VANTAGE
For Serial Nos.
312,000,000 & Higher
Part No. 4501-211 Rev. A
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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
Caster Pivot Bearings Pre-Load
Contents
Clean Engine and Exhaust System
4
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Safety
Safe Operating Practices
Safety
Safety Alert Symbol
This lawn mower meets or exceeds the B71.4
specifications of the American National Standards
Institute in effect at the time of production.
Training
• 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.
Exmark designed and tested this lawn mower to offer
reasonably safe service; however, failure to comply
with the following instructions may result in personal
injury.
• 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.
this manual and on the machine to identify important
safety messages which must be followed to avoid
accidents.
• Never let children or untrained people operate
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:
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
1. has read and understands the Operator's
Manual and recognizes the risks involved;
2. is sufficiently mature to use caution; and
Figure 2
3. is of sufficient size and weight to operate
the controls comfortably and to manage the
mower without taking risks.
Safety Alert Symbol
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
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
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
• 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.
WARNING: Black lettering / Orange background.
Indicates a potentially hazardous situation which, if
not avoided, Could 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.
CAUTION: Black lettering / Yellow background.
Indicates a potentially hazardous situation which, if
not avoided, May result in minor or moderate injury.
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.
CAUTION
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.
5
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Safety
• 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.
DANGER
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.
DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.
• Always place gasoline containers on the
ground away from your vehicle before
filling.
A fire or explosion from gasoline can burn
you, others, and cause property damage.
• 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.
• Fill the fuel tank outdoors on level ground,
in an open area, when the engine is cold.
Wipe up any gasoline that spills.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• 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 this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• 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.
• Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by spark.
• Store gasoline in an approved container
and keep it out of the reach of children.
WARNING
• 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.
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.
• 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.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
• 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
damage and make repairs before restarting
Operation
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.
and operating the mower).
– Before clearing blockages.
– Whenever you leave the mower.
• Stop engine, wait for all moving parts to stop, and
engage parking brake:
– Before refueling.
• Allow engine parts, especially the muffler, to
cool before touching.
– 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.
• Do Not operate the machine without
guards, shields, and safety devices in place
and working properly.
WARNING
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can kill
you.
• 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 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
occur. The operator is responsible for safe operation
on slopes.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
7
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Safety
• 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.
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.
• 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.
• Do Not mow slopes greater than 20 degrees.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Use jack stands to support components when
required.
• Reduce speed and use extreme caution on
slopes.
• Carefully release pressure from components with
stored energy.
• Avoid sudden turns or rapid speed changes.
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• 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.
• 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.
DANGER
Charging or jump starting the battery may
produce explosive gases. Battery gases can
explode causing serious injury.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• Keep sparks, flames, or cigarettes away
from battery.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
• Ventilate when charging or using battery
in an enclosed space.
Maintenance and Storage
• Make sure venting path of battery is
always open once battery is filled with
acid.
• 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.
• Always shield eyes and face from battery.
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Safety
DANGER
WARNING
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.
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.
• Wear safety glasses to shield eyes, and
rubber gloves to protect skin and clothing
when handling electrolyte.
• If equipped, 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.
• Do Not swallow electrolyte.
• In the event of an accident, flush with
water and call a doctor immediately.
• Keep body and hands away from pinhole
leaks or nozzles that eject high pressure
hydraulic fluid.
CAUTION
• Use cardboard or paper, not your hands, to
find hydraulic leaks.
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.
• 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.
Be sure ignition switch is in the “OFF”
position before charging the battery.
WARNING
• Keep all guards, shields and all safety devices in
place and in safe working condition.
Fuel system components are under high
pressure. The use of improper components can
result in system failure, gasoline leakage and
possible explosion.
• Check all bolts frequently to maintain proper
tightness.
• Frequently check for worn or deteriorating
components that could create a hazard.
Use only approved fuel lines and fuel filters for
high pressure systems.
WARNING
Removing standard original equipment 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. Making unauthorized changes to the
engine, fuel or venting system, may violate EPA
and CARB regulations.
Replace all parts including, but not limited to,
tires, belts, blades, and fuel system components
with original Exmark parts.
9
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Safety
Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• 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.
• 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.
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Safety
116-3267
116-0404
116-3283
116-2040
116-3290
116-4181
116-3076
60 Inch Model
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Safety
116-7217
116-5040
1. Forward position – faster 2. Backward position –
slower
116-1887
3. Neutral
1. Fast
2. Slow
4. Reverse
116-4647
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Safety
116-4648
All Units Except EFI
1. PTO-on
2. PTO-off
3. Fast
4. Slow
5. Choke-on
6. Choke-off
116-5026
EFI Only
3. Fast
4. Slow
1. PTO-on
2. PTO-off
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Specifications
Specifications
Model Numbers
Serial Nos: 312,000,000 and Higher
VT651KA484; VT691KA484CA; VT691KA524; VT691KA524CA; VT730EKC524; VT740EKC604;
Systems
Kawasaki: 15 amps
Kohler EFI: 20 amps
Engine
• Battery Type: BCI Group U1
• Battery Voltage: 12 Volt
• Polarity: Negative Ground
• Fuses:
• Engine Specifications: See your Engine Owner’s
Manual
• Engine Oil Type: Exmark 4–Cycle Premium
Engine Oil
• RPM: Full Speed: 3600 ±100 RPM (No Load)
– 30 amp main fuse
Fuel System
• Capacity: 8.0 gal. (30.2 L)
• Fuel Recommendations:
– 25 amp charging system fuse
– 10 amp PTO fuse
– 15 amp accessory fuse
– For best results, use only clean, fresh, unleaded
gasoline with an octane rating of 87 or higher
((R+M)/2 rating method).
Safety Interlock System
• LCD indicators appear for the park brake, drive
levers, and operator presence in the message
display on the front control panel.
– Oxygenated fuel with up to 10% ethanol or
15% MTBE by volume is acceptable.
– Do Not use ethanol blends of gasoline (such
as E15 or E85) with more than 10% ethanol
by volume. Performance problems and/or
engine damage may result which may not be
covered under warranty.
Note: Because the PTO must be disengaged
to start the engine, the LCD indicator will not
illuminate at this time.
• PTO must be disengaged and motion control
levers in neutral to start engine. (It is not
necessary for the operator to be on the platform
to start the engine.)
– Do Not use gasoline containing methanol.
– Do Not store fuel either in the fuel tank or
fuel containers over the winter unless a fuel
stabilizer is used.
• Mower blades will stop if the right side motion
control lever is moved or released into the PTO
disengage position.
– Do Not add oil to gasoline.
• Fuel Filter:
– Kawasaki:
• Engine will stop if the motion control levers are
moved from the neutral position with the park
brake engaged.
Kawasaki P/N 49019-7005
– Kohler EFI:
Kohler P/N 25 050 42
• Fuel Shut-Off Valve: 1/4 turn increments
Operator Controls
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.
Electrical System (Electric Start)
• Charging System: Flywheel Alternator
• Charging Capacity:
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Specifications
Transmission
• Blade Spindles: Solid steel spindles with 1.00 inch
(25.4 mm) I.D. bearings.
• Two Hydro Gear variable displacement high
efficiency pumps independently coupled to two
high efficiency Parker/Ross wheel drive motors.
• Deck Drive:
– Electric clutch mounted on engine shaft.
• Hydraulic Oil: Use Exmark Premium Hydro Oil.
• Hydraulic Oil Capacity: 2.4 qt. (2.2 L)
– Blades driven by one belt (w/self-tensioning
idlers).
• Hydraulic Filter is replaceable cartridge type.
• Deck: Full floating deck is attached to support
frame, removable for service. Deck design allows
for bagging, mulching or side discharge.
P/N 109-4180: 25 microns, 10 psi bypass
(Summer use above 32°F (0°C))
P/N 1-523541: 40 microns, 18 psi bypass (Winter
use below 32°F (0°C))
• Deck Depth:
– 48 inch Deck: 5.5 inches (14.0 cm)
– 52 inch Deck: 5.5 inches (14.0 cm)
– 60 inch Deck: 5.5 inches (14.0 cm)
• Cutting Height Adjustment:
• Speeds:
– 0-8.0 mph (13 km/hr) forward.
– 0-4.0 mph (6 km/hr) reverse.
• Drive wheel release valves allow machine to be
moved when engine is not running.
Adjusts from 1 inch (2.5 cm) to 5 inches (12.7 cm)
in 1/4 inch (6.4 mm) increments
Wheel Drive System
• Mulching Kit: Optional
• Bagger: Optional
Drive wheels are direct coupled to Parker wheel drive
motors with 1 inch (25.4 mm) tapered shaft.
Dimensions
Tires & Wheels
Drive
Front Caster
Overall Width:
Pneumatic
(Air-Filled)
Semi-
Pneumatic
48 inch
Deck
52 inch
Deck
60 inch
Deck
Quantity
Tread
2
2
Deflector
Up
51.8 inches 56.3 inches 63.9 inches
(131.6 cm) (143.0 cm) (162.3 cm)
K500
Smooth
11 x 4.00-5
Size
20 x 10.50–8
4
Deflector
Down
59.6 inches 64.8 inches 72.8 inches
(151.4 cm)
(164.6 cm)
(184.9 cm)
Ply Rating
Pressure
13 psi
(90 kPa)
Overall Length:
48 inch
Deck
52 inch
Deck
60 inch
Deck
Cutting Deck
• Cutting Width:
Platform Up 60.5 inches 60.5 inches 62.4 inches
(153.7 cm) (153.7 cm) (158.5 cm)
– 48 inch Deck: 48 inches (121.9 cm)
– 52 inch Deck: 52 inches (132.1 cm)
– 60 inch Deck: 60 inches (152.4 cm)
• Discharge: Side
Platform
Down
74.0 inches 74.0 inches 75.9 inches
(188.0 cm) (188.0 cm) (192.8 cm)
Overall Height:
• Blade Size: (3 ea.)
48 inch Deck
52 inch Deck
60 inch Deck
– 48 inch Deck: 16.25 inches (41.3 cm)
– 52 inch Deck: 18.00 inches (45.7 cm)
– 60 inch Deck: 20.50 inches (52.1 cm)
50.0 inches
(127.0 cm)
50.0 inches
(127.0 cm)
50.0 inches
(127.0 cm)
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Product Overview
Tread Width: (Outside to Outside of
Tires, Widthwise)
Product Overview
48 inch Deck
52 inch Deck
60 inch Deck
46.5 inches
(118.1 cm)
46.5 inches
(118.1 cm)
50.5 inches
(128.3 cm)
Curb Weight:
48 inch Deck
52 inch Deck
60 inch Deck
855 lb
(388 kg)
875 lb
(397 kg)
883 lb
(401 kg)
Note: Weights will vary slightly depending on engine.
Torque Requirements
Bolt Location
Torque
Figure 3
Cutter Housing Spindle
Nut
130-160 ft-lb
(176-217 N-m)
1. Platform
2. Fuel Cap
4. Motion control levers
5. Engine Controls
6. Park Brake Lever
3. Height-of-Cut
Adjustment
Blade Mounting Bolt
(lubricate with anti-seize)
50-60 ft-lb (68-81 N-m)
30-35 ft-lb (41-47 N-m)
Engine Deck/Mower Deck
Support Mount Bolts
Engine Mounting Bolts
Kawasaki
Kohler
17-23 ft-lb (23-31 N-m)
27-33 ft-lb (37-45 N-m)
Wheel Lug Nuts
Wheel Hub Nuts
90-95 ft-lb (122-129 N-m)
175-225 ft-lb
(237-305 N-m)
Wheel Motor Mounting
Bolts
67-83 ft-lb (91-113 N-m)
Hydro Pump Release
Valves
110-130 in-lb (12-15 N-m)
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Operation
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
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
Figure 4
5. Message display
6. Park brake lever
7. Ignition switch
12. Fuel cap
13. Height-of-cut pin
14. Platform latch
1. LH Motion control lever
2. RH Motion control lever
6. Neutral
7. Forward
3. RH Motion control
lever in PTO disengage
position
8. Front reference/Speed
control bar
4. Reverse
5. Rear reference bar
9. Front of unit
Throttle Control
Located on the RH side of the front control console
When the motion control levers are in the neutral
position, the LCD indicator appears in the message
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 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
Choke Control (All Units Except
Kohler EFI)
The front reference/speed control bar controls the
maximum forward speed and is infinitely variable
from approximately 4–8 mph (6–13 km/hr).
Located on the front control console right of the
PTO engagement switch.
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Operation
Park Brake Lever
disengaged. (It is not necessary for the operator to
be on the platform.)
Located on left side of unit, just to the front of the
Hour Meter
The brake lever engages a parking brake on the drive
wheels.
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
The hour meter is recording when the decimal point
is flashing in Hour/Voltage display.
Located on the LH side of the front control console
Hours are displayed when the key is off or when the
machine is running.
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.
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 for Kawasaki units. Located on
the LH side of the machine, towards the rear of the
engine, on Kohler units.
Figure 6
1. Off
2. On
3. Start
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.
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
Align valve handle with the fuel line to open. Rotate
90° to close.
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Operation
Pull the handle rearward and to the right to latch
the cutting deck into the raised transport position
Fuel Gauge
The fuel gauge monitors the amount of fuel in the
tank.
Electronic Control Unit Malfunction
Indicator
Drive Wheel Release Valves
Kohler EFI Units Only:
Located on the right front corner of the hydrostatic
pumps.
The electronic control unit (ECU) continuously
monitors operation of the EFI system. If a problem
or fault within the system is detected, the malfunction
indicator light (MIL) is illuminated. The MIL is
the light located in the console panel to the left of
the PTO switch. Follow the troubleshooting steps
outlined in the Kohler engine operator’s manual if the
MIL is illuminated.
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.
With a 5/8 wrench, turn both valves one turn
counterclockwise to release the drive system.
Turn clockwise to reset the drive system. Torque to
110-130 in-lb (12-15 N-m). Do Not overtighten.
Do Not tow machine.
Pre-Start
Fill fuel tank on level ground. See Fuel
Recommendations in the Specifications section for
additional gasoline information.
PTO Engagement Switch
Switch must be pulled out (up) to engage the blades.
Switch is pushed in to disengage the blades.
Do Not add oil to gasoline.
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.
The LCD indicator will appear when the PTO switch
Low Voltage Indicator
Located on the front control panel in the message
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
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.
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
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.
Operating Instructions
Open the Fuel Shut-Off Valve
Note: The indicator normally appears when the
engine is off and the key switch is turned to the
“ON” position.
Rotate the valve and align with the fuel line to open.
Starting the Engine
Deck Lift Handle
1. Leave the LH motion control lever in neutral and
the RH lever in the PTO disengage position (see
Located on the RH of the front control panel.
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.
2. Pull the parking brake rearward and over to the
right to engage the parking brake.
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Operation
3. Push in (down) on the PTO switch to the
“disengage” position.
3. Move the right side motion control lever to the
center, operate position.
4. Place the throttle midway between the “SLOW”
and “FAST” positions.
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.
5. On a cold engine, push the choke lever forward
into the “ON” position (except Kohler EFI units).
On a warm engine, leave the choke in the “OFF”
position.
5. Place the throttle in the “FAST” position to begin
mowing.
6. Turn ignition switch to the “START” position.
Release the switch as soon as the engine starts.
Disengaging the PTO
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.
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.
Do Not put hands or feet under the mower or
mower deck when the blades are engaged.
2. Move the motion control levers to the neutral
position; move the RH control lever out to the
PTO disengage position.
3. Place the throttle midway between the “SLOW”
and “FAST” positions.
DANGER
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.
4. Push down on the PTO switch to disengage the
blades.
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.
The PTO switch engages the cutting blades. Be sure
all persons are clear of mower deck and discharge
area before engaging the PTO.
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.
1. Set throttle to “MIDWAY” position.
2. Release the parking brake.
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Operation
Driving the Machine
CAUTION
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.
• Use caution when making turns.
• Slow the machine down before making sharp
turns.
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
Figure 9
Note: The “N” LCD indicator appears when the
RH lever is in the PTO disengage position.
To turn left or right, pull the motion control lever
back toward neutral in the desired turn direction.
When the RH motion control lever is moved directly
inward (together) the drive system is in the neutral
operate position.
The machine will move faster the farther the
motion control levers are moved from the neutral
position.
4. To stop, position both motion control levers in
the neutral operate position.
Driving in Reverse
1. Move the motion control levers to the neutral
operate position.
2. To move rearward in a straight line, slowly move
both levers rearward with equal pressure.
Figure 8
1. LH Motion control lever
2. RH Motion control lever
6. Neutral
7. Forward
3. RH Motion control
lever in PTO disengage
position
8. Front reference/Speed
control bar
4. Reverse
9. Front of unit
5. Rear reference bar
Driving Forward
1. Make sure the motion control levers are in the
neutral position.
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
To turn left or right, release pressure on the
motion control lever toward the desired turn
direction.
5. Backward position —
slower
6. Lock
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.
Adjust the front reference/speed control bar for
desired maximum forward speed.
Important: Make sure the handles are locked
in place so the front reference/speed control
bar does not move during operation.
1. Stop the machine and move the motion control
levers to the neutral position.
2. Disengage the PTO.
Operating the Platform
3. Unlock the handles on both sides of the control
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.
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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
• 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.
1. Platform
2. Raise upward
3. Latch pin knob snaps inward
Operating the Machine with the
Platform Up
Operating the Machine with the
Platform Down
Operating the machine with the platform up is
recommended when:
Operating the machine with the platform down is
recommended when:
• Mowing near drop-off's
• Mowing most areas
• Driving down slopes
• Mowing small areas where the machine is too long
• Areas with low over hanging branches or obstacles
• Loading the machine for transport
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
• 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
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 20 degree 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 20 degrees. 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.
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.
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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.
• Check the condition of the belts.
• Grease the lift linkage pivots.
• Check spark arrester (if equipped).
Every 50 hours
• Remove engine shrouds and clean cooling fins.
• Change the engine oil. (May need more often under severe conditions.)
• Check the spark plugs.
Every 80 hours
Every 100 hours
Every 160 hours
• Replace the primary air cleaner element — check secondary air cleaner element; replace if
dirty. (May need more often under severe conditions. See the Engine 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 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.
• Check the wheel lug nuts.
Every 500 hours
Yearly
• Grease the front caster pivots.
• Grease the deck belt idler pivot.
• Lubricate the 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 or with the message display. If the ignition
key is turned to the “on” position for a few seconds,
the battery voltage will be displayed in the area where
the hours are normally displayed. 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 add oil to the “FULL”
mark on the dipstick. Exmark 4-Cycle Premium
Engine Oil is recommended; refer to the Engine
Owner's manual for an acceptable alternative. Do
Not overfill.
Important: Make sure the negative battery cable
is disconnected and the battery charger used for
charging the battery should have an output of
16 volts and 7 amps or less to avoid damaging
the battery (see chart for recommended charger
settings). This is especially important on Kohler
EFI (Electronic Fuel Injection) units. Failure to
do so may damage the ECU (Electronic Control
Unit).
Important: Do Not operate the engine with the
oil level below the “LOW” (or “ADD”) mark on
the dipstick, or over the “FULL” mark.
Check Battery Charge
Service Interval: As required
Voltage
Reading
Percent
Charge
Maximum Charging
Charger
Settings
Interval
WARNING
CALIFORNIA
12.6 or
greater
100%
No
Charging
Required
16 volts/7
amps
Proposition 65 Warning
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.
12.4 – 12.6 75–100%
12.2 – 12.4 50–75%
30 Minutes
16 volts/7
amps
1 Hour
16 volts/7
amps
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Maintenance
Voltage
Reading
Percent
Charge
Maximum Charging
CAUTION
Charger
Settings
Interval
2 Hours
3 Hours
Connecting the jumper cables incorrectly
(wrong polarity) can immediately damage the
electrical and/or EFI system.
12.0–12.2
11.7–12.0
25–50%
0–25%
14.4 volts/4
amps
Be certain of battery terminal polarity and
jumper cable polarity when hooking up
batteries.
14.4 volts/4
amps
11.7 or less 0%
6 Hours or
More
14.4 volts/2
amps
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).
Important: For Kohler EFI units: Unplug the
harness from the ECU before performing any
welding on the equipment.
Recommended Jump
Starting Procedure
Service Interval: As required
WARNING
Batteries contain acid and produce explosive
gases.
• Shield the eyes and face from the batteries
at all times.
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.
• Do Not lean over the batteries.
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.
CAUTION
Corrosion or loose connections can cause
unwanted electrical voltage spikes at anytime
during the jump starting procedure.
Do Not attempt to jump start with loose or
corroded battery terminals or damage to the
engine or EFI may occur.
3. Connect the positive (+) cable to the positive (+)
terminal of the discharged battery that is wired to
DANGER
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).
Figure 17
Release the Cushion for Rear
Access
1. Plastic slide
2. Cushion bracket with key hole
3. Hairpin
Service Interval: As required
The cushion can be released for rear access to the
machine for maintenance or adjustment.
Check Mower Blades
Service Interval: Before each use or daily
1. Lower the platform.
2. Remove the hairpins on each side of the cushion.
3. Push the plastic slides to the inside.
4. Remove the cushion and lower it to the platform.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Lift deck and secure in raised position as stated in
the Clean Grass Build-Up Under Deck section.
3. Inspect blades and sharpen or replace as required.
5. Perform any maintenance or adjustment on the
machine.
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
Check Safety Interlock
System
1. Install bushing in blade prior to installing bushing in
spindle.
Service Interval: Before each use or daily
B. Install bushing/blade assembly into spindle.
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
The safety interlock system is designed to prevent the
mower blades from rotating unless:
• The right side motion control lever is moved to
the center, operating position.
Figure 19
• The blade control switch (PTO) is pulled on.
1. Use wrench here for
blade installation. This
nut has been torqued to
130-160 ft-lb (176–217
N-m)
2. Torque to 50-60 ft-lb
(68-81 N-m) Apply
lubricant to threads
as needed to prevent
seizing. Copper-based
anti-seize preferable.
Grease acceptable
substitute.
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.
• 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.
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 50-60 ft-lb (68-81 N-m).
Checking the Safety Interlock System
1. Start the engine.
2. Set the parking brake.
3. Move the motion control levers forward.
The engine should initiate shutdown after
momentary pause.
4. Start the engine and release the parking brake.
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Maintenance
5. Move the right side motion control lever to the
center, operating position.
air cleaner element. (May
need more often under
severe conditions. See
the Engine manual for
additional information.)
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.
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.
2. See the Engine Owner's Manual for maintenance
instructions.
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
off position. The blades should stop rotating.
3. The oil drain hose assembly is located on the left
side of the engine.
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 Exmark
4–Cycle Premium Engine 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 the Check Engine Oil
Level section. Do Not overfill. Start the engine
and check for leaks. Stop engine and recheck oil
level.
secondary air cleaner
element; replace if dirty.
(May need more often
under severe conditions.
See the Engine manual for
additional information.)
7. Wipe up any spilled oil from engine deck
mounting surfaces.
Check Hydraulic Oil Level
Every 500 hours—
Replace the secondary
Service Interval: Every 50 hours
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Maintenance
1. Stop engine and wait for all moving parts to stop,
and remove key. 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
7
1
2
2
Every 50
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.
1
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 50 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 13 psi (90 kPa).
4. Semi-pneumatic caster tires do not need to be
inflated.
Check Condition Of Belts
Service Interval: Every 50 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. Look on the top side of the cutting deck to check
the mower blade drive belt condition.
3. Look under the 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.
32
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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.
For Kohler EFI Units:
Note: Seals (Exmark P/N 103-0063) must be
replaced.
WARNING
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.
Fuel system components are under high
pressure. The use of improper components can
result in system failure, gasoline leakage and
possible explosion.
Use only approved fuel lines and fuel filters for
high pressure systems.
9. Insert the assembled nut and axle into the wheel
on the side of the wheel with the new seal and
bearing.
Replacement Filters
Kawasaki
Kawasaki
P/N 49019-7005
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.
Kohler EFI
Kohler
P/N 24 050 03
11. Insert the second bearing and new seal into the
wheel.
Change Hydraulic System
Filter and Fluid
12. Apply a thread locking adhesive to the 2nd spacer
nut and thread onto the axle with the wrench flats
facing outward.
Service Interval: After the first 250 hours
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Maintenance
Every 500 hours/Yearly
(whichever comes
first) thereafter
(Every 250 hours/Yearly if
using Mobil 1 15W50)
CAUTION
Raising the mower 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.
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).
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
1. Stop engine, wait for all moving parts to stop, and
remove key or spark plug wire(s). Engage parking
brake.
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.
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.
Turn filter clockwise until rubber seal contacts the
filter adapter, then tighten the filter an additional
2/3 to 3/4 turn.
Hydraulic System Air Purge
4. Fill reservoir as stated in Check Hydraulic Oil
Service Interval: As required
Level.
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.
Exmark Premium Hydro Oil is recommended.
Refer to the chart for an acceptable alternative:
Hydro Oil
Change Interval
500 Hours
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 (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.
34
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Maintenance
pump. If wheels rotate slowly, the system may
prime after additional running. Check oil level
as stated in Check the Hydraulic Oil Level
section.
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.
Figure 21
2. Loosen 1 1/2 turns only
1. Charge pump cap
Wheel Hub Nut Torque
Specification
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.
Service Interval: After the first 100 hours
Every 500 hours thereafter
Torque the nut on the wheel motor tapered shaft to
175-225 ft-lb (237-305 N-m).
2. Check oil level as stated in Check Hydraulic Oil
Level section.
Note: Do Not use anti-seize compound on the
wheel hub.
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.
Check Spark Arrester
(if equipped)
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.
Service Interval: Every 50 hours
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
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Maintenance
Thread Locking Adhesives
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
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.
• Pump sheave setscrews.
• Sheave retaining bolt in end of engine crankshaft.
• Caster wheel spacer nuts.
CAUTION
Raising the mower 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.
• Platform spring pin.
Mobil HTS Grease (Or
Food-Grade Anti-seize)
Mobil HTS grease (or food-grade anti-seize) is used
in the following locations:
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands or
equivalent support.
Between splines of the cutter housing spindle and
sheave.
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.
Copper-Based Anti-seize
Copper-based anti-seize is used in the following
locations:
1. Park the machine on a level surface and disengage
the blade control switch.
• On threads of Blade Bolts. See Check Mower
Blades section.
2. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
• Between engine crankshaft, pump drive sheave,
and clutch.
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.
• Between pump shafts and sheaves.
Dielectric Grease
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
Dielectric grease should not be applied to sealed
connectors.
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
1. Park the machine on a level surface.
2. Shut off engine and wait for all moving parts to
stop.
Adjusting the Rear of the
Deck
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.
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 to the 3 inch (7.6 cm)
position.
Park Brake Adjustment
If the parking brake does not hold securely, an
adjustment is required.
1. Park the machine on a level surface.
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).
2. Shut off engine and wait for all moving parts to
stop.
3. Check the air pressure in the drive tires. If needed,
adjust to the recommended inflation; refer to
6. If it does not measure correctly, locate the
height-of-cut rod on the right side of the machine
38
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Maintenance
Checking the Tire Pressure in Drive System
b. Loosen the jam nut.
Maintenance.
c. Rotate the yoke. To tighten the brake,
rotate the yoke up. To loosen the brake,
rotate the yoke down.
4. Disengage the park brake.
5. Push down on the brake bar until it touches
the tires. There will be a 3/4 inch (19 mm) gap
between the park brake handle and the slot in the
d. Secure the yoke to lower brake lever with
the hairpin, washer, and clevis pin.
e. Tighten the jam nut.
f. Check the brake operation again.
B. Adjusting the upper brake linkage:
a. Loosen the top jam nut.
b. To tighten the brake, turn the bottom
jam nut clockwise (as viewed from the
top) then turn the top jam nut. Move
the linkage upward to achieve the desired
setting.
c. To loosen the brake, turn the top jam
nut counterclockwise (as viewed from
the top) then turn the bottom nut
counterclockwise. Move the linkage
downward to achieve the desired setting.
Figure 28
1. Brake bar
4. 3/4 inch (19 mm)
5. Park brake handle
2. Push down
3. Slot
6. There are two methods to adjust the park brake;
one or both methods may be used.
A. Adjusting the lower brake lever:
a. Remove the hairpin, washer, and clevis pin
from the lower brake lever and yoke as
Figure 30
1. Move down to loosen
brake
4. Bottom jam nut
2. Move up to tighten brake 5. Linkage
3. Top jam nut
d. Tighten the jam nuts.
e. Check the brake operation again.
7. After the brake is adjusted, the lever switch needs
to be checked.
8. Check the gap between the brake lever and the
be an 1/8 inch (3mm) with the brake engaged.
Figure 29
1. Jam nut
2. Yoke
4. Lower brake lever
5. Washer
3. Clevis pin
6. Hairpin
39
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Maintenance
3. Check the condition of the wire harness leads,
connectors, and terminals. Clean or repair as
necessary.
4. Verify that 12V is present at the clutch connector
when the PTO switch is engaged.
5. Measure the gap between the rotor and armature.
If the gap is greater than .04 inch (1 mm), proceed
with the following steps:
Figure 31
3. Brake lever
A. Loosen both brake mounting bolts one-half
1. Switch
2. 1/8 inch (3mm) gap
needed between switch
and brake lever
Note: Do Not remove the brake pole from
the field shell/armature. The brake pole has
worn to match the armature and needs to
continue to match after the shim is removed
to ensure proper brake torque.
9. If needed, loosen the screws holding the switch
and adjust the switch.
Electric Clutch Adjustment
No adjustment necessary. However when the clutch
brake has worn to the point where the clutch no
longer engages consistently, the shim can be removed
to extend the clutch life.
Figure 33
1. Brake mounting bolt
2. Shim
B. Using needle nose pliers, or by hand, take
hold of the tab and remove the shim (Do Not
discard the shim until proper clutch function
has been confirmed).
Figure 32
1. Armature
5. Brake spacer
6. Re-gap shim
7. Brake pole
2. Field shell
3. Rotor
C. Using a pneumatic line, blow out any debris
from under the brake pole and around the
brake spacers.
4. Brake mounting bolt
D. Re-torque each bolt (M6 x 1) to 10 ft-lb (13
N-m) +/-0.5 ft-lb (0.7 N-m).
Removing the Shim:
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.
E. Using a 0.010 inch thick feeler gauge, verify
that a gap is present between the rotor and
armature face on both sides of the brake pole
as shown. (Due to the way the rotor and
armature faces wear (peaks and valleys) it is
sometimes difficult to measure the true gap.)
2. Using a pneumatic line, blow out any debris
from under the brake pole and around the brake
spacers.
40
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Maintenance
1. With the engine off, turn the ignition switch to
the “ON” position.
2. Locate the LCD indicator in the message display.
G011733
1
Figure 34
1. Feeler gauge
Figure 36
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.
Figure 35
1. Feeler gauge
• If the gap is less than 0.010 inch, then
reinstall the shim and reference the
Troubleshooting section.
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.
• If the gap is sufficient, proceed to the
safety check in step F.
F. Perform the following safety check:
a. Sit on the seat and start the engine.
6. Loosen the lock nuts on the RH motion control
linkage (as viewed from the rear of the machine
in the PTO disengage position, hold the LH
motion control in the position determined in step
4 or 5. Rotate the adjustment rod until the LCD
indicator comes on.
b. Make sure the blades Do Not engage with
the PTO switch “off ” and the clutch
disengaged.
If the clutch does not disengage,
reinstall the shim and reference the
Troubleshooting section.
c. Engage and disengage the PTO switch
ten consecutive times to ensure the clutch
is functioning properly. If the clutch
does not engage properly, reference the
Troubleshooting section.
Motion Control Neutral
Adjustment
Check to see if an adjustment is required:
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Maintenance
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.
Figure 37
3. Lock nut (LH thread)
3. Release the rear cushion from the rear of the
machine.
1. Lock nut
2. Adjustment rod
4. Place the front reference/speed control bar in
the maximum forward position. See Adjusting
the Front Reference/Speed Control Bar in
Operation.
7. Continue to rotate the adjustment rod, counting
the turns, until the LCD indicator turns off.
Rotate the adjustment rod 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.
5. Rotate the adjustment rod on the LH side of the
machine (as viewed from the rear of the machine
6. Looking down towards the adjustment rod —
rotate it counterclockwise, in 1/4 turn increments,
to increase speed or clockwise to decrease speed.
8. Turn the adjustment rod on the LH side (as
viewed from the rear of the machine — see
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.
7. Drive the machine and check the full forward
tracking.
8. Repeat steps 5 through 7 until desired tracking
is obtained.
9. With the motion control levers in the neutral
either forward or back), the neutral LCD indicator
should appear.. If it does not appear, refer to the
Troubleshooting section.
10. Reinstall the rear cushion.
Check the Neutral Switch
Alignment
1. Park the machine on a level surface and disengage
the blade control switch.
Figure 38
1. Rotate to increase speed
2. Adjustment rod
2. Stop engine, wait for all moving parts to stop, and
remove the key or spark plug wire(s).
3. Rotate to decrease speed
3. Set the height of cut to the 3 inch (7.6 cm)
position.
9. Reinstall the rear cushion.
4. Perform the Motion Control Neutral
Adjustment and Motion Control Tracking
Adjustment as stated in the Maintenance section.
5. Release the rear cushion from the rear of the
machine and lower to the platform.
42
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Maintenance
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.
B. If the indicator does not stay lit while moving
the deck up and down, contact an Authorized
Service Dealer. Remove the key.
Adjust RH Motion Control
Handle Position
If the motion control levers do not align horizontally,
adjust the right side motion control lever.
Note: Adjust the horizontal alignment before the
front to back alignment.
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 39
1. Alignment reference
4. Lower neutral switch
surface
2. Upper neutral switch
surface
3. Switch mounting plate
5. Hardware
Figure 40
1. LH Motion control lever
2. RH Motion control lever
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
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.
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.
5. Release the cushion from the rear of the machine.
6. Loosen the nut and bolt holding 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.
7. Adjust the cam until it aligns with the left motion
control lever and tighten the nut and bolt for the
cam.
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.
43
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Maintenance
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
Figure 41
1. Switch screws
2. Nut and bolt
3. Cam
4. Front reference/speed control handle
8. After the cam is adjusted, the lever switch needs
to be checked.
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.
Figure 43
1. Spring disc washers
Figure 42
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.
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Maintenance
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Cleaning
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.
Clean Engine and Exhaust
System Area
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
Clean Grass Build-Up Under
Deck
conditions.)
Service Interval: Before each use or daily
CAUTION
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
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.
2. Raise deck to the transport (maximum cutting
height) position. Lift the front of unit and support
unit using jack stands or equivalent support.
Clean all debris from engine and exhaust system
area.
CAUTION
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Raising the mower 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.
2. Clean all debris from rotating engine air intake
screen, around engine shrouding, and exhaust
system area.
3. Wipe up any excessive grease or oil around the
engine and exhaust system area.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
4. Clean oil coolers (if equipped) of all debris, dirt,
and oil.
3. Clean out any grass build-up from underside of
deck and in discharge deflector.
Remove Engine Shrouds and
Clean Cooling Fins
Waste Disposal
Service Interval: Every 80 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Motor Oil Disposal
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.
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.
3. Make sure cooling shrouds are properly reinstalled.
Operating the engine without cooling shrouds will
cause engine damage due to overheating.
Clean Debris From Machine
Service Interval: Before each use or daily
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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.
46
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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.
11. MIL illuminates and blinks
8. Contact an Authorized Service Dealer.
9. Clean, adjust or replace spark plug.
10. Check the spark plug wire connection.
11. Contact an Authorized Service Dealer.
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Troubleshooting
Problem
Possible Cause
Corrective Action
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.
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 the LH
adjustment rod in the direction that the
mower needs to be adjusted to. Rotate the
adjustment rod 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. Damaged electric clutch.
4. Replace the spring.
5. Contact an Authorized Service Dealer.
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Troubleshooting
Problem
Clutch will not engage.
Possible Cause
1. Fuse is blown.
Corrective Action
1. Replace fuse. Check coil resistance,
battery charge, charging system, and
wiring connections and replace if
necessary.
2. Low voltage supply at the clutch.
2. Check coil resistance, battery charge,
charging system, and wiring connections
and replace if necessary.
3. Damaged coil.
3. Replace clutch.
4. Inadequate current supply.
4. Repair or replace clutch lead wire or
electrical system. Clean connector
contacts.
5. Remove shim or replace clutch.
5. Rotor/armature airgap is too large.
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Schematics
Electrical Diagram–Kohler EFI
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Schematics
Electrical Schematic–All Units Except Kohler EFI
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Schematics
Electrical Schematic–Kohler EFI
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Schematics
Hydraulic Diagram
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Exmark Lazer Z X-Series, Lazer Z S-Series, 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 X-Series, Lazer Z S-Series, 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 X-Series, Lazer Z S-Series, 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.
Rental of like or similar replacement equipment during the period of
any warranty, repair or replacement work.
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.
Warranty Exceptions
Warranty Exceptions
• Bags, Belts and Tires
• Battery
Warranty Period
90 days
1 Year Prorated
*
• Engine
•
* 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.
•
•
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.
•
•
Any claims for lost revenue, lost profit or additional cost as
a result of a claim of breach of warranty.
Attorney's fees.
No Claim of breach of warranty shall be cause for cancellation or
rescission of the contract of sale of any Exmark mower.
• 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.
• 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.
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.
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.
There are no other express warranties except for engine and special
emission system coverage.
This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
All warranty work must be performed by an authorized Exmark Service
Dealer using Exmark approved replacement parts.
G4500-733_B
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Notes:
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Service Record
Date:
Description of Work Done:
Service Done By:
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Figure 44
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.
59
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EXMARK 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
SUN SHADE
TRASH CONTAINER
TURF STRIPER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
12V POWER PORT
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
*Some accessories and options not available for some models.
Place Model No. and Serial No.
Date Purchased
Label Here (Included in the Literature
Pack) or Fill in Below
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Model No.
Serial No.
©2011 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
Part No. 4501-211 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
All Rights Reserved
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