Exmark Automobile Parts 000 Higher User Manual

VANTAGE  
For Serial Nos.  
850,000 & Higher  
Part No. 4500-648 Rev. D  
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Introduction  
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.  
This manual contains operating, maintenance,  
adjustment, and safety instructions for your Exmark  
mower.  
Figure 1  
1. Model and serial number location  
BEFORE OPERATING YOUR MOWER,  
CAREFULLY READ THIS MANUAL IN ITS  
ENTIRETY.  
Model No.  
Serial No.  
By following the operating, maintenance, and safety  
instructions, you will prolong the life of your mower,  
maintain its maximum efficiency, and promote safe  
operation.  
If additional information is needed, or should you  
require trained mechanic service, contact your  
authorized Exmark equipment dealer or distributor.  
Exmark parts manuals are available online at  
All Exmark equipment dealers and distributors are  
kept informed of the latest methods of servicing  
and are equipped to provide prompt and efficient  
service in the field or at their service stations. They  
carry ample stock of service parts or can secure them  
promptly for you from the factory.  
All Exmark parts are thoroughly tested and inspected  
before leaving the factory, however, attention is  
required on your part if you are to obtain the fullest  
measure of satisfaction and performance.  
Whenever you need service, genuine Exmark parts,  
or additional information, contact an Authorized  
Service Dealer or Exmark Customer Service and have  
the model and serial numbers of your product ready.  
Figure 1 identifies the location of the model and serial  
numbers on the product. Write the numbers in the  
space provided.  
3
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Contents  
Introduction ........................................................... 3  
Torque Requirements .................................... 15  
Periodic Maintenance ....................................... 26  
4
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Safety  
• Never let children or untrained people operate  
Safety  
Safety Alert Symbol  
This Safety Alert Symbol (Figure 2) is used both in  
this manual and on the machine to identify important  
safety messages which must be followed to avoid  
accidents.  
or service the equipment. Local regulations may  
restrict the age of the operator.  
• Only adults and mature teenagers should operate  
a mower, and even mature teenagers should have  
adult supervision. Be sure a teenager:  
1. has read and understands the Operator’s  
Manual and recognizes the risks involved;  
This symbol means: ATTENTION! BECOME  
ALERT! YOUR SAFETY IS INVOLVED!  
2. is sufficiently mature to use caution; and  
3. is of sufficient size and weight to operate  
the controls comfortably and to manage the  
mower without taking risks.  
Figure 2  
• The owner/user can prevent and is responsible  
for accidents or injuries occurring to himself or  
herself, other people or property.  
1. Safety alert symbol  
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.  
Preparation  
• Evaluate the terrain to determine what accessories  
and attachments are needed to properly and  
safely perform the job. Only use accessories and  
attachments approved by Exmark.  
DANGER: White lettering / Red background.  
Indicates an imminently hazardous situation which, if  
not avoided, Will result in death or serious injury.  
• Wear appropriate clothing including safety glasses,  
substantial footwear, long trousers, and hearing  
protection. Do Not operate when barefoot or  
when wearing open sandals. Long hair, loose  
clothing or jewelry may get tangled in moving  
parts.  
WARNING: Black lettering / Orange background.  
Indicates a potentially hazardous situation which, if  
not avoided, Could result in death or serious injury.  
CAUTION: Black lettering / Yellow background.  
Indicates a potentially hazardous situation which, if  
not avoided, May result in minor or moderate injury.  
CAUTION  
This manual uses two other words to highlight  
information. Important calls attention to special  
mechanical information and Note emphasizes  
general information worthy of special attention.  
This machine produces sound levels in  
excess of 85 dBA at the operator’s ear and  
can cause hearing loss through extended  
periods of exposure.  
Wear hearing protection when operating this  
machine.  
Safe Operating Practices  
Training  
• Inspect the area where the equipment is to be  
used and remove all rocks, toys, sticks, wires,  
bones, and other foreign objects which can be  
thrown by the machine and may cause personal  
injury to the operator or bystanders.  
• Read the Operator’s Manual and other training  
material. If the operator(s) or mechanic(s) can  
not read English it is the owner’s responsibility to  
explain this material to them.  
• Become familiar with the safe operation of the  
equipment, operator controls, and safety signs.  
• All operators and mechanics should be trained.  
The owner is responsible for training the users.  
5
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Safety  
DANGER  
DANGER  
In certain conditions gasoline is extremely  
flammable and vapors are explosive.  
In certain conditions during fueling, static  
electricity can be released causing a spark  
which can ignite gasoline vapors. A fire or  
explosion from gasoline can burn you and  
others and cause property damage.  
A fire or explosion from gasoline can burn  
you, 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.  
• Always place gasoline containers on the  
ground away from your vehicle before  
filling.  
• Never refill the fuel tank or drain the  
machine indoors or inside an enclosed  
trailer.  
• Do Not fill gasoline containers inside a  
vehicle or on a truck or trailer bed because  
interior carpets or plastic truck bed liners  
may insulate the container and slow the  
loss of any static charge.  
• Do Not fill the fuel tank completely full.  
Fill the fuel tank to the bottom of the filler  
neck. The empty space in the tank allows  
gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine  
or emission system (if equipped).  
• When practical, remove gas-powered  
equipment from the truck or trailer and  
refuel the equipment with its wheels on  
the ground.  
• Never smoke when handling gasoline,  
and stay away from an open flame or  
where gasoline fumes may be ignited by  
spark.  
• If this is not possible, then refuel such  
equipment on a truck or trailer from a  
portable container, rather than from a  
gasoline dispenser nozzle.  
• Store gasoline in an approved container  
and keep it out of the reach of children.  
• If a gasoline dispenser nozzle must be  
used, keep the nozzle in contact with the  
rim of the fuel tank or container opening  
at all times until fueling is complete.  
• Add fuel before starting the engine.  
Never remove the cap of the fuel tank or  
add fuel when engine is running or when  
the engine is hot.  
WARNING  
• If fuel is spilled, Do Not attempt to start  
the engine. Move away from the area of  
the spill and avoid creating any source of  
ignition until fuel vapors have dissipated.  
Gasoline is harmful or fatal if swallowed.  
Long-term exposure to vapors has caused  
cancer in laboratory animals. Failure to use  
caution may cause serious injury or illness.  
• Do Not operate without entire exhaust  
system in place and in proper working  
condition.  
• Avoid prolonged breathing of vapors.  
• Keep face away from nozzle and gas  
tank/container opening.  
• Keep away from eyes and skin.  
• Never siphon by mouth.  
• Check that the operator’s presence controls,  
safety switches, and shields are attached and  
functioning properly. Do Not operate unless they  
are functioning properly.  
6
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Safety  
– After striking a foreign object or abnormal  
Operation  
vibration occurs (inspect the mower for  
damage and make repairs before restarting  
and operating the mower).  
WARNING  
Operating engine parts, especially the  
muffler, become extremely hot. Severe burns  
can occur on contact and debris, such as  
leaves, grass, brush, etc. can catch fire.  
– Before clearing blockages.  
– Whenever you leave the mower.  
• Stop engine, wait for all moving parts to stop, and  
engage parking brake:  
• Allow engine parts, especially the muffler,  
to cool before touching.  
– Before refueling.  
– Before dumping the grass catcher.  
– Before making height adjustments.  
• Remove accumulated debris from muffler  
and engine area.  
• Install and maintain in working order a  
spark arrester before using equipment  
on forest-covered, grass-covered, or  
brush-covered unimproved land.  
WARNING  
Hands, feet, hair, clothing, or accessories can  
become entangled in rotating parts. Contact  
with the rotating parts can cause traumatic  
amputation or severe lacerations.  
WARNING  
Engine exhaust contains carbon monoxide,  
which is an odorless deadly poison that can  
kill you.  
• Do Not operate the machine without  
guards, shields, and safety devices in  
place and working properly.  
• Keep hands, feet, hair, jewelry, or clothing  
away from rotating parts.  
Do Not run engine indoors or in a small  
confined area where dangerous carbon  
monoxide fumes can collect.  
NEVER carry passengers. DO NOT operate  
the mower when people, especially children, or  
pets are in the area.  
• Operate only in daylight or good artificial light,  
keeping away from holes and hidden hazards.  
• Be alert, slow down and use caution when making  
turns. Look behind and to the side before  
changing directions.  
• Be sure all drives are in neutral and parking brake  
is engaged before starting engine.  
• Stop the blades, slow down, and use caution when  
crossing surfaces other than grass and when  
transporting the mower to and from the area to  
be mowed.  
• Never raise deck with blades running.  
• Never operate the mower with damaged guards,  
shields, or covers. Always have safety shields,  
guards, switches and other devices in place and in  
proper working condition.  
• Be aware of the mower discharge path and direct  
discharge away from others.  
• Never mow with the discharge deflector raised,  
removed or altered unless there is a grass  
collection system or mulch kit in place and  
working properly.  
• Do Not operate the mower under the influence  
of alcohol or drugs.  
• Use extreme care when loading or unloading the  
machine into a trailer or truck.  
• Do Not change the engine governor setting or  
overspeed the engine.  
• Use care when approaching blind corners, shrubs,  
trees, or other objects that may obscure vision.  
• Park the machine on level ground. Stop engine,  
wait for all moving parts to stop, remove key and  
engage parking brake:  
Slope Operation  
– Before checking, cleaning or working on the  
mower.  
Use Extreme caution when mowing and/or turning  
on slopes as loss of traction and/or tip-over could  
7
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Safety  
occur. The operator is responsible for safe operation  
on slopes.  
Maintenance and Storage  
• Disengage drives, lower implement, set parking  
brake, stop engine and remove key or disconnect  
spark plug wire. Wait for all movement to stop  
before adjusting, cleaning or repairing.  
DANGER  
Operating on wet grass or steep slopes can  
cause sliding and loss of control. 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  
which may result in serious injury, death or  
drowning.  
• Keep engine and engine area free from  
accumulation of grass, leaves, excessive grease  
or oil, and other debris which can accumulate  
in these areas. These materials can become  
combustible and may result in a fire.  
• Let engine cool before storing and do not store  
near flame or any enclosed area where open pilot  
lights or heat appliances are present.  
• Mow across slopes, never up and down.  
• Do Not mow slopes when grass is wet.  
• Do Not mow near drop-offs or near water.  
• Shut off fuel while storing or transporting. Do  
Not store fuel near flames or drain indoors.  
• Do Not mow slopes greater than 20  
degrees.  
• Park machine on level ground. Never allow  
untrained personnel to service machine.  
• Reduce speed and use extreme caution  
on slopes.  
• Use jack stands to support components when  
required.  
• Avoid sudden turns or rapid speed  
changes.  
• Carefully release pressure from components with  
stored energy.  
• Disconnect battery or remove spark plug wire  
before making any repairs. Disconnect the  
negative terminal first and the positive last.  
Reconnect positive first and negative last.  
• See inside the back cover to determine the  
approximate slope angle of the area to be mowed.  
• Remove or mark obstacles such as rocks, tree  
limbs, etc. from the mowing area. Tall grass can  
hide obstacles.  
• Use care when checking blades. Wrap the blade(s)  
or wear gloves, and use caution when servicing  
them. Only replace damaged blades. Never  
straighten or weld them.  
• Watch for ditches, holes, rocks, dips and rises that  
change the operating angle, as rough terrain could  
overturn the machine.  
• Keep hands and feet away from moving parts.  
If possible, do not make adjustments with the  
engine running.  
• Avoid sudden starts when mowing uphill because  
the mower may tip backwards.  
• Be aware that operating on wet grass, across steep  
slopes or downhill may cause the mower to lose  
traction. Loss of traction to the drive wheels may  
result in sliding and a loss of braking and steering.  
• Charge batteries in an open well ventilated area,  
away from spark and flames. Unplug charger  
before connecting or disconnecting from battery.  
Wear protective clothing and use insulated tools.  
• Always avoid sudden starting or stopping on a  
slope. If tires lose traction, disengage the blades  
and proceed slowly off the slope.  
• Follow the manufacturer’s recommendations for  
wheel weights or counter weights to improve  
stability.  
• Use extreme care with grass catchers or  
attachments. These can change the stability of the  
machine and cause loss of control.  
8
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Safety  
DANGER  
WARNING  
Charging or jump starting the battery may  
produce explosive gases. Battery gases can  
explode causing serious injury.  
Removing standard original equipment  
parts, or using non-Exmark replacement  
parts and accessories may alter the warranty,  
traction, and safety of the machine. Failure  
to use original Exmark parts could cause  
serious injury or death.  
• Keep sparks, flames, or cigarettes away  
from battery.  
• Ventilate when charging or using battery  
in an enclosed space.  
Replace all parts including, but not limited to  
tires, belts, and blades with original Exmark  
parts.  
• Make sure venting path of battery is  
always open once battery is filled with  
acid.  
• Always shield eyes and face from battery.  
WARNING  
Hydraulic fluid escaping under pressure  
can penetrate skin and cause injury. 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.  
DANGER  
Battery electrolyte contains sulfuric acid,  
which is poisonous and can cause severe  
burns. Swallowing electrolyte can be fatal or  
if it touches skin can cause severe burns.  
• Make sure all hydraulic fluid hoses  
and lines are in good condition and  
all hydraulic connections and fittings  
are tight before applying pressure to  
hydraulic system.  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
• Do Not swallow electrolyte.  
• Keep body and hands away from pinhole  
leaks or nozzles that eject high pressure  
hydraulic fluid.  
• In the event of an accident, flush with  
water and call a doctor immediately.  
• Use cardboard or paper, not your hands,  
to find hydraulic leaks.  
CAUTION  
• Safely relieve all pressure in the hydraulic  
system by placing the motion control  
levers in neutral and shutting off the  
engine before performing any work on  
the hydraulic system.  
If the ignition is in the “ON” position there  
is potential for sparks and engagement  
of components. Sparks could cause an  
explosion or moving parts could accidentally  
engage causing personal injury.  
Be sure ignition switch is in the “OFF”  
position before charging the battery.  
• Keep all guards, shields and all safety devices in  
place and in safe working condition.  
• Check all bolts frequently to maintain proper  
tightness.  
• Frequently check for worn or deteriorating  
components that could create a hazard.  
9
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Safety  
Safety and Instructional Decals  
• Keep all safety signs legible. Remove all grease,  
dirt and debris from safety signs and instructional  
labels.  
• New safety signs may be obtained from  
your authorized Exmark equipment dealer or  
distributor or from Exmark Mfg. Co. Inc.  
• Replace all worn, damaged, or missing safety  
signs.  
• Safety signs may be affixed by peeling off the  
backing to expose the adhesive surface. Apply  
only to a clean, dry surface. Smooth to remove  
any air bubbles.  
• When replacement components are installed, be  
sure that current safety signs are affixed to the  
replaced components.  
• Familiarize yourself with the following safety signs  
and instruction labels. They are critical to the safe  
operation of your Exmark commercial mower.  
• If an attachment or accessory has been installed,  
make sure current safety signs are visible.  
1-303508  
109-3148  
1-403005  
98-5954  
115-4186  
1. Interval  
2. Power Take-off (PTO)  
3. Parking brake  
4. Neutral  
5. Operator presence switch  
6. Battery  
106-5517  
1. Warning—Do Not touch the hot surface.  
10  
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Safety  
116-0404  
116-3260  
1. Forward position - faster  
2. Backward position - slower  
116-2040  
116-3267  
116-3076  
116-3283  
11  
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Safety  
116-3290  
116-1886  
116-1887  
3. Neutral  
1. Fast  
2. Slow  
4. Reverse  
116-3067  
1. PTO-on  
2. PTO-off  
3. Fast  
4. Slow  
5. Choke-on  
6. Choke-off  
12  
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Specifications  
Specifications  
Model Numbers  
Serial Nos: 850,000 and Higher  
VT20KAS484; VT20KAS524; VT24KAS484; VT24KAS524; VT24KAS484CA; VT24KAS524CA  
Systems  
necessary for the operator to be on the platform  
to start the engine.)  
Engine  
• Mower blades will stop if the right side motion  
control lever is moved or released into the PTO  
disengage position.  
• Engine Specifications: See your Engine Owner’s  
Manual  
• RPM: Full Speed: 3600 ±100 RPM (No Load)  
• Engine will stop if the motion control levers are  
moved from the neutral position with the park  
brake engaged.  
Fuel System  
• Capacity: 8.0 gal. (30.2 L)  
Operator Controls  
• Type of Fuel: Regular unleaded gasoline, 87  
octane or higher; containing no more than 10%  
methanol or ethanol.  
Steering Control: Fingertip drive control levers  
provide independent speed control, braking and  
neutral to each drive wheel for moving forward or  
reverse, stopping, and power turning.  
• Fuel Filter: Replaceable In-line  
• Fuel Shut-Off Valve: 1/4 turn increments  
Transmission  
Electrical System (Electric Start)  
• Charging System: Flywheel Alternator  
• Charging Capacity: 15 amps  
• Battery Type: BCI Group U1  
• Battery Voltage: 12 Volt  
• Polarity: Negative Ground  
• Fuses:  
• Two Hydro Gear variable displacement high  
efficiency pumps independently coupled to two  
high efficiency Parker/Ross wheel drive motors.  
• Hydraulic Oil: Use Exmark Premium Hydro Oil.  
• Hydraulic Oil Capacity: 2.4 qt. (2.2 L)  
• Hydraulic Filter is replaceable cartridge type.  
– 30 amp main fuse  
P/N 109-4180: 25 microns, 10 psi bypass  
(Summer use above 32°F (0°C))  
– 25 amp charging system fuse  
– 10 amp PTO fuse  
P/N 1-523541: 40 microns, 18 psi bypass (Winter  
use below 32°F (0°C))  
– 15 amp accessory fuse  
• Speeds:  
Safety Interlock System  
– 0-8.0 mph (13 km/hr) forward.  
– 0-4.0 mph (6 km/hr) reverse.  
• LCD indicators appear for the park brake, drive  
levers, and operator presence in the message  
display on the front control panel.  
• Drive wheels release valves allow machine to be  
moved when engine is not running.  
Note: Because the PTO must be disengaged  
to start the engine, the LCD indicator will not  
illuminate at this time.  
Wheel Drive System  
• PTO must be disengaged and motion control  
levers in neutral to start engine. (It is not  
Drive wheels are direct coupled to Parker wheel drive  
motors with 1 inch (25.4 mm) tapered shaft.  
13  
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Specifications  
Tires & Wheels  
Dimensions  
Drive  
Front Caster  
Overall Width:  
Pneumatic  
Semi-  
(Air-Filled)  
Pneumatic  
48 inch Deck  
52 inch Deck  
Quantity  
Tread  
2
2
Deflector Up  
51.8 inches  
(131.6 cm)  
56.3 inches  
(143.0 cm)  
Turf Master  
20 x 10.00–8  
4
Smooth  
11 x 4.00-5  
Deflector Down 59.6 inches  
(151.4 cm)  
64.8 inches  
(164.6 cm)  
Size  
Ply Rating  
Pressure  
14 psi  
(97 kPa)  
Overall Length:  
48 inch Deck  
52 inch Deck  
Platform Up  
59.0 inches  
(150.0 cm)  
59.0 inches  
(150.0 cm)  
Cutting Deck  
• Cutting Width:  
Platform Down 74.0 inches  
(188.0 cm)  
74.0 inches  
(188.0 cm)  
– 48 inch Deck: 48 inches (121.9 cm)  
– 52 inch Deck: 52.00 inches (132.1 cm)  
• Discharge: Side  
Overall Height:  
• Blade Size: (3 ea.)  
48 inch Deck  
52 inch Deck  
50.0 inches (127.0 cm)  
50.0 inches (127.0 cm)  
– 48 inch Deck: 16.25 inches (41.3 cm)  
– 52 inch Deck: 18.00 inches (45.7 cm)  
Tread Width: (Outside to Outside of  
Tires, Widthwise)  
• Blade Spindles: Solid steel spindles with 1.00 inch  
(25.4 mm) I.D. bearings.  
48 inch Deck  
52 inch Deck  
• Deck Drive:  
46.5 inches (118.1 cm)  
46.5 inches (118.1 cm)  
– Electric clutch mounted on engine shaft.  
– Blades driven by one belt (w/self-tensioning  
idlers).  
Curb Weight:  
• Deck: Full floating deck is attached to support  
frame, removable for service. Deck design allows  
for bagging, mulching or side discharge.  
48 inch Deck  
52 inch Deck  
855 lb (388 kg)  
866 lb (393 kg)  
• Deck Depth:  
Note: Weights will vary slightly depending on  
engine.  
– 48 inch Deck: 5.5 inches (14.0 cm)  
– 52 inch Deck: 5.5 inches (14.0 cm)  
• Cutting Height Adjustment:  
Adjusts from 1 inch (2.5 cm) to 5 inches (12.7 cm)  
in 1/4 inch (6.4 mm) increments  
• Mulching Kit: Optional  
• Bagger: Optional  
14  
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Product Overview  
Torque Requirements  
Product Overview  
Bolt Location  
Torque  
Cutter Housing Spindle  
Nut  
140-145 ft-lb  
(190-197 N-m)  
Blade Mounting Bolt  
55-60 ft-lb (75-81 N-m)  
(lubricate with anti-seize)  
30-35 ft-lb (41-47 N-m)  
Engine Deck/Mower  
Deck Support Mount  
Bolts  
Engine Mounting Bolts  
Wheel Lug Nuts  
15-20 ft-lb (20-27 N-m)  
90-95 ft-lb (122-129 N-m)  
Wheel Hub Nuts  
175-225 ft-lb  
(237-305 N-m)  
Wheel Motor Mounting  
Bolts  
30-35 ft-lb (41-47 N-m)  
Figure 3  
4. Motion control levers  
1. Platform  
2. Fuel Cap  
5. Engine Controls  
3. Height-of-Cut  
Adjustment  
6. Park Brake Lever  
15  
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Operation  
rear, to the detent, will put the choke in the “OFF”  
position. Do Not run a warm engine with choke in  
the “ON” position.  
Operation  
Note: Determine the left and right sides of the  
machine from the normal operating position.  
Controls  
Motion Control Levers  
The motion control levers, located on each side of the  
top console, control the forward and reverse motion  
of the machine.  
Moving the levers forward or backward turns  
the wheel on the same side forward or reverse  
respectively. Wheel speed is proportional to the  
amount the lever is moved.  
Figure 5  
1. Throttle  
8. Fuel gauge  
2. RH Motion control lever  
9. PTO engagement switch  
3. LH Motion control lever 10. Choke  
4. Front Reference/Speed 11. Deck lift handle  
Control Bar  
5. Message display  
6. Park brake lever  
7. Ignition switch  
12. Fuel cap  
13. Height-of-cut pin  
14. Platform latch  
Figure 4  
1. LH Motion control lever  
2. RH Motion control lever  
3. RH Motion control  
lever in PTO disengage  
position  
4. Reverse  
5. Rear reference bar  
6. Neutral  
7. Forward  
8. Front reference/Speed  
Throttle Control  
control bar  
Located on the RH side of the front control console  
(red lever) (see Figure 5).  
9. Front of unit  
The throttle is used to control engine speed. Moving  
the throttle lever forward will increase engine speed  
and moving the throttle lever to the rear will decrease  
engine speed. Moving the throttle forward into the  
detent is full throttle.  
When the motion control levers are in the neutral  
position, the LCD indicator appears in the message  
display on the front control console (see Figure 5  
and Figure 7).  
When the motion control levers are in the neutral  
position and the RH motion control lever is moved  
into the PTO disengage position, the mower blades  
will disengage.  
Front Reference/Speed Control Bar  
Located in front of the motion control levers (see  
Figure 5).  
The front reference/speed control bar controls the  
maximum forward speed and is infinitely variable  
from approximately 4–8 mph (6–13 km/hr).  
Choke Control  
Located on the front control console right of the  
PTO engagement switch.  
Park Brake Lever  
The choke is used to aid in starting a cold engine.  
Moving the choke lever forward will put the choke in  
the “ON” position and moving the choke lever to the  
Located on left side of unit, just to the front of the  
LH motion control lever (see Figure 5).  
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Operation  
The brake lever engages a parking brake on the drive  
wheels.  
Hour Meter  
Located on the LH side of the front control console  
in the message display (see Figure 5 and Figure 7).  
Note: The LCD indicator appears in the message  
display on the front console when the park brake is  
engaged (see Figure 5 and Figure 7).  
The hour meter records the number of hours that  
the engine has run.  
To engage the brake, pull the lever rearward and to  
the right to position into the engaged position.  
To release, pull the brake lever back and over to the  
left, position into the slot and push the lever forward.  
When parking on a steep slope, the wheels must be  
chocked or blocked in addition to the brake being  
engaged. The unit must be tied down and brake  
engaged when transporting.  
Figure 7  
Park brake must be disengaged before moving  
motion control out of neutral or engine will kill.  
1. LCD Indicators  
2. Low voltage indicator light  
3. Hour/Voltage display  
Ignition Switch  
Located on the LH side of the front control console  
(see Figure 5).  
The hour meter is recording when the decimal point  
is flashing in Hour/Voltage display.  
The ignition switch is used to start and stop the  
engine. The switch has three positions “OFF”, “ON”  
and “START”. Insert key into switch and rotate  
clockwise to the “ON” position. Rotate clockwise to  
the next position to engage the starter (key must be  
held against spring pressure in this position). Allow  
the key to return to the “ON” position immediately  
after the engine starts.  
Hours are displayed when the key is off or when the  
machine is running.  
Note: If the ignition key is turned to the “ON”  
position for a few seconds before cranking the  
engine, the battery voltage will display in the area  
where the hours are normally displayed.  
Note: The LCD indicators appear when each  
control meets the “safe to start” mode. Because the  
PTO must be disengaged to start the engine, the  
LCD indicator will not illuminate at this time.  
Fuel Shut-Off Valve  
Located on the RH side of the control tower behind  
the knee cushion.  
Figure 6  
The fuel shut-off valve is used to shut off the fuel  
when the machine will not be used for a few days,  
during transport to and from the jobsite, and when  
parked inside a building.  
1. Off  
2. On  
3. Start  
Note: To start the engine, place the LH motion  
control lever in neutral, the RH motion control  
in PTO disengage position, and the PTO switch  
disengaged. (It is not necessary for the operator to  
be on the platform.)  
Align valve handle with the fuel line to open. Rotate  
90° to close.  
Fuel Gauge  
Located on the top left side of the tank (see Figure 5).  
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Operation  
The fuel gauge monitors the amount of fuel in the  
tank.  
Pre-Start  
Fill fuel tank on level ground. For best results use  
only clean, fresh regular grade unleaded gasoline with  
an octane rating of 87 or higher.  
Drive Wheel Release Valves  
Located on the left rear corner of the hydrostatic  
pumps.  
Important: Never use methanol, gasoline  
containing methanol, gasohol containing more  
than 10% ethanol, premium gasoline, or white  
gas because the fuel system could be damaged.  
Drive wheel release valves are used to release the  
hydrostatic drive system to allow the machine to be  
moved by hand without the engine running.  
Do Not add oil to gasoline.  
With a 5/8 wrench, turn both valves one turn  
counterclockwise to release the drive system.  
Do Not use gasoline that has been stored since the  
last mowing season or longer.  
Turn clockwise to reset the drive system. Do Not  
overtighten. Do Not tow machine.  
Do Not overfill fuel tank. Fill the fuel tank to the  
bottom of the filler neck. The empty space in the  
tank allows gasoline to expand. Overfilling may result  
in fuel leakage or damage to the engine or emission  
system (if equipped).  
PTO Engagement Switch  
Located on front control panel (see Figure 5).  
Make sure you understand the controls, their  
locations, their functions, and their safety  
requirements.  
Switch must be pulled out (up) to engage the blades.  
Switch is pushed in to disengage the blades.  
The LCD indicator will appear when the PTO switch  
is engaged (see Figure 7).  
Refer to the Maintenance section and perform all the  
necessary inspection and maintenance steps.  
Low Voltage Indicator  
Operating Instructions  
Located on the front control panel in the message  
display (see Figure 5 and Figure 7).  
Open the Fuel Shut-Off Valve  
A low voltage condition (less than 12.3 volts) exists  
when the low voltage indicator light appears on the  
message display while the engine is running.  
Rotate the valve and align with the fuel line to open.  
Starting the Engine  
If the ignition key is turned to the “ON” position for  
a few seconds before cranking the engine, the battery  
voltage will display in the area where the hours are  
normally displayed.  
1. Leave the LH motion control lever in neutral and  
the RH lever in the PTO disengage position (see  
Figure 4).  
2. Pull the parking brake rearward and over to the  
right to engage the parking brake.  
Note: The indicator normally appears when the  
engine is off and the key switch is turned to the  
“ON” position.  
3. Push in (down) on the PTO switch to the  
“disengage” position.  
Deck Lift Handle  
4. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
Located on the RH of the front control panel.  
5. On a cold engine, push the choke lever forward  
into the “ON” position.  
Pull the handle rearward to raise the cutting deck.  
Allow the handle to move forward to lower the  
cutting deck to the cut height that has been set.  
On a warm engine, leave the choke in the “OFF”  
position.  
Pull the handle rearward and to the right to latch  
the cutting deck into the raised transport position  
(Figure 5).  
6. Turn ignition switch to the “START” position.  
Release the switch as soon as the engine starts.  
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Operation  
Important: Do Not crank the engine  
continuously for more than ten seconds at a  
time. If the engine does not start, allow a 60  
second cool-down period between starting  
attempts. Failure to follow these guidelines  
can burn out the starter motor.  
Disengaging the PTO  
1. Set the throttle midway between the “SLOW”  
and “FAST” positions.  
2. Push down on the PTO switch to disengage the  
blades.  
Note: The PTO will be disengaged by releasing  
the right side motion control lever and allowing it  
to spring outward to the PTO disengage position.  
The PTO will not re-engage when the RH motion  
control lever is moved out of the PTO disengage  
position without pulling up on the PTO switch.  
To fully disengage the PTO, continue to push the  
switch downward.  
7. If the choke is in the “ON” position, gradually  
return choke to the “OFF” position as the engine  
warms up.  
PTO Engagement  
DANGER  
The rotating blades under the mower deck  
are dangerous. Blade contact can cause  
serious injury or kill you.  
Stopping the Engine  
1. Bring the unit to a full stop.  
2. Move the motion control levers to the neutral  
position; move the RH control lever out to the  
PTO disengage position.  
Do Not put hands or feet under the mower  
or mower deck when the blades are engaged.  
3. Place the throttle midway between the “SLOW”  
and “FAST” positions.  
DANGER  
4. Push down on the PTO switch to disengage the  
blades.  
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. Thrown objects or blade  
contact can cause serious injury or death.  
5. Engage the parking brake.  
6. Allow the engine to run for a minimum of 15  
seconds, then turn the ignition switch to the  
“OFF” position to stop the engine.  
Never operate the mower with the discharge  
deflector raised, removed, or altered unless  
there is a grass collection system or mulch  
kit in place and working properly.  
7. Remove the key to prevent children or other  
unauthorized persons from starting engine.  
8. Close the fuel shut-off valve when the machine  
will not be in use for a few days, when  
transporting, or when the unit is parked inside  
a building.  
The PTO switch engages the cutting blades. Be sure  
all persons are clear of mower deck and discharge  
area before engaging the PTO.  
Driving the Machine  
1. Set throttle to “MIDWAY” position.  
2. Release the parking brake.  
CAUTION  
3. Move the right side motion control lever to the  
center, operate position.  
Machine can spin very rapidly by positioning  
one lever too much ahead of the other.  
Operator may lose control of the machine,  
which may cause damage to the machine  
or injury.  
4. Continue holding the right side motion control  
lever in the center, operate position and pull up  
on the blade control switch (PTO) and release.  
The clutch should engage and the mower blades  
begin rotating.  
• Use caution when making turns.  
• Slow the machine down before making  
sharp turns.  
5. Place the throttle in the “FAST” position to begin  
mowing.  
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Operation  
Important: To begin movement (forward or  
backward), the brake lever must be disengaged  
(pushed forward) before the motion control  
levers can be moved or the engine will stop.  
When the RH motion control lever is positioned  
fully outward (apart), the drive system is in the PTO  
disengage position (Figure 8).  
Note: The “N” LCD indicator appears when the  
RH lever is in the PTO disengage position.  
When the RH motion control lever is moved directly  
inward (together) the drive system is in the neutral  
operate position.  
Figure 9  
To turn left or right, pull the motion control lever  
back toward neutral in the desired turn direction.  
Figure 8  
The machine will move faster the farther the  
motion control levers are moved from the neutral  
position.  
1. LH Motion control lever  
2. RH Motion control lever  
3. RH Motion control  
lever in PTO disengage  
position  
4. Reverse  
5. Rear reference bar  
6. Neutral  
7. Forward  
8. Front reference/Speed  
control bar  
4. To stop, position both motion control levers in  
the neutral operate position.  
9. Front of unit  
Driving in Reverse  
Driving Forward  
1. Move the motion control levers to the neutral  
operate position.  
1. Make sure the motion control levers are in the  
neutral position.  
2. To move rearward in a straight line, slowly move  
both levers rearward with equal pressure.  
2. Release the parking brake.  
3. To move forward in a straight line, move both  
levers forward with equal pressure.  
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Operation  
Figure 11  
4. Forward position —  
Figure 10  
1. Front of the machine  
2. Control tower  
3. Unlock  
faster  
5. Backward position —  
slower  
6. Lock  
To turn left or right, release pressure on the  
motion control lever toward the desired turn  
direction.  
3. To stop, position both motion control levers in  
the neutral operate position.  
4. Move the bar forward to obtain the fastest speed.  
Move the bar backward to obtain the slowest  
speed.  
Adjusting the Front Reference/Speed  
Control Bar  
5. On both sides, rotate and push the handles inward  
to lock the handles against the control tower.  
Important: Make sure the handles are locked  
in place so the front reference/speed control  
bar does not move during operation.  
Adjust the front reference/speed control bar for  
desired maximum forward speed.  
1. Stop the machine and move the motion control  
levers to the neutral position.  
Operating the Platform  
2. Disengage the PTO.  
The machine can be used with the platform in the  
up or down position. It is the operator’s preference  
on which position to use.  
3. Unlock the handles on both sides of the control  
tower by pulling outward (see Figure 11).  
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Operation  
WARNING  
The operator platform is heavy and may  
cause injury when lowering and raising  
the operator platform. The platform may  
suddenly drop if not supported when the  
latch pin is pulled out.  
• Do Not put your hands or fingers in the  
platform pivot area when lowering or  
raising the operator platform.  
• Make sure the platform is supported  
when the latch pin is pulled out.  
Figure 12  
1. Platform  
2. Raise upward  
3. Latch pin knob snaps inward  
• Make sure the latch secures the platform  
when folding it in the up position. Push  
it tight against the cushion for the latch  
pin to lock into place.  
Operating the Machine with the  
Platform Down  
Operating the Machine with the  
Platform Up  
Operating the machine with the platform down is  
recommended when:  
Operating the machine with the platform up is  
recommended when:  
• Mowing most areas  
• Driving down slopes  
• Mowing near drop-offs  
To lower the platform, push the platform forward  
against the cushion to release pressure on the latch  
pin, pull the knob outward, and lower the platform  
(see Figure 13).  
• Mowing small areas where the machine is too long  
• Areas with low over hanging branches or obstacles  
• Loading the machine for transport  
• Unloading the machine after transport  
• Driving up or backing down slopes or ramps.  
• Turning in tight areas where platform may contact  
obstacles.  
To raise the platform, pull the bottom upward and  
push it tight against the cushion. The latch pin knob  
will snap inward to lock the platform into place (see  
Figure 12).  
Figure 13  
1. Pull latch pin knob outward  
2. Platform  
3. Lower  
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Operation  
Adjusting the Cutting Height  
The cutting height of the mower deck is adjusted  
from 1 to 5 inches (2.5 cm to 12.7 cm) in 1/4 inch  
(6.4 mm) increments.  
1. Stop the machine and move the motion control  
levers to the neutral position.  
2. Disengage the PTO.  
3. Raise and lock the deck to the 5 inch (12.7 cm)  
transport position.  
The deck is raised by pulling the deck lift handle  
rearward and to the right to place it into the  
transport lock position.  
Figure 15  
1. Height adjustment pin  
3. Deck lift handle  
2. Height of cut holes  
Transporting  
Transporting a Unit  
Use a heavy-duty trailer or truck to transport the  
machine. Lock brake and block wheels. Securely  
fasten the machine to the trailer or truck with straps,  
chains, cable, or ropes. Be sure that the trailer or truck  
has all necessary lighting and marking as required by  
law. Secure a trailer with a safety chain.  
Figure 14  
1. Transport lock position  
2. RH Motion control lever  
3. Front reference/speed  
control bar  
4. Deck lift handle  
Note: When changing the cutting height  
positions, always come to a complete stop  
and disengage the PTO.  
CAUTION  
This unit does not have proper turn  
signals, lights, reflective markings, or a  
slow moving vehicle emblem. Driving on a  
street or roadway without such equipment  
is dangerous and can lead to accidents  
causing personal injury. Driving on a street  
or roadway without such equipment may also  
be a violation of State laws and the operator  
may be subject to traffic tickets and/or fines.  
4. Insert the height adjustment pin into the hole  
corresponding to the desired cutting height.  
See the decal on the side of the deck lift plate for  
cut heights (reference Figure 15).  
5. Pull the deck lift handle rearward and to the left  
and slowly allow the deck to lower to the cutting  
height.  
Do Not drive a unit on a public street or  
roadway.  
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Operation  
Avoid sudden acceleration when driving up a ramp  
and sudden deceleration when backing down a ramp.  
Both maneuvers can cause the unit to tip backward.  
WARNING  
Loading a unit on a trailer or truck increases  
the possibility of backward tip-over.  
Backward tip-over could cause serious injury  
or death.  
• Use extreme caution when operating a  
unit on a ramp.  
• Use only a single, full width ramp; Do  
Not use individual ramps for each side  
of the unit.  
• If individual ramps must be used, use  
enough ramps to create an unbroken  
ramp surface wider than the unit.  
• Do Not exceed a 15° angle between ramp  
and ground or between ramp and trailer  
or truck.  
• Avoid sudden acceleration while driving  
unit up a ramp to avoid tipping backward.  
• Avoid sudden deceleration while backing  
unit down a ramp to avoid tipping  
backward.  
Loading a Unit  
Use extreme caution when loading units on trailers or  
trucks. One full width ramp that is wide enough to  
extend beyond the rear tires is recommended instead  
of individual ramps for each side of the unit. With  
the platform up, a full width ramp provides a surface  
to walk on behind the unit. If it is not possible to use  
one full width ramp, use enough individual ramps to  
simulate a full width continuous ramp.  
Ramp should be long enough so that the angles  
between the ramp and the ground and the ramp and  
the trailer or truck do not exceed 15°. A steeper angle  
may cause mower deck components to get caught as  
the unit moves from ramp to trailer or truck. Steeper  
angles may also cause the unit to tip backward. If  
loading on or near a slope, position the trailer or  
truck so it is on the down side of the slope and the  
ramp extends up the slope. This will minimize the  
ramp angle. The trailer or truck should be as level  
as possible.  
Important: Do Not attempt to turn the unit  
while on the ramp, you may lose control and  
drive off the side.  
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Maintenance  
Maintenance  
Note: Determine the left and right sides of the machine from the normal operating position.  
WARNING  
WARNING  
While maintenance or adjustments are being  
made, someone could start the engine.  
Accidental starting of the engine could  
seriously injure you or other bystanders.  
The engine can become very hot. Touching  
a hot engine can cause severe burns.  
Allow the engine to cool completely before  
service or making repairs around the engine  
area.  
Remove the key from the ignition switch,  
engage parking brake, 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).  
Recommended Maintenance Schedule(s)  
Maintenance Service  
Maintenance Procedure  
Interval  
• Change the engine oil.  
After the first 5 hours  
After the first 100 hours  
After the first 250 hours  
• Check the wheel hub torque specification.  
• Check the wheel lug nuts.  
• Change the hydraulic filter and fluid.  
• Check the engine oil level.  
• Check the mower blades.  
• Check the safety interlock system.  
• Check for loose hardware.  
Before each use or daily  
• Clean the engine and exhaust system area.  
• Clean the grass and debris build-up from the machine and cutting deck.  
• Clean the grass build-up from under the deck.  
• Check the hydraulic oil level.  
• Check the tire pressures.  
Every 40 hours  
• Check the condition of the belts.  
• Check spark arrester (if equipped).  
Every 50 hours  
Every 80 hours  
• Remove engine shrouds and clean cooling fins.  
• Change the engine oil. (May need more often under severe conditions.)  
• Check the electric clutch.  
Every 100 hours  
• Check the spark plugs.  
Every 160 hours  
Every 200 hours  
• Grease the lift linkage pivots.  
• Replace the primary air cleaner element — check secondary air cleaner element; replace if  
dirty. (May need more often under severe conditions. See the Engine Owner’s Manual for  
additional information.)  
Every 250 hours  
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Maintenance  
Maintenance Service  
Interval  
Maintenance Procedure  
• Replace the secondary air cleaner element (May need more often under severe conditions.  
See the Engine Owner’s Manual for additional information.)  
• Change the hydraulic filter and fluid (Every 250 hours/yearly if using Mobil 1 15W50)  
• Check the wheel hub torque specification.  
Every 500 hours  
• Check the wheel lug nuts.  
• Check the battery charge.  
Monthly  
Yearly  
• Grease the front caster pivots.  
• Grease the deck belt idler pivot.  
• Grease the front caster wheel hubs.  
Periodic Maintenance  
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  
storage when the open circuit voltage drops to 12.4  
volts.  
Check Engine Oil Level  
Service Interval: Before each use or daily  
1. Stop engine and wait for all moving parts to stop.  
Make sure unit is on a level surface.  
Note: To prevent damage due to freezing, battery  
should be fully charged before putting away for  
winter storage.  
2. Check with engine cold.  
3. Clean area around dipstick. Remove dipstick and  
wipe oil off. Reinsert the dipstick and push it all  
the way down into the tube. Do Not screw into  
place. Remove the dipstick and read the oil level.  
Check the voltage of the battery with a digital  
voltmeter. Locate the voltage reading of the battery in  
the table and charge the battery for the recommended  
time interval to bring the charge up to a full charge  
of 12.6 volts or greater.  
4. If the oil level is low, wipe off the area around the  
oil fill cap, remove cap and fill to the “FULL”  
mark on the dipstick. Use oil as specified in  
Engine Owner’s Manual. Do Not overfill.  
Important: Make sure the negative battery  
cables are disconnected and the battery charger  
used for charging the battery has an output of  
16 volts and 7 amps or less to avoid damaging  
the battery (see chart for recommended charger  
settings).  
Important: Do Not operate the engine with the  
oil level below the “LOW” (or “ADD”) mark on  
the dipstick, or over the “FULL” mark.  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
Charger  
Settings  
Interval  
Check Battery Charge  
Service Interval: Monthly  
12.6 or  
greater  
100%  
No  
Charging  
Required  
16 volts/7  
amps  
WARNING  
CALIFORNIA  
Proposition 65 Warning  
12.4 – 12.6 75–100%  
12.2 – 12.4 50–75%  
30 Minutes  
16 volts/7  
amps  
1 Hour  
16 volts/7  
amps  
Battery posts, terminals, and related  
accessories contain lead and lead  
compounds, chemicals known to the State of  
California to cause cancer and reproductive  
harm. Wash hands after handling.  
12.0–12.2  
25–50%  
2 Hours  
14.4 volts/4  
amps  
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Maintenance  
Voltage  
Reading  
Percent  
Charge  
Maximum Charging  
CAUTION  
Connecting the jumper cables incorrectly  
(wrong polarity) can immediately damage  
the electrical system.  
Charger  
Settings  
Interval  
11.7–12.0  
0–25%  
3 Hours  
14.4 volts/4  
amps  
11.7 or less 0%  
6 Hours or  
More  
14.4 volts/2  
amps  
Be certain of battery terminal polarity and  
jumper cable polarity when hooking up  
batteries.  
Recommended Jump  
Starting Procedure  
Service Interval: As required  
Note: The following instructions are adapted  
from the SAE J1494 Rev. Dec. 2001 – Battery  
Booster Cables – Surface Vehicle Recommended  
Practice (SAE – Society of Automotive  
Engineers).  
1. Check the weak battery for terminal corrosion  
(white, green, or blue “snow”), it must be cleaned  
off prior to jump starting. Clean and tighten  
connections as necessary.  
WARNING  
Batteries contain acid and produce explosive  
gases.  
CAUTION  
Corrosion or loose connections can cause  
unwanted electrical voltage spikes at anytime  
during the jump starting procedure.  
• Shield the eyes and face from the batteries  
at all times.  
• Do Not lean over the batteries.  
Do Not attempt to jump start with loose or  
corroded battery terminals or damage to the  
engine may occur.  
Note: Be sure the vent caps are tight and level.  
Place a damp cloth, if available, over any vent  
caps on both batteries. Be sure the vehicles do  
not touch and that both electrical systems are  
off and at the same rated system voltage. These  
instructions are for negative ground systems only.  
DANGER  
3. Connect the positive (+) cable to the positive (+)  
terminal of the discharged battery that is wired to  
the starter or solenoid as shown in Figure 16.  
Jump starting a weak battery that is cracked,  
frozen, has low electrolyte level, or an  
open/shorted battery cell, can cause an  
explosion resulting in serious personal injury.  
Do Not jump start a weak battery if these  
conditions exist.  
2. Make sure the booster is a good and fully charged  
lead acid battery at 12.6 volts or greater. Use  
properly sized jumper cables (4 to 6 AWG) with  
short lengths to reduce voltage drop between  
systems. Make sure the cables are color coded or  
labeled for the correct polarity.  
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Maintenance  
6. Raise the cushion and slide it onto the pins on  
both sides of the machine (Figure 17).  
7. Push the plastic slides into the cushion bracket  
and secure them with a hairpin.  
Figure 16  
1. Positive (+) cable on discharged battery  
2. Positive (+) cable on booster battery  
3. Negative (–) cable on the booster battery  
4. Negative (–) cable on the engine block  
5. Booster battery  
6. Discharged battery  
7. Engine block  
4. Connect the other end of the positive cable to the  
positive terminal of the booster battery.  
5. Connect the black negative (–) cable to the other  
terminal (negative) of the booster battery.  
6. MAKE THE FINAL CONNECTION ON  
THE ENGINE BLOCK OF THE STALLED  
VEHICLE (NOT TO THE NEGATIVE POST)  
AWAY FROM THE BATTERY. STAND BACK.  
7. Start the vehicle and remove the cables in the  
reverse order of connection (the engine block  
(black) connection is the first to disconnect).  
Release the Cushion for Rear  
Access  
Figure 17  
1. Plastic slide  
2. Cushion bracket with key hole  
Service Interval: As required  
3. Hairpin  
The cushion can be released for rear access to the  
machine for maintenance or adjustment.  
Check Mower Blades  
1. Lower the platform.  
Service Interval: Before each use or daily  
2. Remove the hairpin cotter pins on each side of  
the cushion.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Push the plastic slides to the inside.  
2. Lift deck and secure in raised position as stated in  
4. Remove the cushion and lower it to the platform.  
the Clean Grass Build-Up Under Deck section.  
5. Perform any maintenance or adjustment on the  
machine.  
3. Inspect blades and sharpen or replace as required.  
4. Reinstall the blades (if they were removed) in the  
following order:  
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Maintenance  
A. Install bushing through blade with bushing  
flange on bottom (grass) side of blade.  
WARNING  
Incorrect installation of the blade or  
components used to retain the blade can  
be dangerous. Failure to use all original  
components and assembled as shown could  
allow a blade or blade component to be  
thrown out from under the deck resulting in  
serious personal injury or death.  
Always install the original Exmark blades,  
blade bushings, and blade bolts as shown.  
Figure 18  
1. Install bushing in blade prior to installing bushing in  
spindle.  
Check Safety Interlock  
System  
B. Install bushing/blade assembly into spindle.  
Service Interval: Before each use or daily  
CAUTION  
If safety interlock switches are disconnected  
or damaged the machine could operate  
unexpectedly causing personal injury.  
• Do not tamper with the interlock  
switches.  
• Check the operation of the interlock  
switches daily and replace any damaged  
switches before operating the machine.  
Understanding the Safety Interlock System  
Figure 19  
The safety interlock system is designed to prevent the  
mower blades from rotating unless:  
1. Use wrench here for  
blade installation. This  
nut has been torqued to  
140–145 ft-lb (190–197  
N-m)  
2. Torque to 55-60 ft-lb  
(75-81 N-m) Apply  
lubricant to threads  
as needed to prevent  
seizing. Copper-based  
anti-seize preferable.  
Grease acceptable  
substitute.  
• The right side motion control lever is moved to  
the center, operating position.  
• The blade control switch (PTO) is pulled on.  
The safety interlock system is designed to stop  
the mower blades if you move or release the right  
side motion control lever into the PTO disengage  
position.  
C. Apply lubricant to threads of blade bolt as  
needed to prevent seizing. Copper-based  
anti-seize preferable. Grease acceptable  
substitute. Install blade bolt finger tight. Place  
wrench on the top spindle nut then torque the  
blade bolts to 55-60 ft-lb (75-81 N-m).  
• The right side motion control lever is moved to  
the center, operating position, the parking brake  
is engaged, and the blade control switch (PTO) is  
pulled on.  
Checking the Safety Interlock System  
1. Start the engine.  
2. Set the parking brake.  
29  
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Maintenance  
3. Move the motion control levers forward.  
The engine should initiate shutdown after  
momentary pause.  
Manual for additional  
information.)  
Every 500 hours—Replace  
the secondary air cleaner  
element (May need more  
often under severe  
conditions. See the  
Engine Owner’s Manual  
for additional information.)  
4. Start the engine and release the parking brake.  
5. Move the right side motion control lever to the  
center, operating position.  
6. Continue holding the right side motion control  
lever in the center, operating position and pull up  
on the blade control switch (PTO) and release.  
The clutch should engage and the mower blades  
begin rotating.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. See the Engine Owner’s Manual for maintenance  
instructions.  
7. Move or release the right side motion control  
lever into the neutral position. The blades  
should stop rotating and the engine should  
continue running.  
Change Engine Oil  
Service Interval: After the first 5 hours  
8. Push the blade control switch down and move  
the right side motion control lever to the center,  
operating position.  
Every 100 hours (May  
need more often under  
severe conditions.)  
9. Continue holding the right side motion control  
lever in the center, operating position and pull up  
on the blade control switch (PTO) and release.  
The clutch should engage and the mower blades  
begin rotating.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Drain oil while engine is warm from operation.  
10. Push the blade control switch (PTO) down to the  
3. The oil drain hose assembly is located on the left  
side of the engine.  
off position. The blades should stop rotating.  
11. With the engine running, pull up the blade control  
switch (PTO) and release without holding right  
side motion control lever to the center, operating  
position. The blades should not rotate.  
Place pan under machine to catch oil. Remove oil  
drain plug. Allow oil to drain and replace oil drain  
plug. Torque plug to 20-24 ft-lb (27-33 N-m).  
4. Replace the oil filter per the Engine Owner’s  
Manual. Clean around the oil filter and carefully  
remove the filter by unscrewing it. Make sure no  
oil drains onto the belt drive or clutch through  
the holes in the engine deck. Before the new  
filter is installed, apply a thin coating of oil on the  
surface of the rubber seal. Turn filter clockwise  
until rubber seal contacts the filter adapter, then  
tighten filter an additional 2/3 to 3/4 turn.  
Check for Loose Hardware  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Visually inspect machine for any loose hardware  
or any other possible problem. Tighten hardware  
or correct the problem before operating.  
5. Clean around oil fill cap and remove cap. Fill to  
specified capacity and replace cap.  
Service Air Cleaner  
Service Interval: Every 250 hours—Replace  
the primary air cleaner  
element — check  
6. Use oil recommended in engine owner’s manual.  
Do Not overfill. Start the engine and check for  
leaks. Stop engine and recheck oil level.  
7. Wipe up any spilled oil from engine deck  
mounting surfaces.  
secondary air cleaner  
element; replace if dirty.  
(May need more often  
under severe conditions.  
See the Engine Owner’s  
Check Hydraulic Oil Level  
Service Interval: Every 40 hours  
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Maintenance  
1. Stop engine and wait for all moving parts to stop.  
Engage parking brake.  
2. Lubricate fittings with NGLI grade #2  
multi-purpose gun grease.  
2. Clean area around hydraulic reservoir cap and  
remove cap. Oil level should be to the top of the  
baffle inside the tank. If not, add oil. Use Exmark  
Premium Hydro oil. Replace hydraulic reservoir  
cap and tighten until snug. Do Not overtighten.  
Refer to the following chart for fitting locations  
and lubrication schedule.  
Lubrication Chart  
Fitting  
Locations  
Initial  
Pumps  
Number of  
Places  
Service  
Interval  
Note: The baffle is labeled “HOT” and  
“COLD”. The oil level varies with the  
1–2  
1
7
1
2
2
Every 200  
hours  
1. Lift Linkage  
Pivots  
temperature of the oil. The “HOT” level shows  
the level of oil when it is at 225°F (107°C). The  
“COLD” level shows the level of the oil when  
it is at 75°F (24°C). Fill to the appropriate level  
depending upon the temperature of the oil. For  
example: If the oil is about 150°F (65°C), fill to  
halfway between the “HOT” and “COLD” levels.  
If the oil is at room temperature (about 75°F  
(24°C)), fill only to the “COLD” level.  
2. Deck Belt Idler  
Pivot  
Yearly  
*Yearly  
*Yearly  
3. Front Caster  
Wheel Hubs  
*0  
*0  
4. Front Caster  
Pivots  
Check Tire Pressures  
Service Interval: Every 40 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Check tire pressure in drive tires.  
3. Inflate drive tires to 12–16 psi (83–110 kPa).  
4. Semi-pneumatic caster tires do not need to be  
inflated.  
Check Condition Of Belts  
Service Interval: Every 40 hours  
* See step 3 for special lubrication instructions on  
the front caster pivots.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Lubricate front caster pivots once a year. Remove  
hex plug and cap. Thread grease zerk in hole and  
pump with grease until it oozes out around top  
bearing. Remove grease zerk and thread plug back  
in. Place cap back on.  
2. Remove the mower deck belt shield to check  
mower blade drive belt condition.  
3. Look under engine deck to check the pump drive  
belt condition.  
Lubricate Caster Wheel Hubs  
4. Check all idler arms to be sure they pivot freely.  
Service Interval: Yearly  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Lubricate Grease Fittings  
Note: See chart for service intervals.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
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Maintenance  
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,  
then re-torque to 20-25 in-lb (2-3 N-m). Make  
sure axle does not extend beyond either nut.  
14. Reinstall the seal guards over the wheel hub and  
insert wheel into caster fork. Reinstall caster bolt  
and tighten nut fully.  
Important: To prevent seal and bearing damage,  
check the bearing adjustment often. Spin the  
caster tire. The tire should not spin freely  
(more than 1 or 2 revolutions) or have any side  
play. If the wheel spins freely, adjust torque on  
spacer nut until there is a slight amount of drag.  
Reapply thread locking adhesive.  
Figure 20  
2. Spacer nut with wrench  
1. Seal guard  
flats  
2. Remove caster wheel from caster forks.  
3. Remove seal guards from the wheel hub.  
Check Spark Plugs  
Service Interval: Every 160 hours  
4. Remove one of the spacer nuts from the axle  
assembly in the caster wheel. Note that thread  
locking adhesive has been applied to lock the  
spacer nuts to the axle. Remove the axle (with  
the other spacer nut still assembled to it) from  
the wheel assembly.  
Remove spark plugs, check condition and reset gaps,  
or replace with new plugs. See Engine Owner’s  
Manual.  
5. Pry out seals, and inspect bearings for wear or  
damage and replace if necessary.  
Change Fuel Filter  
Service Interval: As required  
6. Pack the bearings with a NGLI grade #1  
multi-purpose grease.  
A fuel filter is installed in the fuel line between the  
fuel tank and the engine. Replace when necessary.  
7. Insert one bearing, one new seal into the wheel.  
Replacement Filters  
Note: Seals (Exmark P/N 103-0063) must be  
replaced.  
Kawasaki  
Kawasaki  
P/N 49019-7005  
8. If the axle assembly has had both spacer nuts  
removed (or broken loose), apply a thread locking  
adhesive to one spacer nut and thread onto the  
axle with the wrench flats facing outward. Do  
Not thread spacer nut all of the way onto the end  
of the axle. Leave approximately 1/8 inch (3 mm)  
from the outer surface of the spacer nut to the  
end of the axle inside the nut.  
Change Hydraulic System  
Filter and Fluid  
Service Interval: After the first 250 hours  
Every 500 hours/Yearly  
(whichever comes  
first) thereafter  
(Every 250 hours/Yearly if  
using Mobil 1 15W50)  
9. Insert the assembled nut and axle into the wheel  
on the side of the wheel with the new seal and  
bearing.  
10. With the open end of the wheel facing up, fill  
the area inside the wheel around the axle full of  
NGLI grade #1 multi-purpose grease.  
Note: Use only Exmark Part No. 109–4180 for  
Summer use above 32°F (0°C) or P/N 1-523541 for  
Winter use below 32°F (0°C) (Refer to Transmission  
section in Specifications for filter specifications).  
11. Insert the second bearing and new seal into the  
wheel.  
12. Apply a thread locking adhesive to the 2nd spacer  
nut and thread onto the axle with the wrench flats  
facing outward.  
1. Stop engine, wait for all moving parts to stop, and  
remove key or spark plug wire(s). Engage parking  
brake.  
32  
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Maintenance  
2. Carefully clean area around filter. It is important  
that no dirt or contamination enter hydraulic  
system.  
3. Unscrew filter to remove and allow oil to drain  
from reservoir.  
Note: Do Not change hydraulic system oil (except  
for what can be drained when changing filter), unless  
it is felt the oil has been contaminated or been  
extremely hot.  
Changing oil unnecessarily could damage hydraulic  
system by introducing contaminates into the system.  
Important: Before reinstalling new filter, fill  
it with Exmark Premium Hydro oil and apply  
a thin coat of oil on the surface of the rubber  
seal.  
Hydraulic System Air Purge  
Service Interval: As required  
Turn filter clockwise until rubber seal contacts the  
filter adapter, then tighten the filter an additional  
2/3 to 3/4 turn.  
Air must be purged from the hydraulic system  
when any hydraulic components, including oil  
filter, are removed or any of the hydraulic lines are  
disconnected.  
4. Fill reservoir as stated in Check Hydraulic Oil  
Level.  
The critical area for purging air from the hydraulic  
system is between the oil reservoir and each  
charge pump located on the top of each variable  
displacement pump (Figure 21). Air in other parts of  
the hydraulic system will be purged through normal  
operation once the charge pump is “primed”.  
Exmark Premium Hydro Oil is recommended.  
Refer to the chart for an acceptable alternative:  
Hydro Oil  
Change Interval  
500 Hours  
Exmark Premium Hydro  
Oil (Preferred)  
250 Hours  
Mobil 1 15W50  
5. Loosen filter 1/2 turn and allow a small amount  
of oil to leak from the oil filter (this allows air to  
be purged from the oil filter and supply hose from  
the hydraulic reservoir). Turn filter clockwise  
until rubber seal contacts the filter adapter. Then  
tighten the filter an additional 2/3 to 3/4 turn.  
6. Raise the rear of machine up and support with  
jack stands (or equivalent support) just high  
enough to allow drive wheels to turn freely.  
Figure 21  
CAUTION  
1. Charge pump cap  
2. Loosen 1 1/2 turns only  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
1. Stop engine and wait for all moving parts to stop.  
Raise the rear of the machine up onto jack stands  
high enough to raise the drive wheels off the  
ground.  
2. Check oil level as stated in Check Hydraulic Oil  
Level section.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
3. Start engine and move throttle control ahead to  
full throttle position. Move RH motion control  
lever inward (together) and move both levers  
forward with equal pressure.  
7. If either drive wheel does not rotate, one or both  
of the charge pumps (located on the top of the  
main pump as shown in Figure 21) may have lost  
their “prime”. Refer to Hydraulic System Air  
Purge section.  
If either drive wheel does not rotate, it is possible  
to assist the purging of the charge pump by  
carefully rotating the tire in the forward position.  
33  
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Maintenance  
Note: It is necessary to lightly touch the charge  
pump cap with your hand to check the pump  
temperature. If the cap is too hot to touch, turn  
off engine. The pumps may be damaged if the  
pump becomes too hot.  
WARNING  
Hot exhaust system components may ignite  
gasoline vapors even after the engine is  
stopped. Hot particles exhausted during  
engine operation may ignite flammable  
materials. Fire may result in personal injury  
or property damage.  
If either drive wheel still does not rotate continue  
with step 4.  
4. Thoroughly clean the area around each of the  
charge pump housings.  
Do Not refuel or run engine unless spark  
arrester is installed.  
5. To “prime” charge pump, loosen two hex socket  
head capscrews (shown in Figure 21) 1 1/2 turns  
only. Make sure engine is not running. Lift  
the charge pump housing upward and wait for  
a steady flow of oil to flow out from under the  
housing. Retighten the capscrews. Do this for  
both pumps.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Wait for muffler to cool.  
3. If any breaks in the screen or welds are observed,  
replace arrester.  
4. If plugging of the screen is observed, remove  
arrester and shake loose particles out of the  
arrester and clean screen with a wire brush (soak  
in solvent if necessary). Reinstall arrester on  
exhaust outlet.  
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 respective  
pump. If wheels rotate slowly, the system may  
prime after additional running. Check oil level  
as stated in Check the Hydraulic Oil Level  
section.  
Thread Locking Adhesives  
Thread locking adhesives such as “Loctite 242”  
or “Fel-Pro, Pro-Lock Nut Type” are used on the  
following fasteners:  
• Pump sheave setscrews.  
• Sheave retaining bolt in end of engine crankshaft.  
• Caster wheel spacer nuts.  
7. Allow unit to run several minutes after the charge  
pumps are “primed” with drive system in the full  
speed position. Check oil level as stated in Check  
the Hydraulic Oil Level section.  
8. Check hydro drive linkage adjustment as stated in  
Hydro Drive Linkage Adjustment section in  
Adjustments.  
Mobil HTS Grease (Or  
Food-Grade Anti-seize)  
Mobil HTS grease (or food-grade anti-seize) is used  
in the following locations:  
Wheel Hub Nut Torque  
Specification  
Service Interval: After the first 100 hours  
• Between the cutter housing spindle and bearings.  
• Between the cutter housing spindle and sheave.  
• Under top cutter housing bearing guard.  
Every 500 hours thereafter  
Torque the nut on the wheel motor tapered shaft to  
175-225 ft-lb (237-305 N-m).  
Copper-Based Anti-seize  
Copper-based anti-seize is used in the following  
locations:  
Note: Do Not use anti-seize compound on the  
wheel hub.  
• On threads of Blade Bolts. See Check Mower  
Blades section.  
• Between engine crankshaft and pump and blade  
drive sheaves.  
Check Spark Arrester  
(if equipped)  
Service Interval: Every 50 hours  
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Maintenance  
• On clutch arm assembly between bearings and  
shaft and between lower sheave and shaft.  
Adjustments  
Note: Disengage PTO, shut off engine, wait for  
all moving parts to stop, engage parking brake, and  
remove key before servicing, cleaning, or making any  
adjustments to the unit.  
• Between pump shafts and sheaves.  
Dielectric Grease  
Dielectric grease is used on all blade type electrical  
connections to prevent corrosion and loss of contact.  
CAUTION  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
Deck Leveling  
Note: Side to side deck leveling should be done by  
an Authorized Service Dealer. Small adjustments can  
be accomplished by increasing the tire pressure in  
the tire on the low side.  
1. Park the machine on a level surface and disengage  
the blade control switch.  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Check the air pressure in the drive tires. If needed,  
adjust to the recommended inflation; refer to  
Checking the Tire Pressure in Drive System  
Maintenance section.  
4. Set the height of cut lever to the 3 inch (7.6 cm)  
position.  
5. Raise the discharge deflector.  
6. Carefully rotate the blades front to rear. Measure  
from the tip of the front blade to the level surface  
(Figure 22). The blades should measure 3 inches  
(7.6 cm).  
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Maintenance  
4. Check and adjust the side to side blade level if  
you have not checked the setting; refer to Deck  
Leveling.  
5. Carefully rotate the blades front to rear  
(Figure 24). Measure from the tip of the front  
blade to the level surface and the tip of the rear  
blade to the level surface on all blades. The blades  
should be 1/4 inch (6.4 mm) lower in the front  
than in the rear.  
Figure 22  
2. Measure here  
1. Blades front to rear  
7. Measure between the outside cutting edges and  
the flat surface (Figure 23). If both measurements  
are not within 3/16 inch (5 mm), an adjustment is  
required; contact an Authorized Service Dealer.  
Figure 24  
1. Blades front to rear  
2. Measure here  
6. Loosen the rear lock nuts on both adjustment  
rods (Figure 25).  
Figure 23  
1. Blades side to side  
2. Measure here  
8. Lower the discharge deflector.  
Adjusting the Cutting Deck  
Rake  
1. Park the machine on a level surface and disengage  
the blade control switch.  
Figure 25  
1. Adjustment rod  
2. Rear lock nut  
3. Front lock nut  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Note: Make sure the engine deck brackets  
are resting firmly on the rear lift points (see  
Figure 26). If it is lifting off, tighten the front  
locknut of the adjusting rod on the opposite side.  
3. Check the air pressure in the drive tires. If needed,  
adjust to the recommended inflation; refer to  
Checking the Tire Pressure in Drive System  
Maintenance section.  
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Maintenance  
Figure 27  
1. Adjustment screw  
Figure 26  
2. Engine deck brackets  
7. Turn the adjustment screw until the blade tips  
match 3 inches (7.6 cm).  
1. Rear lift points  
7. To raise the front of the mowing deck, tighten the  
front locking nuts by the same amount on both  
front adjusting rods. Tighten both rear locking  
nuts. Check the side to side level of the mower  
again; refer to Deck Leveling.  
Pump Drive Belt Tension  
Self-tensioning - No adjustment necessary.  
Mower Deck Drive Belt  
Tension  
Note: Rake adjustments may affect the motion  
control neutral position. See the Motion Control  
Neutral Adjustment and Motion Control  
Tracking Adjustment sections in Maintenance.  
Self-tensioning - No adjustment necessary.  
Check the Park Brake  
Adjusting the Rear of the  
Deck  
1. Park the machine on a level surface and disengage  
the blade control switch.  
1. Park the machine on a level surface.  
2. Shut off engine and wait for all moving parts to  
stop.  
3. When the park brake is released, the brake bars  
should lift off the tires and the hand lever should  
travel forward to the end of the slot in the control  
panel. When engaging the brake, the hand lever  
should travel 3/4 inch (19 mm) at the control  
panel slot when the brake bars first contact the  
tire. Measure the gap from the front of the lever  
to the end of the slot in the control panel when  
the brake bar contacts the tire.  
2. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Check the air pressure in the drive tires. If needed,  
adjust to the recommended inflation; refer to  
Checking the Tire Pressure in Drive System  
Maintenance section.  
4. Set the height of cut to the 3 inch (7.6 cm)  
position.  
Park Brake Adjustment  
If the parking brake does not hold securely, an  
adjustment is required.  
5. Carefully rotate the blades front to rear. Measure  
from the tip of the front blade to the level surface.  
The blades should measure 3 inches (7.6 cm).  
1. Park the machine on a level surface.  
6. If it does not measure correctly, locate the  
height-of-cut rod on the right side of the machine  
(see Figure 27).  
2. Shut off engine and wait for all moving parts to  
stop.  
3. Disengage the park brake.  
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Maintenance  
4. To adjust the brake, remove the hairpin, washer,  
and clevis pin from the lower brake lever and yoke  
as shown in Figure 28.  
Figure 29  
3. Brake lever  
Figure 28  
1. Switch  
2. 1/8 inch (3mm) gap  
1. Jam nut  
2. Yoke  
3. Clevis pin  
4. Lower brake lever  
5. Washer  
6. Hairpin  
needed between switch  
and brake lever  
12. If needed, loosen the screws holding the switch  
and adjust the switch.  
5. Loosen the jam nut.  
6. Rotate the yoke. To tighten the brake, rotate the  
yoke up. To loosen the brake, rotate the yoke  
down.  
Electric Clutch Adjustment  
Service Interval: Every 100 hours  
Note: The brake rod should be threaded into  
both yokes the same distance.  
The clutch is adjustable to ensure proper engagement  
and proper braking.  
7. Secure the yoke to lower brake lever with the  
hairpin, washer, and clevis pin.  
1. Stop engine, wait for all moving parts to stop,  
and remove key. Engage parking brake. Allow  
the machine to cool completely before starting  
these instructions.  
8. Tighten the jam nut.  
9. Check the brake operation again.  
10. After the brake is adjusted, the lever switch needs  
to be checked.  
2. Insert a 0.015–0.021 inch (0.381–0.533 mm)  
feeler gauge through one inspection slot in the  
side of the assembly. Make sure it is between the  
armature and the rotor friction surfaces.  
11. Check the gap between the brake lever and the  
switch as shown in Figure 29. The gap needs to  
be an 1/8 inch (3mm) with the brake engaged.  
3. The gap should be at least 0.015 (0.381 mm) and  
not more than 0.021 (0.533 mm). If adjustment is  
needed, then set at 0.015 (0.381 mm) for each of  
the three adjustment slot positions.  
4. Tighten the lock nuts until there is slight binding  
on the feeler gauge but it can be moved easily  
within the air gap (see Figure 30).  
38  
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Maintenance  
6. Loosen the lock nuts on the turnbuckle on the  
RH motion control (as viewed from the rear of  
the machine — see Figure 32). With the right  
motion control in the PTO disengage position,  
hold the LH motion control in the position  
determined in step 4 or 5. Rotate the turnbuckle  
until the LCD indicator comes on.  
Figure 30  
3. Feeler gauge  
1. Adjusting nut  
2. Slot  
Motion Control Neutral  
Adjustment  
Figure 32  
Check to see if an adjustment is required:  
1. Lock nut  
3. Lock nut (LH thread)  
2. Turnbuckle  
1. With the engine off, turn the ignition switch to  
the “ON” position.  
2. Locate the LCD indicator in the message display.  
7. Continue to rotate the turnbuckle, counting the  
turns, until the LCD indicator turns off. Rotate  
the turnbuckle in the opposite direction half the  
number of turns counted. Release the LH motion  
control lever and tighten the lock nuts on the  
right side.  
8. Adjust the turnbuckle on the LH side (as viewed  
from the rear of the machine — see Figure 33)  
until the left control has approximately the same  
natural neutral position as the right. If more  
adjustment is needed, contact an Authorized  
Service Dealer. Final adjustment of the left side  
is done in the tracking adjustment section. If no  
adjustment is required, see Check the Neutral  
Switch Alignment section.  
Figure 31  
1. Neutral LCD indicator  
3. With the motion control levers in the neutral  
position (see Figure 4) (with no force on the lever  
either forward or back), the neutral LCD indicator  
should appear.  
4. If the indicator illuminates, move the RH lever  
first forward, then backward, noting the position  
of the control lever when the indicator disappears.  
The amount of movement, both forward and  
back, should be approximately the same; if not,  
go to step 6.  
5. If the indicator does not illuminate, move both  
motion control levers forward and then backward.  
Continue to watch the message display and note  
the position of the controls when it appears.  
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Maintenance  
Check the Neutral Switch  
Alignment  
1. Park the machine on a level surface and disengage  
the blade control switch.  
2. Stop engine, wait for all moving parts to stop, and  
remove the key or spark plug wire(s).  
3. Set the height of cut to the 3 inch (7.6 cm)  
position.  
4. Perform the Motion Control Neutral  
Adjustment and Motion Control Tracking  
Adjustment as stated in the Maintenance section.  
Figure 33  
1. Rotate to increase speed  
2. Turnbuckle  
3. Rotate to decrease speed  
5. Release the rear cushion from the rear of the  
machine and lower to the platform.  
6. Check the alignment on the LH and RH neutral  
switches upper and lower surfaces (reference  
Figure 34). If they are not in alignment, loosen the  
hardware on the lower neutral switch and adjust it  
forward or rearward as necessary. Once aligned,  
tighten the hardware. Check the neutral switch  
alignment again as the deck is moved through the  
highest and lowest cut height setting; adjust the  
lower neutral switch surface if necessary.  
9. Reinstall the rear cushion.  
Motion Control Tracking  
Adjustment  
If the machine travels or pulls to one side when the  
motion control levers are in the full forward position,  
adjust the tracking.  
1. Push both control levers forward the same  
distance.  
2. Check if the machine pulls to one side. If it does,  
stop the machine and set the parking brake.  
3. Release the rear cushion from the rear of the  
machine.  
4. Place the front reference/speed control bar in  
the maximum forward position. See Adjusting  
the Front Reference/Speed Control Bar in  
Operation.  
5. Rotate the turnbuckle on the LH side of the  
machine (as viewed from the rear of the machine  
— see Figure 33).  
Figure 34  
6. Looking down towards the turnbuckle — rotate  
it counterclockwise, in 1/4 turn increments, to  
increase speed or clockwise to decrease speed.  
1. Alignment reference  
4. Lower neutral switch  
surface  
5. Hardware  
2. Upper neutral switch  
surface  
7. Drive the machine and check the full forward  
tracking.  
3. Switch mounting plate  
8. Repeat steps 5 through 7 until desired tracking  
is obtained.  
7. Adjust the upper neutral switch surface left  
or right if side-to-side alignment is needed.  
The upper and lower switches should be as  
9. Reinstall the rear cushion.  
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Maintenance  
close together as possible without touching  
(approximately .06 inch (1.5 mm) gap is desirable).  
The switch mounting plate can be moved up or  
down to adjust the position of the lower neutral  
switch.  
5. Release the cushion from the rear of the machine.  
6. Loosen the nut and bolt holding the cam.  
7. Adjust the cam until it aligns with the left motion  
control lever and tighten the nut and bolt for the  
cam.  
8. Check the function of the neutral switches by  
temporarily replacing the key. With the engine  
off, turn the ignition switch to the “ON” position.  
Locate the LCD indicator in the message display.  
Raise and lower the deck.  
A. If the indicator displays while moving the deck  
up and down, the neutral switches have been  
adjusted properly and no further adjustment  
is necessary.  
B. If the indicator does not stay lit while moving  
the deck up and down, contact an Authorized  
Service Dealer. Remove the key.  
Figure 36  
1. Switch screws  
2. Nut and bolt  
3. Cam  
Adjust RH Motion Control  
Handle Position  
4. Front reference/speed control handle  
If the motion control levers do not align horizontally,  
adjust the right side motion control lever.  
8. After the cam is adjusted, the lever switch needs  
to be checked.  
Note: Adjust the horizontal alignment before the  
front to back alignment.  
9. Check the gap between the control lever and  
switch as shown in Figure 37. The gap needs  
to be an 1/8 inch (3mm) with the right motion  
control lever in the neutral, operate position.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Push the right motion control lever down out of  
locked neutral position.  
3. Check if it aligns horizontally with the left motion  
control lever.  
Figure 35  
1. LH Motion control lever  
2. RH Motion control lever  
3. RH Motion control lever in PTO disengaged position  
4. Check the horizontal alignment here  
4. To adjust the right motion control lever  
horizontally, the cam needs to be adjusted.  
41  
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Maintenance  
Figure 38  
1. Spring disc washers  
Figure 37  
1. Switch  
2. Cam  
3. Right motion control lever in the neutral operate position  
4. 1/8 inch (3mm)  
10. If needed, loosen the screws holding the switch  
and adjust the switch.  
11. Tighten the switch screws.  
Caster Pivot Bearings  
Pre-Load Adjustment  
Remove dust cap from caster and tighten nyloc nut  
until washers are flat and back 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 shown in Figure 38.  
42  
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Maintenance  
Clean Debris From Machine  
Service Interval: Before each use or daily  
Cleaning  
Clean Engine and Exhaust  
System Area  
Service Interval: Before each use or daily  
(May be required more  
often in dry or dirty  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
2. Clean off any oil, debris, or grass build-up on the  
machine and cutting deck, especially under deck  
belt shields, around the fuel tank, around engine  
and exhaust area.  
conditions.)  
Clean Grass Build-Up Under  
Deck  
CAUTION  
Excessive debris around engine cooling air  
intake and exhaust system area can cause  
engine, exhaust area, and hydraulic system  
to overheat which can create a fire hazard.  
Service Interval: Before each use or daily  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
Clean all debris from engine and exhaust  
system area.  
2. Raise deck to the transport (maximum cutting  
height) position. Lift the front of unit and support  
unit using jack stands or equivalent support.  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
CAUTION  
2. Clean all debris from rotating engine air intake  
screen, around engine shrouding, and exhaust  
system area.  
Raising the mower deck for service or  
maintenance relying solely on mechanical  
or hydraulic jacks could be dangerous. The  
mechanical or hydraulic jacks may not be  
enough support or may malfunction allowing  
the unit to fall, which could cause injury.  
3. Wipe up any excessive grease or oil around the  
engine and exhaust system area.  
Remove Engine Shrouds and  
Clean Cooling Fins  
Do Not rely solely on mechanical or hydraulic  
jacks for support. Use adequate jack stands  
or equivalent support.  
Service Interval: Every 80 hours  
1. Stop engine, wait for all moving parts to stop, and  
remove key. Engage parking brake.  
3. Clean out any grass build-up from underside of  
deck and in discharge deflector.  
2. 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.  
Waste Disposal  
Motor Oil Disposal  
3. Make sure cooling shrouds are properly  
reinstalled. Operating the engine without  
cooling shrouds will cause engine damage due to  
overheating.  
Engine oil and hydraulic oil are both pollutants to  
the environment. Dispose of used oil at a certified  
recycling center or according to your state and local  
regulations.  
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Maintenance  
Battery Disposal  
DANGER  
Battery electrolyte contains sulfuric acid,  
which is poisonous and can cause severe  
burns. Swallowing electrolyte can be fatal or  
if it touches skin can cause severe burns.  
• Wear safety glasses to shield eyes, and  
rubber gloves to protect skin and clothing  
when handling electrolyte.  
• Do Not swallow electrolyte.  
• In the event of an accident, flush with  
water and call a doctor immediately.  
Federal law states that batteries should not be placed  
in the garbage. Management and disposal practices  
must be within relevant federal, state, or local laws.  
If a battery is being replaced or if the unit containing  
the battery is no longer operating and is being  
scrapped, take the battery to a local certified recycling  
center. If no local recycling is available return the  
battery to any certified battery reseller.  
44  
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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 caused  
by an empty fuel tank.  
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major  
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have  
this work done by your Engine Service Dealer.  
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.  
Problem  
Starter does not crank.  
Possible Cause  
1. PTO is engaged.  
Corrective Action  
1. Disengage the PTO.  
2. One of the speed control levers are not  
in neutral position.  
2. Ensure the speed control lever is in the  
neutral position.  
3. Battery does not have a full charge.  
3. Charge the battery. See Check  
Battery Charge and Recommended  
Jump Starting Procedure sections in  
Maintenance.  
4. Electrical connections are corroded, loose 4. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
5. Fuse is blown.  
6. Neutral LCD indicator does not  
illuminate.  
5. Replace the blown fuse.  
6. Check reed switch.  
7. Relay or switch is defective.  
7. Contact an Authorized Service Dealer.  
Engine will not start, starts hard, or fails to  
keep running.  
1. Fuel tank is empty.  
1. Fill the fuel tank.  
2. Fuel shutoff valve is closed.  
2. Open the fuel shutoff valve.  
3. The throttle and choke are not in the  
correct position.  
3. Be sure the throttle control is midway  
between the “SLOW” and “FAST”  
positions, and the choke is in the “ON”  
position for a cold engine or the “OFF”  
position for a warm engine.  
4. Dirt in fuel filter.  
4. Replace the fuel filter.  
5. Dirt, water, or stale fuel is in the fuel  
system.  
5. Contact an Authorized Service Dealer.  
6. Air cleaner is dirty.  
6. Clean or replace the air cleaner element.  
7. Electrical connections are corroded, loose 7. Check the electrical connections for  
or faulty.  
good contact. Clean connector terminals  
thoroughly with electrical contact cleaner,  
apply dielectric grease and reconnect.  
8. Relay or switch is defective.  
9. Faulty spark plug.  
10. Spark plug wire is not connected.  
8. Contact an Authorized Service Dealer.  
9. Clean, adjust or replace spark plug.  
10. Check the spark plug wire connection.  
Engine loses power.  
1. Engine load is excessive.  
1. Reduce the ground speed.  
2. Air cleaner is dirty.  
3. Oil level in the crankcase is low.  
2. Clean or replace the air cleaner element.  
3. Add oil to the crankcase.  
4. Cooling fins and air passages for the  
engine are plugged.  
4. Remove the obstructions from the cooling  
fins and air passages.  
5. Vent hole in the fuel cap is plugged.  
6. Dirt in fuel filter.  
5. Clean or replace the fuel cap.  
6. Replace the fuel filter.  
7. Dirt, water, or stale fuel is in the fuel  
system.  
7. Contact an Authorized Service Dealer.  
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Troubleshooting  
Problem  
Possible Cause  
Corrective Action  
Engine overheats.  
1. Engine load is excessive.  
1. Reduce the ground speed.  
2. Add oil to the crankcase.  
2. Oil level in the crankcase is low.  
3. Cooling fins and air passages for the  
engine are plugged.  
3. Remove the obstructions from the cooling  
fins and air passages.  
Mower pulls left or right (with levers fully  
forward).  
1. Tire pressure in drive tires not correct.  
2. Tracking needs adjustment.  
1. Adjust tire pressure in the drive tires.  
2. Adjust the tracking by turning turnbuckle  
on the LH turnbuckle in the direction that  
the mower needs to be adjusted to. Rotate  
the turnbuckle in 1/4 turn increments  
until the mower tracks correctly.  
Machine does not drive.  
Uneven cutting height.  
1. Bypass valve is not closed tight.  
1. Tighten the bypass valve.  
2. Change the belt.  
2. Drive or pump belt is worn, loose or  
broken.  
3. Drive or pump belt is off a pulley.  
3. Change the belt.  
1. Blade(s) not sharp.  
1. Sharpen the blade(s).  
2. Install new cutting blade(s).  
3. Level mower deck from side-to-side and  
front-to-rear.  
2. Cutting blade(s) is/are bent.  
3. Mower deck is not level.  
4. Underside of mower is dirty.  
5. Tire pressure in drive tires not correct.  
6. Blade spindle bent.  
4. Clean the underside of the mower.  
5. Adjust tire pressure in the drive tires.  
6. Contact an Authorized Service Dealer.  
7. Tips of adjacent blades are at an uneven  
cutting height. Blades tips should be even  
within 3/16 inch which is approximately  
one blade thickness.  
7. Replace blades, spindles and (or) check  
for damage to mower deck.  
Abnormal vibration.  
1. Install new cutting blade(s).  
1. Cutting blade(s) is/are bent or unbalanced.  
2. Blade mounting bolt is loose.  
3. Engine mounting bolts are loose.  
4. Loose engine pulley, idler pulley, or blade  
pulley.  
2. Tighten the blade mounting bolt.  
3. Tighten the engine mounting bolts.  
4. Tighten the appropriate pulley.  
5. Engine pulley is damaged.  
6. Blade spindle is bent.  
7. Belt is damaged.  
5. Contact an Authorized Service Dealer.  
6. Contact an Authorized Service Dealer.  
7. Install new belt.  
Blades do not rotate.  
1. Drive belt is off pulley.  
1. Check belt for damage; replace if  
necessary. Install drive belt and check  
adjusting shafts and belt guides for correct  
position.  
2. Deck belt is worn, loose or broken.  
3. Deck belt is off pulley.  
2. Install new deck belt.  
3. Install deck pulley and check the idler  
pulley, idler arm and spring for correct  
position and function.  
4. Broken or missing idler spring.  
5. Electric clutch out of adjustment.  
6. Damaged electric clutch.  
4. Replace the spring.  
5. Adjust the clutch air gap.  
6. Contact an Authorized Service Dealer.  
46  
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Schematics  
Schematics  
Electrical Diagram  
C A K B L  
O R A N G E  
W O N R B  
V I O L E T  
R E D  
B L U E  
O R A N G E  
C A K B L  
V I O L E T  
R E D  
R E D  
P I N K  
P I N K  
P I N K  
G012957  
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Schematics  
Electrical Schematic  
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Schematics  
Hydraulic Diagram  
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Exmark Lazer Z, Lazer Z Advantage Series X, and Vantage Turf Equipment  
3Year Limited Commercial Warranty  
5Year or 750 Hours Limited Consumer Warranty  
General Warranty 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 reasonable discretion) to  
be defective in factory materials or workmanship.  
Instructions for Obtaining Warranty Service  
The product must be registered with original proof of purchase by an  
Exmark Service Dealer before obtaining any warranty service.  
Contact any Exmark Service Dealer to arrange service at their dealership.  
To locate a dealer convenient to you, access our website at  
402-223-6375.  
This warranty may only be assigned or transferred to a second (or third)  
owner by an authorized Exmark dealer. The warranty period commences  
upon the date of the original retail purchase.  
If for any reason you are dissatisfied with the Service Dealer’s analysis or  
with the assistance provided, contact us at:  
Commercial Warranty Conditions  
This warranty applies to Exmark Lazer Z, Lazer Z Advantage Series (AS)  
X, and Vantage turf equipment sold in the U.S. or Canada for a period of  
three years for commercial usage.  
Exmark Customer Service Department  
The Exmark Warranty Company  
2101 Ashland Avenue  
Beatrice, NE 68310  
This warranty includes the cost of parts and labor for a period of two  
years and the cost of parts for one additional year. This warranty does not  
cover pickup and delivery charges to and from any authorized Exmark  
Service Dealer.  
402-223-6375 or  
Owner’s Responsibilities  
If your product requires warranty service it must be returned to an  
authorized Exmark service dealer within the warranty period. This  
warranty extends only to turf equipment operated under normal  
conditions. You must read the operator’s manual. You must also properly  
service and maintain your Exmark product as described in the operator’s  
manual. Such routine maintenance, whether performed by a dealer or by  
you, is at your expense.  
Consumer Warranty Conditions  
This warranty applies to Exmark Lazer Z, Lazer Z AS X, and Vantage  
turf equipment sold in the U.S. or Canada for a period of five years or  
750 hours (whichever occurs first) for residential usage.  
Residential usage means use of the product on the same lot as your home.  
Use at more than one location is considered commercial use, and the  
commercial use warranty detailed above would apply.  
General Conditions  
The sole liability of Exmark and Exmark Warranty Company with respect  
to this warranty shall be repair or replacement of defective components as  
set forth herein. Neither Exmark nor Exmark Warranty Company  
shall be liable for any incidental or consequential loss or damage.  
This warranty only includes the cost of parts and labor. For the first  
warrantable service repair, Exmark will cover up to $45 for associated  
pick-up and delivery charges to and from any authorized Exmark Service  
Dealer. Additional transportation charges may apply, contact your Dealer  
for details.  
Such damages include but are not limited to:  
Expenses related to gasoline, oil or lubricants.  
Travel time, overtime, after hours time or other extraordinary repair  
charges or charges relating to repairs or replacements outside of  
normal business hours at the place of business of the authorized  
Exmark Service Dealer.  
Warranty Exceptions  
Warranty Exceptions  
• Bags, Belts and Tires  
• Battery  
Warranty Period  
90 days  
1 Year Prorated  
2 years*  
• Engine (except Kohler EFI)  
• Kohler EFI Engine  
Rental of like or similar replacement equipment during the period of  
any warranty, repair or replacement work.  
3 years*  
Any telephone or telegram charges or travel charges.  
Loss or damage to person or property other than that covered by the  
terms of this warranty.  
* The Engine warranty is covered by the engine manufacturer. Please  
refer to the engine manufacturer’s warranty statement that is included in  
the literature packet.  
Any claims for lost revenue, lost profit or additional cost as  
a result of a claim of breach of warranty.  
Attorney's fees.  
Items and Conditions Not Covered  
This warranty does not cover the following:  
• Any damage or deterioration due to normal use, wear and tear, or  
exposure.  
• Cost of regular maintenance service or parts, such as filters, fuel,  
lubricants, tune-up parts, and adjustments.  
• Any product or part which has been altered or misused or required  
replacement or repair due to normal wear, accidents, or lack of proper  
maintenance.  
No Claim of breach of warranty shall be cause for cancellation or  
rescission of the contract of sale of any Exmark mower.  
All implied warranties of merchantability (that the product is fit for  
ordinary use) and fitness for use (that the product is fit for a  
particular purpose) are limited to the duration of the express  
warranty.  
• Any repairs necessary due to use of parts, accessories or supplies,  
including gasoline, oil or lubricants, incompatible with the turf  
equipment or other than as recommended in the operator's manual or  
other operational instructions provided by Exmark.  
Some states do not allow exclusions of incidental or consequential  
damages, or limitations on how long an implied warranty lasts, so the  
above exclusions and limitations may not apply to you.  
This warranty gives you specific legal rights, and you may also have  
other rights which vary from state to state.  
There are no other express warranties except for engine and special  
emission system coverage.  
All warranty work must be performed by an authorized Exmark Service  
Dealer using Exmark approved replacement parts.  
G4500-590_C  
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Notes:  
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Notes:  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
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Figure 39  
This page may be copied for personal use.  
1. The maximum slope you can safely operate the machine on is 20 degrees. Use the slope indicator to determine the  
degree of slope of hills before operating. Do Not operate this machine on a slope greater than 20 degrees. Fold  
along the appropriate line to match the recommended slope.  
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.  
3. Example of how to compare slope with folded edge.  
55  
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SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS  
MID-MOUNT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
FULL SUSPENSION SEAT  
DECK LIFT ASSIST KIT  
HITCH KIT  
OPERATOR CONTROLLED DISCHARGE  
ROLL OVER PROTECTION SYSTEM (ROPS)  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
TURF STRIPER  
12V POWER PORT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
MICRO-MULCH SYSTEM  
OUT-FRONT RIDING ACCESSORIES AND OPTIONS  
CUSTOM RIDE SEAT SUSPENSION SYSTEM  
DUAL-TAIL WHEEL  
SNOW BLADE  
SNOWBLOWER  
FLOOR PAN EXTENDER  
HITCH KIT  
SUN SHADE  
TRASH CONTAINER  
LIGHT KIT  
ULTRA VAC COLLECTION SYSTEM  
ULTRA VAC QUICK DISPOSAL SYSTEM  
WEATHER CAB  
MICRO-MULCH SYSTEM  
ROLL OVER PROTECTION SYSTEM (ROPS)  
WALK-BEHIND ACCESSORIES AND OPTIONS  
GRASS CATCHER  
TURF STRIPER  
STANDON  
MICRO-MULCH SYSTEM  
Place Model No. and Serial No.  
Label Here (Included in the Literature  
Pack) or Fill in Below  
Date Purchased  
Engine Model No. and Spec. No.  
Engine Serial No. (E/No)  
Model No.  
Serial No.  
© 2010 Exmark Mfg. Co., Inc.  
Industrial Park Box 808  
Beatrice, NE 68310  
Part No. 4500-648 Rev. D  
(402) 223-6300  
Fax (402) 223-5489  
Printed in the USA  
All Rights Reserved  
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