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Exmark 4500-367 - page 1
NA VIGA TOR ® For Serial Nos. 790,000 & Higher Part No. 4500-367 Rev . A ...
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Exmark 4500-367 - page 2
W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer , birth defects, or other reproductiv e har m. Important: When the mo wer is used or operated on any Califor nia forest, br ush or grass co vered land, a w orking spark arr ester must be attached to ...
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Exmark 4500-367 - page 3
Introduction CONGRATULATIONS on the purchase of y our Exmark Mow er . T his product has been carefully designed and manufactured to giv e you a maximum amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for your Exmark mow er . BEFORE OPERATING Y OUR MO WER, ...
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Exmark 4500-367 - page 4
Contents Introduction .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 3 Safety .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . 5 Safety Alert Symbol . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 5 ...
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Exmark 4500-367 - page 5
Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both in this man ual and on the mac hine to identify important safety messages which m ust be follow ed to av oid accidents This symbol means: ATTENTION! BECOME ALERT! Y OUR SAFETY IS INV OL VED! Figure 2 1. Safety alert symbol The safety alert symbol appears abo ve infor ...
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Exmark 4500-367 - page 6
Safety DANGER In certain conditions gasoline is extremely ammable and v apors are explosi v e. A re or explosion from gasoline can bur n y ou, others, and cause proper ty damage. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never rell the fuel tank or drain the machine indo ...
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Exmark 4500-367 - page 7
Safety • Check that the operator’ s presence controls , safety switc hes , and shields are attached and functioning properly . Do Not operate unless they are functioning properly . Operation W ARNING Operating engine par ts, especially the mufer, become extremely hot. Sev ere bur ns can occur on contact and debris, such as leav es, grass, br ...
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Exmark 4500-367 - page 8
Safety • Stop engine, w ait for all moving parts to stop , and engag e parking brake: – Before refueling . – Before dumping the grass catc her . W ARNING Hands, feet, hair , clothing , or accessories can become entang led in rotating par ts. Contact with the rotating par ts can cause traumatic amputation or sev ere lacerations. • Do Not ope ...
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Exmark 4500-367 - page 9
Safety • A void sudden star ts when mowing do wnhill. Mow er may tip forwards . • Be aw are that operating on wet g rass , across steep slopes or downhill ma y cause the mo wer to lose traction. Loss of traction to the driv e wheels ma y result in sliding and a loss of braking and steering . • Alwa ys av oid sudden starting or stopping on a s ...
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Exmark 4500-367 - page 10
Safety Safety and Instructional Decals • Keep all safety signs legible . R emov e all grease, dirt and debris from safety signs and instructional labels . • R eplace all w or n, damaged, or missing safety signs . • When replacement components are installed, be sure that cur rent safety signs are afx ed to the replaced components . • If a ...
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Exmark 4500-367 - page 11
Safety 103-9034 103-9724 109-4273 109-4638 109-7318 1 16-0404 1 1 ...
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Exmark 4500-367 - page 12
Safety 1 16-1 175 Molded in LH Console Molded into Front of Hopper 12 ...
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Exmark 4500-367 - page 13
Specications Specications Model Numbers Serial Nos: 790,000 and Higher NA V20K C; NA V27K C Systems Engine • Engine Specications: See y our Engine Owner’ s Manual • RPM: Full Speed: 3600 ±50 RPM (No Load) Idle: 1500 RPM Fuel System • Capacity: 7.5 gal. (28 L) • T ype of Fuel: R egular unleaded gasoline, 87 octane or higher . • ...
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Exmark 4500-367 - page 14
Specications • Hydraulic Filter : R eplaceable cartridg e type . – Summer use abov e 32°F (0°C): P/N 109-0071: 25 microns , 10 psi bypass – Winter use belo w 32°F (0°C): P/N 1-523541: 40 microns , 18 psi bypass • Speeds: – 0-7.0 mph (11.3 km/hr) forw ard. – 0-5.5 mph (8.6 km/hr) rev erse. • Driv e wheel release valv es allow ma ...
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Exmark 4500-367 - page 15
Product Overview Curb Weight: 42 inch Deck 48 inch Deck 850 lb (386 kg) 1145 lb (519 kg) T orque Requirements Bolt Location T orque Blade Mounting Bolt 85-110 ft-lb (115-149 N-m) Engine Mounting Bolts 30-35 ft-lb (41-47 N-m) Wheel Lug Nuts 90-95 ft-lb (122-129 N-m) Wheel Motor Mounting Bolts 72-77 ft-lb (98-104 N-m) Wheel Hub Locknut 210-250 ft-lb ...
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Exmark 4500-367 - page 16
Operation Operation Note: Deter mine the left and right sides of the machine from the nor mal operating position. Controls Steering Levers Located in the center in front of the seat. Pulling back on the steering lev ers , progressively slows , then rev erses the direction of trav el of the respectiv e dri ve wheels . By moving both steering levers ...
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Exmark 4500-367 - page 17
Operation Drive Wheel Release V alves Located on the top left front corner of h ydrostatic pumps . Driv e wheel release v alves are used to release the hy drostatic driv e system to allow the machine to be pushed without the engine r unning . Tilt seat up to gain access to pumps . With a 7/16 wrench, turn both v alves one turn counterclockwise to r ...
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Exmark 4500-367 - page 18
Operation Important: Do Not crank the engine continuously for more than ten seconds at a time. If the engine does not star t, allow a 60 second cool-down period betw een star ting attempts. F ailure to follow these guidelines can bur n out the star ter motor . 7. If the chok e is in the “ON” position, gradually return c hoke to the “OFF” po ...
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Exmark 4500-367 - page 19
Operation T o turn left or right, pull one of the steering lev ers back tow ard neutral in the direction desired. The mac hine will mo ve faster the farther the speed control lev er is mo ved aw ay from neutral. 4. T o stop , pull the speed control lev er back to the neutral position. Driving in Rev erse 1. T o mov e rearward in a straight line app ...
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Exmark 4500-367 - page 20
Operation W ARNING Loading a unit on a trailer or tr uck increases the possibility of tip-ov er . Tip-ov er could cause serious injur y or death. • Use extreme caution when operating a unit on a ramp . • Use only a single, full width ramp; Do Not use indi vidual ramps for each side of the unit. • If individual ramps must be used, use enough r ...
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Exmark 4500-367 - page 21
Maintenance Maintenance Note: Deter mine the left and right sides of the mac hine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystanders. Remo ve the k ey from the ignition s witch, engage parki ...
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Exmark 4500-367 - page 22
Maintenance Maintenance Ser vice Inter v al Maintenance Procedure Monthly • Check the battery c harge. Y early • Lubricate g rease ttings . • Lubricate the caster wheel hubs . Periodic Maintenance Check Engine Oil Level Service Interval: Before each use or daily 1. Stop engine and wait for all mo ving parts to stop . Make sure unit is on a ...
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Exmark 4500-367 - page 23
Maintenance Check Safety Interlock System Service Interval: Before each use or daily Note: T o prev ent engine cut-outs on rough ter rain the seat kill switch has a 1/2 second delay . 1. Check starting circuit. Starter should crank with, parking brak e engaged , PTO disengaged and speed control lev er in the neutral position. The operator does not ...
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Exmark 4500-367 - page 24
Maintenance Before reinstalling new lter , apply a thin coating of oil on the surface of the rubber seal. T urn lter clockwise until rubber seal contacts the lter adapter then tighten lter an additional 1/2 to 3/4 tur n. 6. Clean around oil ll cap and remo ve cap . Fill to specied capacity and replace cap . 7. R emov e drain hose ...
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Exmark 4500-367 - page 25
Maintenance Lubrication Chart Fitting Locations Initial Pumps Number of Places Ser vice Inter v al 1. Caster Piv ot *0 3 *Y early 2. PTO Idler 1 1 Y early 3. Pump Idler 1 1 Y early 4. Rear Caster Hub *0 1 *Y early * See step 3 for special lubrication instr uctions on the front and rear caster pi vots and the Lubricate Rear Caster Wheel Hubs section ...
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Exmark 4500-367 - page 26
Maintenance 11. Insert the second bearing and new seal into the wheel. 12. Apply a thread loc king adhesiv e to the 2nd spacer nut and thread onto the axle with the wrench ats facing outward. 13. T or que the n ut to 75-80 in-lb (8-9 N-m), loosen, then re-tor que to 20-25 in-lb (2-3 N-m). Make sure axle does not extend beyond either n ut. 14. R ...
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Exmark 4500-367 - page 27
Maintenance Change Hydraulic System Filter Service Interval: After the rst 250 hours Every 500 hours/Y early (whichever comes rst) thereafter (Every 250 hours/Y early if using Mobil 1 15W50) Note: Use only Exmark P art No . 109-0071 for Summer use abov e 32°F (0°C) or P/N 1-523541 for Winter use belo w 32°F (0°C). (R efer to the Hydrostat ...
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Exmark 4500-367 - page 28
Maintenance Check Wheel Hub Locknuts Service Interval: After the rst 100 hours Every 500 hours thereafter T or que to 210–250 ft-lb (285–339 N-m). Check Wheel Lug Nuts Service Interval: After the rst 100 hours Every 500 hours thereafter T or que to 90–95 ft-lb (122–129 N-m) cross pattern. Fuel T ank — Mounting Hardware Specicatio ...
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Exmark 4500-367 - page 29
Maintenance 10. R e-install clevis pin and hairpin to secure brak e band. 11. Engag e the PTO lev er . 12. Loosen the jam nuts and adjust linkage until the top of the idler arm is aligned with the bottom of notch on tension ar m as sho wn in Figure 9. Figure 9 1. T ension Arm 2. Loosen jam nuts 3. When PT O is engaged, align top of idler arm with b ...
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Exmark 4500-367 - page 30
Maintenance Adjust Safety Switch Adjust all safety switc hes so plunger extends 3/16 inch to 1/4 inc h (4.8 mm-6.4 mm) from switc h body when plunger is compressed (see Figure 12). Figure 12 1. 3/16 inch to 1/4 inch (4.8 mm-6.4 mm) Brake Adjustment Check to make sure each brak e is adjusted properly . 1. Pull the brake lev er up and back to the eng ...
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Exmark 4500-367 - page 31
Maintenance loose enough to be mov ed comfortably by the operator . Figure 15 1. Speed Control Lever 3. Spring disc washers 2. Friction Plate 4. Hex locknut Speed Control Linkage Adjustment W ARNING Engine must be running and driv e wheels must be tur ning so motion control adjustment can be perfor med. Contact with moving par ts or hot surfaces ma ...
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Exmark 4500-367 - page 32
Maintenance across the ter minals in the connector of the wiring harness. 3. Start the engine . 4. R un the unit at least 5 min utes with the speed control lev er at full forward speed to bring hy draulic system oil up to operating temperature. R eturn speed control lever to neutral (full rear) position. 5. T o obtain the neutral position, adjust t ...
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Exmark 4500-367 - page 33
Maintenance Figure 19 1. T o increase steering responsiveness hook pump control sprints directly on anchor bolt. T o decrease steering responsiveness hook pump control springs on anchor tabs as shown. T racking Adjustment See Motion Control Linkage Adjustment section PT O Drive Pulley Alignment PTO dri ve pulley alignment is necessar y for any of t ...
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Exmark 4500-367 - page 34
Maintenance Rear Caster Pivot Bearings Pre-Load Adjustment R emov e dust cap from caster and tighten nyloc nut until w ashers are at. Bac k off 1/4 of a turn to properly set the pre-load on the bearings . If disassembled, make sure the spring disc washers are reinstalled as sho wn in Figure 21. Figure 21 1. Spring disc washers Hopper Door Adjust ...
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Exmark 4500-367 - page 35
Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) CAUTION Excessi ve debris around the engine cooling air intak e and inside of the pump driv e belt compar tment and damaged or missing r ub ber bafes can cause the engine and hy draulic sys ...
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Exmark 4500-367 - page 36
T roubleshooting T roubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mow er use. When a problem occurs , do not o verlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The follo wing table lists some of the common causes ...
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Exmark 4500-367 - page 37
T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e. 1. R educe the ground speed. 2. Oil lev el in the crankcase is low . 2. Add oil to the crankcase . Engine ov erheats . 3. Cooling ns and air passages for the engine are plug ged. 3. R emove the obstructions from the cooling ns and air passages . 1. T ra ...
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Exmark 4500-367 - page 38
Schematics Schematics Electrical Diagram ENGINE ENGINE OVERHEA T BUZZER ENGINE O VERHEA T LED ACCESSOR Y PLUG CLOSED WITH HOPPER DOWN SWITCH IS CLOSED WITH OPERA TOR IN SEA T TEMP SWITCH SEA T DELA Y MODULE CONTROL SEA T SWITCH BA TTER Y GROUND SEA T DELA Y MODULE INPUT HOPPER SWITCH BLACK ORANGE ORANGE PINK PINK ORANGE ORANGE PINK ORANGE PINK T AN ...
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Exmark 4500-367 - page 39
Schematics Electrical Logic Schematic BLACK BLACK ACCESSOR Y PLUG ORANGE BLACK RED L T. BLUE BLACK VIOLET WIPER MOT OR HOPPER FILL SWITCH S P + BUZZER M BLACK L T. BLUE BLACK L T. BLUE BRO WN SEA T SWITCH BA TTER Y (+) 12V RED BRO WN ORANGE PINK PINK ORANGE ORANGE ORANGE DK. BLUE S P + TEMP SWITCH BUZZER ORANGE ORANGE PINK PINK ENGINE OVERHEA T LED ...
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Exmark 4500-367 - page 40
Schematics Hydraulic Diagram G006950 CASE DRAIN CHARGE PUMP HIGH PRESSURE BYP ASS V AL VE BYP ASS V AL VE HIGH PRESSURE FOR W ARD HIGH PRESSURE FOR W ARD HIGH PRESSURE REVERSE HIGH PRESSURE REVERSE 40 ...
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Exmark 4500-367 - page 41
Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty 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 ex ercise of our reasonable discretion) to be defect i ve in factor ...
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Exmark 4500-367 - page 42
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Exmark 4500-367 - page 44
MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF A CCESSORIES AND OPTIONS W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED ...
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