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.
numbers on the product. Write the numbers in the
space provided.
3
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Adjust RH Motion Control Handle
Contents
Introduction ........................................................... 3
Caster Pivot Bearings Pre-Load
Clean Engine and Exhaust System
4
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Safety
• Never let children or untrained people operate
Safety
Safety Alert Symbol
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
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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.
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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
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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
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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.
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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
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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
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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
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
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
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
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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
Note: The LCD indicator appears in the message
display on the front console when the park brake is
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
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
17
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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
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
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
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
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
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
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
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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-off’s
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
• 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 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
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
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
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.
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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.
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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
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
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.
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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
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
(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
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
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
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
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
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
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
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
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Maintenance
6. Loosen the lock nuts on the turnbuckle on the
RH motion control (as viewed from the rear of
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
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
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
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
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
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.
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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
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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.
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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.
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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.
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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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