUTION POTENTIAL HAZARD ♦ Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. WHAT CAN HAPPEN ♦ The mechanical or hydraulic jacks may not be enough support or may misfunction allowing the unit to fall, which could cause injury. HOW TO AVOID THE HAZARD ♦ DO NOT rely solely on mechanical or hydraulic jacks for support.
FIGURE 8 BLADE BOLT INSTALLATION 5.1.4 Check safety interlock system. Service Interval: Daily a) For your safety, your Exmark mower is equipped with Operator Presence Controls (OPC). When either the mower blades are engaged, or the speed control lever is not in neutral and both hands are removed from the handles, the mower engine MUST stop. b) For Electric Start Units Only: Check starting circuit.
5.1.7 Change engine oil. Service Interval: See Engine Owner's Manual NOTE: Change oil after first five (5) hours of operation. Follow engine manufacturer’s recommendations for future oil changes. a) Disengage blade clutch. b) Stop engine and wait for all moving parts to stop. Remove ignition key or spark plug wire(s). c) Drain oil while engine is warm from operation. d) Oil drain valve is located on left hand side of engine. Place pan under machine to catch oil and open valve with 10mm wrench.
5.1.9 Change hydraulic system filter. Service Interval: After First 250 hrs, then yearly thereafter. Note: Use only Exmark Part No. 513211 for Summer use above 32° F (0° C) or Part No. 523541 for Winter use below 32° F (0° C). Refer to 2.7.2 for filter specifications. a) Place unit on a level surface, stop engine and wait for all moving parts to stop. Remove ignition key or spark plug wire(s). b) Carefully clean area around filter.
d) Thoroughly clean the area around each of the charge pump housings. LOOSEN 1-1/2 TURNS ONLY CHARGE PUMP CAP FIGURE 9 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 this for both pumps. Note: Hydraulic reservoir can be pressurized to up to 5 psi to speed this process.
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” (See Figure 12). Refer to section 5.2.2 for adjustment. 5.1.14 Lubrication Service Interval: Refer to Chart. a) Stop engine and wait for all moving parts to stop. Remove ignition key or spark plug wire(s).
5.1.17 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 properly reinstalled. Operating the engine without cooling shrouds will cause engine damage due to overheating. Change fuel filter.
Note: To prevent damage due to freezing, battery should be fully charged before putting away for winter storage. a) Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater.
FIGURE 10 CUTTING HEIGHT ADJUSTMENT FIGURE 11 ANTI-SCALP ROLLER BOLT INSTALLATION ANTI-SCALP ROLLER AND CUTTING HEIGHT ADJUSTMENT c) Adjust anti-scalp rollers For Normal Operating Conditions. Place rollers in one of the positions shown in Figure 11. Rollers will maintain 3/4 in. (19 mm) clearance to the ground to minimize gouging and roller wear or damage. For Maximum Deck Flotation, place rollers one hole position lower. Rollers should maintain 1/4 in. (6.4 mm) minimum clearance to ground.
Indicator Align Bolt to Indicator within 1/16” 5.2.3 Turnbuckle Engine Deck FIGURE 12 BLADE ENGAGEMENT LINKAGE PTO Safety Switch: Mounted to a tab on the inside lefthand side of the fuel tank support. a) Stop engine and wait for all moving parts to stop. Remove ignition key or spark plug wire(s). b) With PTO disengaged and the bellcrank touching the rear of the slot in the engine deck, adjust the PTO safety switch (if needed) until the bellcrank arm is 5/16” from the switch body.
1. Raise the rear of the machine up onto jack stands high enough to raise the drive wheels off of the ground. 2. Start the engine and move the throttle ahead to the full throttle position. Place the neutral lock latches in the drive position as shown in Figure 7 and move the speed control lever to the “mid-speed” position. Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill. 3.
neutral, until left wheel stops rotating forward. Turn the rear nut an additional 1/2 turn and tighten the front nut making sure not to put a bind on the linkage. Make sure flat part of linkage is perpendicular to pin part of swivel. See Figure 15. FIGURE 15 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.
STANDARD PISTOL GRIP HANDLES ECS HANDLES FIGURE 16 DRIVE LEVER AND LATCH IN NEUTRAL POSITION 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 unit and observe the tracking on a level, smooth, hard surface such as concrete or asphalt. 3.
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 eyes, and rubber gloves to protect skin and clothing when handling electrolyte. ♦ Do not swallow electrolyte. Federal law states that batteries should not be placed in the garbage.
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 corrosion at all wiring connections. Even minor corrosion may cause a faulty connection. Clean connector terminals thoroughly with electrical contact cleaner, apply dielectric grease and reconnect.
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10. WARRANTY Limited Warranty Exmark Commercial Turf Equipment 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 manufactured by Exmark and found by us (in the exercise of our reasonable discretion) to be defective in factory material or workmanship.
As a condition to this warranty, customer shall have read the operator's manual and shall have completed and returned to Exmark Warranty Company, within the prescribed time, the Exmark warranty registration. The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein.
NOTES - 44 -
SERVICE RECORD Date Description of Work Done Done By - 45 - Service
ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCE POST, POLE ETC.) THI S IS A THIS 2 0 ° SLO PE ° S LO P E IS A 1 5° SL OPE THIS IS A 10 THIS IS A 5° SLOPE FOLD ALONG APPROPRIATE LINE EXAMPLE: COMPARE SLOPE WITH FOLDED EDGE.
SEE EXMARK’S COMPLETE LINE OF PRODUCTS FOR TURF CARE LAZER Z® LAZER Z® HP LAZER Z® XP TURF RANGER® TURF TRACER® TURF TRACER® HP METRO® METRO® HP VIKING HYDRO ULTRA VAC™ GRASS CATCHER SELF STEERING SULKY MICRO-MULCH ™ ACCESSORY WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. ©1997,1998, 1999, 2000, 2001 EXMARK MFG. CO. INC. INDUSTRIAL PARK BOX 808 BEATRICE, NE 68310 PART NO.
