Exmark VANTAGE X Series Operator's Manual

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V ANTAGE®X-SERIES

ForSerialNos. 315,000,000&Higher

PartNo.4502-224Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemical

orchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Theengineinthisproductisnot equippedwithasparkarrestermufer.Itisa violationofCaliforniaPublicResourceCode (CPRC)Section4442touseoroperatethis engineonanyforest-covered,brush-covered, orgrass-coveredlandasdenedinCPRC4126. Otherstatesorfederalareasmayhavesimilar laws.

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

Thissparkignitionsystemcomplieswiththe CanadianstandardICES-002.Cesystèmed’allumage parètincelledevèhiculeestconformeàlanorme NMB-002duCanada.

TheenclosedEngineOwner’sManualis suppliedforinformationregardingTheU.S. EnvironmentalProtectionAgency(EPA)and theCaliforniaEmissionControlRegulationof emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit. ShouldthisengineOwner’sManualbecome damagedorillegible,replaceimmediately. Replacementsmaybeorderedthroughthe enginemanufacturer.

Exmarkreservestherighttomakechangesor addimprovementstoitsproductsatanytime withoutincurringanyobligationtomakesuch changestoproductsmanufacturedpreviously. Exmark,oritsdistributorsanddealers,accept noresponsibilityforvariationswhichmaybe evidentintheactualspecicationsofitsproducts andthestatementsanddescriptionscontained inthispublication.

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety instructions,youwillprolongthelifeofyourmower, maintainitsmaximumefciency,andpromotesafe operation.

Important:Tomaximizesafety,performance, andproperoperationofthismachine,itis essentialthatalloperatorscarefullyreadand fullyunderstandthecontentsoftheOperator’s manualprovidedwiththeproduct.Safe operationofExmarkequipmentisessential. Failuretocomplywiththeoperatinginstructions orreceivepropertrainingmayresultininjury.

Gotohttp://www.Exmark.comforadditional safeoperationinformation,suchassafetytips, trainingmaterials,andOperator’smanuals.

Ifadditionalinformationisneeded,orshould yourequiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare keptinformedofthelatestmethodsofservicing andareequippedtoprovidepromptandefcient serviceintheeldorattheirservicestations.They carryamplestockofservicepartsorcansecurethem promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready .

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals......................10

Specications........................................................16

ModelNumbers.............................................16

Systems..........................................................16

Dimensions....................................................17

TorqueRequirements.....................................18

ProductOverview.................................................18

Operation..............................................................19

Controls.........................................................19

Pre-Start.........................................................22

OperatingInstructions...................................22

Transporting..................................................26

Maintenance..........................................................27

RecommendedMaintenanceSchedule(s)............27

PeriodicMaintenance........................................28

CheckEngineOilLevel..................................28

CheckMowerBlades......................................30

CheckSafetyInterlockSystem........................31

CheckforLooseHardware.............................32

ServiceAirCleaner.........................................32

ChangeEngineOil.........................................32

CheckHydraulicOilLevel..............................32

CheckTirePressures......................................33

CheckConditionOfBelts...............................33

LubricateGreaseFittings................................33

LubricateCasterWheelHubs.........................33

CheckSparkPlugs..........................................34

ChangeHydraulicSystemFilterand

Fluid..........................................................34

WheelHubNutTorqueSpecication..............36

CheckSparkArrester(ifequipped)..................36

ThreadLockingAdhesives..............................37

MobilHTSGrease(OrFood-Grade

Anti-seize)..................................................37

Copper-BasedAnti-seize................................37

DielectricGrease............................................37

Adjustments......................................................37

DeckLeveling................................................37

AdjustingtheCuttingDeckRake....................38

AdjustingtheRearoftheDeck........................39

PumpDriveBeltTension................................39

MowerDeckDriveBeltTension.....................39

ChecktheParkBrake......................................39

ParkBrakeAdjustment...................................39

ElectricClutchAdjustment.............................41

NeutralAdjustment........................................42

TrackingAdjustment......................................45

DriveLeverResistanceAdjustment.................45

CasterPivotBearingsPre-Load

Adjustment................................................46

Cleaning............................................................46

CleanEngineandExhaustSystem

Area...........................................................46

RemoveEngineShroudsandClean

CoolingFins...............................................46

CleanDebrisFromMachine...........................46

CleanGrassBuild-UpUnderDeck.................47

WasteDisposal...............................................47

Troubleshooting....................................................48

Schematics............................................................51

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4 specicationsoftheAmericanNationalStandards Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer reasonablysafeservice;however,failuretocomply withthefollowinginstructionsmayresultinpersonal injury.

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

SafetyAlertSymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Indicatesanimminentlyhazardous

situationwhich,ifnotavoided,Willresultindeathor seriousinjury.

WARNING:Indicatesapotentiallyhazardous situationwhich,ifnotavoided,Couldresultindeath orseriousinjury.

CAUTION:Indicatesapotentiallyhazardous situationwhich,ifnotavoided,Mayresultinminor ormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)cannot readthismanual,itistheowner’sresponsibilityto explainthismaterialtothem;otherlanguagesmay beavailableonourwebsite.

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses, substantialfootwear,andhearingprotection.Do Notoperatewhenbarefootorwhenwearingopen sandals.Longhair,looseclothingorjewelrymay gettangledinmovingparts.

CAUTION

Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

Safety

•Inspecttheareawheretheequipmentistobe usedandremoveallrocks,toys,sticks,wires, bones,andotherforeignobjectswhichcanbe thrownbythemachineandmaycausepersonal injurytotheoperatororbystanders.

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Fillthefueltanktothebottomoftheller neck.Theemptyspaceinthetankallows gasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengine oremissionsystem.

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitegasolinevapors.Areor explosionfromgasolinecanburnyouand othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.Do Notuseanozzlelockopendevice.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperatorpresencecontrols, safetyswitches,andshieldsareattachedand functioningproperly .DoNotoperateunlessthey arefunctioningproperly .

Safety

Operation

WARNING

Operatingengineparts,especiallythemufer, becomeextremelyhot.Severeburnscanoccur oncontactanddebris,suchasleaves,grass, brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to coolbeforetouching.

•Removeaccumulateddebrisfrommuferand enginearea.

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea, DoNotoperatethemachine;seekshelter.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

•Neveroperatethemowerwithdamagedguards, shields,orcovers.Alwayshavesafetyshields, guards,switchesandotherdevicesinplaceandin properworkingcondition.

•Nevermowwiththedischargedeectorraised, removedoralteredunlessthereisagrass collectionsystemormulchkitinplaceand workingproperly.

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait forallmovingpartstostop,removekeyand engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

–Beforemakingheightadjustments.

WARNING

Hands,feet,hair,clothing,oraccessoriescan becomeentangledinrotatingparts.Contact withtherotatingpartscancausetraumatic amputationorseverelacerations.

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesinplace andworkingproperly.

•Keephands,feet,hair,jewelry,orclothing awayfromrotatingparts.

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhen makingturns.Lookbehindandtothesidebefore changingdirections.

•Stoptheblades,slowdown,andusecaution whencrossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning onslopesaslossoftractionand/ortip-overcould occur.Theoperatorisresponsibleforsafeoperation onslopes.

Safety

DANGER

Operatingonwetgrassorsteepslopescan causeslidingandlossofcontrol.Lossofcontrol and/orlossofoperator'sfootingcouldresultina fallwithanarmorleggettingunderthemower orenginedeckwhichmayresultinseriousinjury, deathordrowning.

•Mowacrossslopes,neverupanddown.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan20degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

•Removeormarkobstaclessuchasrocks,tree limbs,etc.fromthemowingarea.Tallgrasscan hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

MaintenanceandStorage

•Disengagedrives,setparkingbrake,stopengine andremovekeyordisconnectsparkplugwire. Waitforallmovementtostopbeforeadjusting, cleaningorrepairing.

•Keepengineandengineareafreefrom accumulationofgrass,leaves,excessivegrease oroil,andotherdebriswhichcanaccumulate intheseareas.Thesematerialscanbecome combustibleandmayresultinare.

•Letenginecoolbeforestoringanddonotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•Disconnectbatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthe negativeterminalrstandthepositivelast. Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s) orweargloves,andusecautionwhenservicing them.Onlyreplacedamagedblades.Never straightenorweldthem.

•Keephandsandfeetawayfrommovingparts. Ifpossible,donotmakeadjustmentswiththe enginerunning.

•Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugcharger beforeconnectingordisconnectingfrombattery. Wearprotectiveclothinganduseinsulatedtools.

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

•Ventilatewhenchargingorusingbattery inanenclosedspace.

•Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.

•Alwaysshieldeyesandfacefrombattery.

Safety

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagementof components.Sparkscouldcauseanexplosion ormovingpartscouldaccidentallyengage causingpersonalinjury.

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

WARNING

Removalormodicationoforiginalequipment, partsand/oraccessoriesmayalterthewarranty, controllability,andsafetyofthemachine. Unauthorizedmodicationstotheoriginal equipmentorfailuretouseoriginalExmark partscouldleadtoseriousinjuryordeath. Unauthorizedchangestothemachine,engine, fuelorventingsystem,mayviolateapplicable safetystandardssuchas:ANSI,OSHAand NFPAand/orgovernmentregulationssuchas EPAandCARB.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjuryorgangrenemay result.

•Ifequipped,makesureallhydraulicuid hosesandlinesareingoodconditionandall hydraulicconnectionsandttingsaretight beforeapplyingpressuretohydraulicsystem.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands,to ndhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrollevers inneutralandshuttingofftheenginebefore performinganyworkonthehydraulicsystem.

WARNING

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponentscan resultinsystemfailure,gasolineleakageand possibleexplosion.

Useonlyapprovedfuellinesandfuelltersfor highpressuresystems.

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe backingtoexposetheadhesivesurface.Apply onlytoaclean,drysurface.Smoothtoremove anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

106-5517

1.Warning—donottouchthehotsurface.

112-8760

1.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.

2.Cutting/dismembermentofhandorfoot—stayaway frommovingparts.

112-9028

1.Warning—stayawayfrommovingparts;keepallguards inplace.

114-3489

1.Thrownobjecthazard;cutting/dismemberment hazard—donotoperatethemachinewiththedischarge openinguncovered;alwaysoperatethemachinewith thereardischargedeector,dischargecoverorgrass collectorinstalled.

115-4212

1.Hydraulicoillevel3.Warning—donottouch

thehotsurface.

2.ReadtheOperator's Manual.

Safety

116-2040

1.Heightofcut(HOC)high

3.Heightofcut(HOC)-low

2.Heightofcut(HOC)medium

116-3283

116-7217

116-7912

1.Interval4.Neutral

2.PowerT ake-off(PTO)5.Operatorpresence control

3.Parkingbrake6.Battery

116-8283

1.Warning—readtheOperator'sManualforinstructions

ontorquingthebladebolt/nutto55-60ft-lb(75-81N-m).

116-8772

1.Accessory,15A

3.Charge,25A

2.PTO,10A

4.Main,30A

Safety

116-8894

1.Motioncontrol—forward

3.Motioncontrol—reverse

2.Motioncontrol—neutral

116-9143

1.Warning-ReadtheOperator’sManual.DoNotoperate thismachineunlessyouaretrained.Wearhearing protection.

2.Warning-Stayawayfrommovingparts;keepallguards inplace.Stopengineandremovekeybeforeadjusting, servicing,orcleaning.

3.Warning-DisengagePTO,shiftspeedcontroltoneutral, andengageparkingbrakebeforeleavingtheoperator’s position.

117–2718

126-2055

1.Wheellugnuttorque95ft-lb(129N-m)(4x)

2.Wheelhubnuttorque235ft-lb(319N-m)

3.ReadandunderstandtheOperator’smanualbefore performinganymaintenance,checktorqueafterrst 100hoursthenevery500hoursthereafter.

Safety

116-8778

EFIUnits

1.Parkingbrake-disengage

5.Throttle-fast

2.Parkingbrake-engaged

6.Continuousvariablesetting

3.PTO-on

7.Throttle-slow

4.PTO-off8.Checkengine

116-9144

1.Thrownobjecthazard-Pickupobjectsthatcouldbethrown bymower.DoNotoperatewhenpeopleandpetsarein thearea.Keepdeectorinplace.

4.ReadtheOperator’smanual.

2.Cutting/dismembermenthazard-DoNotoperateonslopes greaterthan20degrees.DoNotmowwetslopes-use extremecautionwhenoperatingonslopes;mowacross slopesnotupanddown.

5.Filltobottomofllerneck;warning-DoNotoverllthetank.

3.Crushing/dismembermenthazardofbystanders-DoNot carrypassengers,lookforwardanddownwhenoperating themachine,lookbehindanddownwhenreversing.

Safety

116-9145

1.Speedcontrol–fast

6.Turnknobtoadjusttracking

2.Continuousvariablespeed7.Motioncontrol–forward

3.Speedcontrol–slow

8.Motioncontrol–neutral

4.Speedcontrol–neutral

9.Motioncontrol–reverse

5.Readtheinstructionsbeforeservicingorperforming maintenance

116-9164

1.ReadtheOperator’sManualbeforeperformingan maintenance

4.Greaselinkagepivots(7)every50hours

2.Greasethebeltidlerevery500hours5.Checktirepressureevery50hours

3.Greasefrontcasterpivotsandwheelbearingsevery500 hours

6.Checkhydraulicoillevel(Onlyuserecommendedhydro oil)

Safety

116-9321

AllUnitsExceptEFI

1.Parkingbrake–disengaged

6.Continuousvariablesetting

2.Parkingbrake–engaged7.Throttle–slow

3.PTO–on8.Choke–on

4.PTO–off9.Choke–off

5.Throttle–fast

Specications

ModelNumbers

SerialNos:315,000,000andHigher

VTX651GKA48400;VTX730EKC52400;VTX740EKC60400

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•EngineOilType:Exmark4–CyclePremium EngineOil

•RPM:FullSpeed:3600±100RPM(NoLoad)

FuelSystem

•Capacity:8.0gal.(30.2L)

•FuelRecommendations:

–Forbestresults,useonlyclean,fresh,unleaded

gasolinewithanoctaneratingof87orhigher ((R+M)/2ratingmethod).

–Oxygenatedfuelwithupto10%ethanolor

15%MTBEbyvolumeisacceptable.

–DoNotuseethanolblendsofgasoline(such

asE15orE85)withmorethan10%ethanol byvolume.Performanceproblemsand/or enginedamagemayresultwhichmaynotbe

coveredunderwarranty. –DoNotusegasolinecontainingmethanol. –DoNotstorefueleitherinthefueltankor

fuelcontainersoverthewinterunlessafuel

stabilizerisused. –DoNotaddoiltogasoline.

•FuelFilter: –Kawasaki:

KawasakiP/N49019-0014

–KohlerEFI:

KohlerP/N2505042

•FuelShut-OffValve:1/4turn

ElectricalSystem(ElectricStart)

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

Kawasaki:15amps

KohlerEFI:20amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses: –30ampmainfuse –25ampchargingsystemfuse –10ampPTOfuse –15ampaccessoryfuse

SafetyInterlockSystem

•LCDindicatorsappearfortheparkbrake,drive

levers,andoperatorpresenceinthemessage displayonthefrontcontrolpanel.

Note:BecausethePTOmustbedisengaged tostarttheengine,theLCDindicatorwillnot illuminateatthistime.

•PTOmustbedisengagedandspeedcontrollever

inneutraltostartengine.(Itisnotnecessaryfor theoperatortobeontheplatformtostartthe engine.)

•MowerbladeswillstopifboththeOPClevers

arereleased.

•Enginewillstopifthespeedcontrolleveris

movedfromtheneutralpositionwiththepark brakeengaged.

OperatorControls

SteeringControl:Fingertipdrivecontrollevers provideindependentspeedcontrol,brakingand neutraltoeachdrivewheelformovingforwardor reverse,stopping,andpowerturning.

Transmission

•TwoHydroGearvariabledisplacementhigh

efciencypumpsindependentlycoupledtotwo highefciencyParker/Rosswheeldrivemotors.

Specications

•HydraulicOil:UseExmarkPremiumHydroOil.

•HydraulicOilCapacity:2.4qt.(2.2L)

•HydraulicFilterisreplaceablecartridgetype.

P/N109-4180:25microns,10psibypass (Summeruseabove32°F(0°C))

P/N1-523541:40microns,18psibypass(Winter usebelow32°F(0°C))

•Speeds:

–0-8.0mph(13km/hr)forward.

–0-4.0mph(6km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

WheelDriveSystem

DrivewheelsaredirectcoupledtoParkerwheeldrive motorswith11/4inch(31.8mm)taperedshaft.

Tires&Wheels

Drive

FrontCaster

Pneumatic (Air-Filled)

SemiPneumatic

Quantity

Tread

K500

Smooth

Size20x10.50–811x4.00-5

PlyRating

Pressure

13psi (90kPa)

CuttingDeck

•CuttingWidth:

–48inchDeck:48inches(121.9cm)

–52inchDeck:52inches(132.1cm)

–60inchDeck:60inches(152.4cm)

•Discharge:Side

•BladeSize:(3ea.)

–48inchDeck:16.25inches(41.3cm)

–52inchDeck:18.00inches(45.7cm)

–60inchDeck:20.50inches(52.1cm)

•BladeSpindles:Solidsteelspindleswith1.00inch (25.4mm)I.D .bearings.

•DeckDrive:

–Electricclutchmountedonengineshaft.

–Bladesdrivenbyonebelt(w/self-tensioning

idlers).

•Deck:Fulloatingdeckisattachedtosupport frame,removableforservice.Deckdesignallows forbagging,mulchingorsidedischarge.

•DeckDepth:

–48inchDeck:5.5inches(14.0cm)

–52inchDeck:5.5inches(14.0cm)

–60inchDeck:5.5inches(14.0cm)

•CuttingHeightAdjustment:Adjustsfrom1inch (2.5cm)to5.5inches(14cm)in1/4inch(6.4 mm)increments.

•MulchingKit:Optional

•Bagger:Optional

Dimensions

OverallWidth:

48inch Deck

52inch Deck

60inch Deck

Deector Up

51.8inches (131.6cm)

56.3inches (143.0cm)

63.9inches (162.3cm)

Deector Down

59.6inches (151.4cm)

64.8inches (164.6cm)

72.8inches (184.9cm)

OverallLength:

48inch Deck

52inch Deck

60inch Deck

Platform Up

60.5inches (153.7cm)

62.4inches (158.5cm)

Platform Down

74.0inches (188.0cm)

75.9inches (192.8cm)

OverallHeight:

48inchDeck52inchDeck60inchDeck

50.0inches (127.0cm)

TreadWidth:(OutsidetoOutsideof Tires,Widthwise)

48inchDeck52inchDeck60inchDeck

46.5inches (118.1cm)

50.5inches (128.3cm)

ProductOverview

CurbWeight:

48inchDeck52inchDeck60inchDeck

855lb (388kg)

875lb (397kg)

883lb (401kg)

Note:Weightswillvaryslightlydependingonengine.

TorqueRequirements

BoltLocation

Torque

CutterHousingSpindle Nut

130-160ft-lb (176-217N-m)

BladeMountingBolt (lubricatewithanti-seize)

50-60ft-lb(68-81N-m)

ClutchMountingBolt

50-60ft-lb(68-81N-m)

EngineDeck/Mower DeckSupportMount Bolts

30-35ft-lb(41-47N-m)

EngineMountingBolts Kawasaki Kohler

30-35ft-lb(41-47N-m) 27-33ft-lb(37-45N-m)

WheelLugNuts

85-105ft-lb(115-142 N-m)

WheelHubNuts175-225ft-lb

(237-305N-m)

WheelMotorMounting Bolts

67-83ft-lb(91-113N-m)

HydroPumpRelease Valves

110-130in-lb(12-15N-m)

ProductOverview

Figure3

1.Platform

4.Drivelevers

2.FuelCap5.EngineControls

3.Height-of-Cut Adjustment

6.ParkBrakeLever

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

OperatorPresenceControl(OPC) Levers

Locatedontheupperhandleassemblydirectlybelow thehandlegrips(seeFigure4).

Figure4

LHupperhandleassemblyshown

1.Neutrallocklatch

3.OPCLever

2.Rotateneutrallocklatch4.Driveleverinneutral position

Whentheseleversaredepressed,theOPCsystem sensesthattheoperatorisinthenormaloperator's position.

Note:TheLCDindicatorappearsinthemessage displayonthefrontconsolewhentheOPCleversare depressed(seeFigure5andFigure7).

Whentheleversarereleased,theOPCsystem sensesthattheoperatorhasmovedfromthenormal operatingposition.

•Iftheleversarereleasedwiththespeedcontrol notinneutral,theenginewillkill(withorwithout PTOengaged).

•Iftheleversarereleasedwiththespeedcontrolin neutralandthePTOengaged,themowerblades disengagebuttheengineremainsrunning.

DriveLevers

Locatedoneachsideoftheupperhandleassembly aheadofandbelowthehandlegrips(seeFigure4).

Theseleversindividuallycontrolthespeedand directionofeachdrivewheel.Whenthespeed controlleverismovedoutoftheneutralposition andtheneutrallocklatchesaremovedintothedrive positionandthedriveleversarereleased,thedrive wheelsareengagedintheforwarddirection.

Squeezingthelefthandand/orrighthandlever causesthelefthandand/orrighthanddrivewheel respectivelytoslowdown,stop,orreverse,depending onhowfareachdriveleveris“squeezed”.Squeezing thedriveleversbeyondtheneutralpositioncauses thedrivewheelstoengageinthereversedirection regardlessofthepositionoftheneutrallocklatches andthespeedcontrollever.

NeutralLockLatches

Locatedontheupperhandleassemblyontheends ofthehandlegrips(seeFigure4).

Theselatchesallowtheoperatortolockthedrive leversina“neutral”positionwherethedrivewheels arenotengagedineitheraforwardorreverse direction.

ChokeControl(AllUnitsExcept KohlerEFI)

LocatedontheRHsideofthefrontcontrolconsole (seeFigure5).

Thechokeisusedtoaidinstartingacoldengine. Movingthechokeleverforwardwillputthechokein the“ON”positionandmovingthechokelevertothe rear,tothedetent,willputthechokeinthe“OFF” position.DoNotrunawarmenginewithchokein the“ON”position.

Operation

Figure5

1.Platformlatch

9.Ignitionswitch

2.Choke

10.Fuelgauge

3.RHhandlegripwith neutrallocklatch

11.PTOengagementswitch

4.Trackingknob12.Throttle

5.Speedcontrollever13.Decklifthandle

6.LHhandlegripwith neutrallocklatch

14.Fuelcap

7.Parkbrakelever

15.Height-of-cutpin

8.Messagedisplay

ThrottleControl

LocatedontheRHsideofthefrontcontrolconsole (redlever)(seeFigure5).

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

SpeedControlLever

Locatedinmiddleofcontrolconsole(seeFigure5).

Thespeedcontrollevercontrolsthemaximum forwardspeedandisinnitelyvariablefromneutral 0–8.0mph(12.9km/hr).

Parkbrakemustbedisengagedtomovespeedcontrol outofneutralorenginewillkill.

Note:TheLCDindicatorappearsinthemessage displayonthefrontconsolewhenthespeedcontrol leverisintheneutralposition(seeFigure5and Figure7).

ParkBrakeLever

Locatedonleftsideofunit(seeFigure5).

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Note:TheLCDindicatorappearsinthemessage displayonthefrontconsolewhentheparkbrakeis engaged(seeFigure5andFigure7).

Toengagethebrake,pulltheleverrearwardandto therighttopositionintotheengagedposition.

Torelease,pullthebrakeleverbackandovertothe left,positionintotheslotandpushtheleverforward.

Whenparkingonasteepslope,thewheelsmustbe chockedorblockedinadditiontothebrakebeing engaged.Theunitmustbetieddownandbrake engagedwhentransporting.

Parkbrakemustbedisengagedbeforemovingspeed controloutofneutralorenginewillkill.

IgnitionSwitch

LocatedontheLHsideofthefrontcontrolconsole (seeFigure5).

Theignitionswitchisusedtostartandstopthe engine.Theswitchhasthreepositions“OFF”,“ON” and“START”.Insertkeyintoswitchandrotate clockwisetothe“ON”position.Rotateclockwiseto thenextpositiontoengagethestarter(keymustbe heldagainstspringpressureinthisposition).Allow thekeytoreturntothe“ON”positionimmediately aftertheenginestarts.

Figure6

1.Off3.Start

2.On

Note:T ostarttheengine,operatormusthavespeed controlleverinneutral,OPCleversdepressed,and thePTOdisengaged.(Itisnotnecessaryforthe operatortobeontheplatform.)

Operation

HourMeter

LocatedontheLHsideofthefrontcontrolconsole inthemessagedisplay(seeFigure5andFigure7).

Thehourmeterrecordsthenumberofhoursthat theenginehasrun.

Figure7

1.LCDIndicators

2.Lowvoltageindicatorlight

3.Hour/Voltagedisplay

Thehourmeterisrecordingwhenthedecimalpoint isashinginHour/Voltagedisplay.

Hoursaredisplayedwhenthekeyisofforwhenthe machineisrunning.

Note:Iftheignitionkeyisturnedtothe“ON” positionforafewsecondsbeforecrankingtheengine, thebatteryvoltagewilldisplayintheareawherethe hoursarenormallydisplayed.

Note:TheLCDindicatorsappearwheneach controlmeetsthe“safetostart”mode.Becausethe PTOmustbedisengagedtostarttheengine,the LCDindicatorwillnotilluminateatthistime.

FuelShut-OffValve

LocatedontheRHsideofthecontroltowerbehind thekneecushionforKawasakiunits.Locatedon theLHsideofthemachine,towardstherearofthe engine,onKohlerunits.

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Alignvalvehandlewiththefuellinetoopen.Rotate 90°toclose.

FuelGauge

Locatedonthetopleftsideofthetank(seeFigure5).

Thefuelgaugemonitorstheamountoffuelinthe tank.

DriveWheelReleaseValves

Locatedontherightfrontcornerofthehydrostatic pumps.

Drivewheelreleasevalvesareusedtoreleasethe hydrostaticdrivesystemtoallowthemachinetobe movedbyhandwithouttheenginerunning.

Witha5/8wrench,turnbothvalvesoneturn counterclockwisetoreleasethedrivesystem.

Turnclockwisetoresetthedrivesystem.Torqueto 110-130in-lb(12-15N-m).DoNotovertighten.

DoNottowmachine.

PTOEngagementSwitch

Locatedonfrontcontrolpanel(seeFigure5).

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

TheLCDindicatorwillappearwhenthePTOswitch isengaged(seeFigure7).

LowVoltageIndicator

Locatedonthefrontcontrolpanelinthemessage display(seeFigure5andFigure7).

Alowvoltagecondition(lessthan12.3volts)exists whenthelowvoltageindicatorlightappearsonthe messagedisplaywhiletheengineisrunning.

Iftheignitionkeyisturnedtothe“ON”positionfor afewsecondsbeforecrankingtheengine,thebattery voltagewilldisplayintheareawherethehoursare normallydisplayed.

Note:Theindicatornormallyappearswhenthe engineisoffandthekeyswitchisturnedtothe “ON”position.

DeckLiftHandle

LocatedontheRHofthefrontcontrolpanel.

Pullthehandlerearwardtoraisethecuttingdeck. Allowthehandletomoveforwardtolowerthe cuttingdecktothecutheightthathasbeenset.

Operation

Pullthehandlerearwardandtotherighttolatchthe cuttingdeckintotheraisedtransportposition(see Figure5).

ElectronicControlUnitMalfunction Indicator

KohlerEFIUnitsOnly:

Theelectroniccontrolunit(ECU)continuously monitorsoperationoftheEFIsystem.Ifaproblem orfaultwithinthesystemisdetected,themalfunction indicatorlight(MIL)isilluminated.TheMILis thelightlocatedintheconsolepaneltotheleftof thePTOswitch.Followthetroubleshootingsteps outlinedintheKohlerengineoperator’smanualifthe MILisilluminated.

Pre-Start

Fillfueltankonlevelground.SeeFuel RecommendationsintheSpecicationssectionfor

additionalgasolineinformation.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe tankallowsgasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineoremission system.

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

Foroperationonhillyterrain,afrontweightkit accessory(P/N116-2935)maybeaddedtoenhance stabilityandcontrol.Seetherecommendations below:

•Operatorlessthan200lb(91kg)—noadditional weights.

•Operator200–275lb(91-125kg)—useonefront weightkit.

•Operatorover275lb(125kg)—useone frontweightkitplus2additionalweights(P/N 103-2455-01).

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethevalveandalignwiththefuellinetoopen.

StartingtheEngine

1.Onacoldengine,placethethrottlemidway betweenthe“Slow”and“Fast”positionsand placethechokeinthe“On”position(except onKohlerEFIunits).Onawarmengine,place thethrottlelevermidwaybetween“Slow”and “Fast”positionsandleavethechokeinthe“Off” position.

2.Movethespeedcontrollevertoneutral.

3.Turnignitionswitchto“Start”position.Release theswitchassoonastheenginestarts.

4.Onacoldengine,graduallyreturnchoketothe “Off”positionafterenginestartsandwarmsup.

Important:Donotcranktheengine continuouslyformorethantensecondsat atime.Iftheenginedoesnotstart,allowa 60secondstartercool-downperiodbetween startingattempts.Failuretofollowthese guidelinescanburnoutthestartermotor.

Note:Itishelpfultohavetheleftandright neutrallocklatcheslockedinneutralwhenstarting theengine.RefertoNeutralLockLatches sectioninControls.

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeckare dangerous.Bladecontactcancauseserious injuryorkillyou.

DoNotputhandsorfeetunderthemoweror mowerdeckwhenthebladesareengaged.

Operation

DANGER

Anuncovereddischargeopeningwillallow objectstobethrowninanoperator’sor bystander’sdirection.Also,contactwiththe bladecouldoccur.Thrownobjectsorblade contactcancauseseriousinjuryordeath.

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunlessthere isagrasscollectionsystemormulchkitinplace andworkingproperly.

ThePTOswitchengagesthecuttingblades.Besure thatallpersonsareclearofmowerdeckanddischarge areabeforeengagingthePTO.

1.Setthrottleto“MIDWAY”position.

2.PullthePTOswitchoutwardtothe“ROTATE” positiontoengagetheblades.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushthePTOswitchintothe“STOP”position todisengagetheblades.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Lockdriveleversinneutral.

3.DisengagethePTO.

4.Movespeedcontrollevertoneutral.

5.Engagetheparkingbrake.

6.Placethethrottlemidwaybetweenthe“SLOW” and“FAST”positions.

7.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

8.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

9.Closethefuelshut-offvalvewhenthemachine willnotbeinuseforafewdays,when transporting,orwhentheunitisparkedinside abuilding.

DrivingtheMachine

DriveLever/NeutralLockLatchOperation

Tolockthedriveleversin“neutrallock”,squeezethe driveleverstothe“neutral”position(DoNotsqueeze thedriveleversallthewaybackasthiswillcausethe drivewheelstogointofullreversedirection).See Figure8position1.Placethumbsontheinnerlobe oftheneutrallocklatchesandrotatethemunder thedriveleversintothe“neutrallock”position.See Figure8position2.Releasethedrivelevers.

CAUTION

Iftheneutrallocklatchesarenotcompletely engagedthedriveleverscouldunexpectedlyslip intotheforwarddriveposition.Ifthedrivelevers slipintothedrivepositiontheunitcouldlurch forwardandcauseinjuryorpropertydamage.

Besurethedriveleversarepasttherollerand securelyseatedatthebottomoftheneutrallock latches.

Toplacethedriveleversinthe“forward”position, slightlysqueezethedriveleverswhileplacingthumbs ontheouterthumblobeoftheneutrallocklatches (ortheindexngeronthefrontlobe)androtatethem fromunderthedrivelevers.Slowlyandcarefully releasethedrivelevers.SeeFigure8position3.

Toplacethedriveleversinthe“reverse”position, squeezethedriveleverspasttheneutralposition.See Figure8position4.

Figure8

1.DriveLeverinneutral position

3.DriveLeverinforward position

2.DriveLeverlockedin neutralposition

4.DriveLeverinreverse position

DrivingForward

1.Releasetheparkingbrake.

Operation

2.Withdriveleverslockedin“neutral”,shiftspeed controllevertodesiredforwardspeed.

3.Slowlysqueezeandholdbothdriveleversin theneutralpositionandrotatebothneutrallock latchesfromtheneutrallockpositiontothe forwardposition.

Note:DoNotsqueezebothdriveleversallthe wayback.Thiswillcausethedrivewheelsto engageinthereversedirection.

4.Tomoveforwardinastraightline,smoothly releasebothdriveleverstoengagedrivewheels.

Toturnleftorright,squeezetherighthanddrive levertoturnrightandthelefthanddrivelever toturnleft.

Tomakea“zeroturn”,squeezeeithertheleft handortherighthanddriveleverbackintothe reversepositionwhiletheoppositedriveleverisin aforwardpositionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine, avoidquick,jerkymovementsofthedrivelevers. Movethedriveleverssmoothlyanddeliberately .

Tostop,squeezedriveleversbacktothe“neutral” position.Movetheneutrallocklatchesintothe “neutrallock”positionandreleasedrivelevers. Movethespeedcontrollevertotheneutral position.

5.Iftheunittrackstoonesideortheother,turnthe quicktrackknob.Turntheknobrightto“steer” right,turntheknobleftto“steer”left.

DrivinginReverse

Tomoverearwardinastraightline,squeezedrive leversintothereverseposition.

Toturnleftorright,squeezetherighthanddrivelever toturnleftandthelefthanddrivelevertoturnright.

Tomakea“zeroturn”,squeezeeitherthelefthand ortherighthanddriveleverbackintothereverse positionwhiletheoppositedriveleverisinaforward positionatanequalbutoppositespeed.

Note:Forsmoothoperationofthismachine,avoid quick,jerkymovementsofthedrivelevers.Movethe driveleverssmoothlyanddeliberately .

Tostop,squeezedriveleversbacktothe“neutral” position.Movetheneutrallocklatchesintothe “neutrallock”positionandreleasedrivelevers.Move thespeedcontrollevertotheneutralposition.

OperatingthePlatform

Themachinecanbeusedwiththeplatforminthe upordownposition.Itistheoperator'spreference onwhichpositiontouse.

WARNING

Theoperatorplatformisheavyandmaycause injurywhenloweringandraisingtheoperator platform.Theplatformmaysuddenlydropifnot supportedwhenthelatchpinispulledout.

•DoNotputyourhandsorngersinthe platformpivotareawhenloweringorraising theoperatorplatform.

•Makesuretheplatformissupportedwhen thelatchpinispulledout.

•Makesurethelatchsecurestheplatform whenfoldingitintheupposition.Pushit tightagainstthecushionforthelatchpinto lockintoplace.

OperatingtheMachinewiththe PlatformUp

Operatingthemachinewiththeplatformupis recommendedwhen:

•Mowingneardrop-off's

•Mowingsmallareaswherethemachineistoolong

•Areaswithlowoverhangingbranchesorobstacles

•Loadingthemachinefortransport

•Unloadingthemachineaftertransport

•Drivinguporbackingdownslopesorramps.

•Turningintightareaswhereplatformmaycontact obstacles.

Toraisetheplatform,pullthebottomupwardand pushittightagainstthecushion.Thelatchpinknob willsnapinwardtolocktheplatformintoplace(see Figure9).

Operation

Figure9

1.Platform

2.Raiseupward

3.Latchpinknobsnapsinward

OperatingtheMachinewiththe PlatformDown

Operatingthemachinewiththeplatformdownis recommendedwhen:

•Mowingmostareas

•Drivingdownslopes

Tolowertheplatform,pushtheplatformforward againstthecushiontoreleasepressureonthelatch pin,pulltheknoboutward,andlowertheplatform (seeFigure10).

Figure10

1.Pulllatchpinknoboutward

2.Platform

3.Lower

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjustedin 1/4inch(6.4mm)increments.

1.Stopthemachineandmovethelockdrivelevers inneutral.

2.DisengagethePTO.

3.Movespeedcontrollevertoneutral.

4.Raiseandlockthedecktothetransportposition.

Thedeckisraisedbypullingthedecklifthandle rearwardandtotherighttoplaceitintothe transportlockposition.

Figure11

1.Transportlockposition

3.Decklifthandle

2.RHhandleassembly

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

5.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheight.

Seethedecalonthesideofthedeckliftplatefor cutheights(referenceFigure12).

6.Pullthedecklifthandlerearwardandtotheleft andslowlyallowthedecktolowertothecutting height.

Operation

Figure12

1.Heightadjustmentpin

3.Decklifthandle

2.Heightofcutholes

Transporting

TransportingaUnit

Useaheavy-dutytrailerortrucktotransportthe machine.Lockbrakeandblockwheels.Securely fastenthemachinetothetrailerortruckwithstraps, chains,cable,orropes.Ifpossible,bothfrontand rearstrapsshouldbedirecteddownandoutward fromthemachine.Besurethatthetrailerortruck hasallnecessarylightingandmarkingasrequiredby law .Secureatrailerwithasafetychain.

CAUTION

Thisunitdoesnothaveproperturnsignals, lights,reectivemarkings,oraslowmoving vehicleemblem.Drivingonastreetorroadway withoutsuchequipmentisdangerousand canleadtoaccidentscausingpersonalinjury. Drivingonastreetorroadwaywithoutsuch equipmentmayalsobeaviolationofStatelaws andtheoperatormaybesubjecttotrafctickets and/ornes.

DoNotdriveaunitonapublicstreetorroadway .

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over.Backward tip-overcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit onaramp.

•Useonlyasingle,fullwidthramp;DoNot useindividualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.

•DoNotexceeda20degreeanglebetween rampandgroundorbetweenrampandtrailer ortruck.

•Avoidsuddenaccelerationwhiledrivingunit uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

LoadingaUnit

Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinstead ofindividualrampsforeachsideoftheunit.With theplatformup,afullwidthrampprovidesasurface towalkonbehindtheunit.Ifitisnotpossibletouse onefullwidthramp,useenoughindividualrampsto simulateafullwidthcontinuousramp.

Rampshouldbelongenoughsothattheangles betweentherampandthegroundandtheramp andthetrailerortruckdonotexceed20degrees.A steeperanglemaycausemowerdeckcomponentsto getcaughtastheunitmovesfromramptotrailer ortruck.Steeperanglesmayalsocausetheunitto tipbackward.Ifloadingonornearaslope,position thetrailerortrucksoitisonthedownsideofthe slopeandtherampextendsuptheslope.Thiswill minimizetherampangle.Thetrailerortruckshould beaslevelaspossible.

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

Removethekeyfromtheignitionswitch,engage parkingbrake,andpullthewire(s)offthespark plug(s)beforeyoudoanymaintenance.Also pushthewire(s)asidesoitdoesnotaccidentally contactthesparkplug(s).

WARNING

Theenginecanbecomeveryhot.Touchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst5hours

•Changetheengineoil.

Aftertherst100hours

•Checkthewheelhubtorquespecication.

•Checkthewheellugnuts.

Aftertherst250hours

•Changethehydrauliclteranduid.

Beforeeachuseordaily

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Cleantheengineandexhaustsystemarea.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthedeck.

Every50hours

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasetheliftlinkagepivots.

•Checksparkarrester(ifequipped).

Every80hours

•Removeengineshroudsandcleancoolingns.

Every100hours

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

Every160hours

•Checkthesparkplugs.

Every250hours

•Replacetheprimaryaircleanerelement—checksecondaryaircleanerelement;replaceif dirty.(Mayneedmoreoftenundersevereconditions.SeetheEnginemanualforadditional information.)

Maintenance

MaintenanceService

Interval

MaintenanceProcedure

Every500hours

•Replacethesecondaryaircleanerelement.(Mayneedmoreoftenundersevereconditions. SeetheEnginemanualforadditionalinformation.)

•Changethehydrauliclteranduid(Every250hours/yearlyifusingMobil115W50)

•Checkthewheelhubtorquespecication.

•Checkthewheellugnuts.

Yearly

•Greasethefrontcasterpivots.

•Greasethedeckbeltidlerpivot.

•Lubricatethecasterwheelhubs.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstickand wipeoiloff.Reinsertthedipstickandpushitall thewaydownintothetube.DoNotscrewinto place.Removethedipstickandreadtheoillevel.

4.Iftheoillevelislow ,wipeofftheareaaroundthe oilllcap,removecapandaddoiltothe“FULL” markonthedipstick.Exmark4-CyclePremium EngineOilisrecommended;refertotheEngine Owner'smanualforanacceptablealternative.Do Notoverll.

Important:DoNotoperatetheenginewiththe oillevelbelowthe“LOW”(or“ADD”)markon thedipstick,oroverthe“FULL”mark.

CheckBatteryCharge

ServiceInterval:Asrequired

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof timewithoutrechargingthemwillresultinreduced performanceandservicelife.Topreserveoptimum batteryperformanceandlife,rechargebatteriesin storagewhentheopencircuitvoltagedropsto12.4 volts.

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Checkthevoltageofthebatterywithadigital voltmeterorwiththemessagedisplay.Iftheignition keyisturnedtothe“on”positionforafewseconds, thebatteryvoltagewillbedisplayedintheareawhere thehoursarenormallydisplayed.Locatethevoltage readingofthebatteryinthetableandchargethe batteryfortherecommendedtimeintervaltobring thechargeuptoafullchargeof12.6voltsorgreater.

Important:Makesurethenegativebatterycable isdisconnectedandthebatterychargerusedfor chargingthebatteryshouldhaveanoutputof 16voltsand7ampsorlesstoavoiddamaging thebattery(seechartforrecommendedcharger settings).ThisisespeciallyimportantonKohler EFI(ElectronicFuelInjection)units.Failureto dosomaydamagetheECU(ElectronicControl Unit).

Voltage Reading

Percent Charge

Maximum Charger Settings

Charging Interval

12.6or greater

100%

16volts/7 amps

No Charging Required

12.4–12.675–100%

16volts/7 amps

30Minutes

12.2–12.450–75%

16volts/7 amps

1Hour

Maintenance

Voltage Reading

Percent Charge

Maximum Charger Settings

Charging Interval

12.0–12.225–50%

14.4volts/4 amps

2Hours

11.7–12.00–25%

14.4volts/4 amps

3Hours

11.7orless

14.4volts/2 amps

6Hoursor More

Important:ForKohlerEFIunits:Unplugthe harnessfromtheECUbeforeperformingany weldingontheequipment.

RecommendedJump StartingProcedure

ServiceInterval:Asrequired

1.Checktheweakbatteryforterminalcorrosion (white,green,orblue“snow”),itmustbecleaned offpriortojumpstarting.Cleanandtighten connectionsasnecessary.

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe engineorEFImayoccur.

DANGER

Jumpstartingaweakbatterythatiscracked, frozen,haslowelectrolytelevel,oran open/shortedbatterycell,cancausean explosionresultinginseriouspersonalinjury.

DoNotjumpstartaweakbatteryifthese conditionsexist.

2.Makesuretheboosterisagoodandfullycharged leadacidbatteryat12.6voltsorgreater.Use properlysizedjumpercables(4to6A WG)with shortlengthstoreducevoltagedropbetween systems.Makesurethecablesarecolorcodedor labeledforthecorrectpolarity.

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricaland/orEFIsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

Note:Thefollowinginstructionsareadapted fromtheSAEJ1494Rev .Dec.2001–Battery BoosterCables–SurfaceVehicleRecommended Practice(SAE–SocietyofAutomotive Engineers).

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

Note:Besuretheventcapsaretightandlevel. Placeadampcloth,ifavailable,overanyvent capsonbothbatteries.Besurethevehiclesdo nottouchandthatbothelectricalsystemsare offandatthesameratedsystemvoltage.These instructionsarefornegativegroundsystemsonly.

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure13.

Maintenance

Figure13

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

5.Connecttheblacknegative(–)cabletotheother terminal(negative)oftheboosterbattery.

6.MAKETHEFINALCONNECTIONON THEENGINEBLOCKOFTHESTALLED VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK.

7.Startthevehicleandremovethecablesinthe reverseorderofconnection(theengineblock (black)connectionisthersttodisconnect).

ReleasetheCushionforRear Access

ServiceInterval:Asrequired

Thecushioncanbereleasedforrearaccesstothe machineformaintenanceoradjustment.

1.Lowertheplatform.

2.Removethehairpinsoneachsideofthecushion.

3.Pushtheplasticslidestotheinside.

4.Removethecushionandlowerittotheplatform.

5.Performanymaintenanceoradjustmentonthe machine.

6.Raisethecushionandslideitontothepinson bothsidesofthemachine(Figure14).

7.Pushtheplasticslidesintothecushionbracket andsecurethemwithahairpin.

Figure14

1.Plasticslide

2.Cushionbracketwithkeyhole

3.Hairpin

CheckMowerBlades

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Liftdeckandsecureinraisedpositionasstatedin theCleanGrassBuild-UpUnderDecksection.

3.Inspectbladesandsharpenorreplaceasrequired.

4.Reinstalltheblades(iftheywereremoved)inthe followingorder:

Maintenance

A.Installbushingthroughbladewithbushing

angeonbottom(grass)sideofblade.

Figure15

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

Figure16

1.Usewrenchherefor bladeinstallation.This nuthasbeentorquedto 130-160ft-lb(176–217 N-m)

2.Torqueto50-60ft-lb (68-81N-m)Apply lubricanttothreads asneededtoprevent seizing.Copper-based anti-seizepreferable. Greaseacceptable substitute.

C.Applylubricanttothreadsofbladeboltas

neededtopreventseizing.Copper-based anti-seizepreferable.Greaseacceptable substitute.Installbladeboltngertight.Place wrenchonthetopspindlenutthentorquethe bladeboltsto50-60ft-lb(68-81N-m).

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

CAUTION

Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitches beforeoperatingthemachine.

UnderstandingtheSafetyInterlockSystem

Thesafetyinterlocksystemisdesignedtoprevent themowerbladesfromrotating;unlessatleastone oftheOPCleversisengagedandthebladecontrol switch(PTO)ispulledon.

Thesafetyinterlocksystemisdesignedtostopthe mowerbladesifyoureleasebothOPClevers.

Note:Parkbrakemustbedisengagedbeforethe speedcontrolleverismovedoutofneutralorengine willkill.

CheckingtheSafetyInterlockSystem

1.Starttheengine.

2.Engagetheparkingbrake.

3.MoveeitherOPClevertotheoperatingposition andpushthespeedcontrolleverforward.

Theengineshouldinitiateshutdownafter momentarypause.

4.Starttheengineandreleasetheparkingbrake.

5.MoveeitherOPClevertotheoperatingposition.

6.ContinueholdingtheeitherOPCleverinthe operatingpositionandpullupontheblade

Maintenance

controlswitch(PTO)andrelease.Theclutch shouldengageandthemowerbladesbegin rotating.

7.ReleasebothOPClevers.Thebladesshould

stoprotatingandtheengineshouldcontinue running.

8.Pushthebladecontrolswitchdownandmove eitherOPCleverintotheoperatingposition.

9.ContinueholdingeitherOPCleverinthe operatingpositionandpullupontheblade controlswitch(PTO)andrelease.Theclutch shouldengageandthemowerbladesbegin rotating.

10.Pushthebladecontrolswitch(PTO)downtothe offposition.Thebladesshouldstoprotating.

11.Withtheenginerunning,pullupthebladecontrol switch(PTO)andreleaseeitherOPCleverfrom theoperatingposition.Thebladesshouldnot

rotate.

Note:Ifbothoftheleversarereleasedwiththe speedcontrolnotinneutral,theenginewillkill (withorwithoutPTOengaged).

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every250hours—Replace

theprimaryaircleaner element—check secondaryaircleaner element;replaceifdirty. (Mayneedmoreoften undersevereconditions. SeetheEnginemanualfor additionalinformation.)

Every500hours— Replacethesecondary aircleanerelement.(May needmoreoftenunder severeconditions.See

theEnginemanualfor additionalinformation.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.SeetheEngineOwner'sManualformaintenance instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May needmoreoftenunder severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainhoseassemblyislocatedontheleft sideoftheengine.

Placepanundermachinetocatchoil.Removeoil drainplug.Allowoiltodrainandreplaceoildrain plug.Torqueplugto20-24ft-lb(27-33N-m).

4.ReplacetheoillterpertheEngineOwner's Manual.Cleanaroundtheoillterandcarefully removethelterbyunscrewingit.Makesureno oildrainsontothebeltdriveorclutchthrough theholesintheenginedeck.Beforethenew lterisinstalled,applyathincoatingofExmark 4–CyclePremiumEngineOilonthesurfaceof therubberseal.Turnlterclockwiseuntilrubber sealcontactsthelteradapter,thentightenlter anadditional2/3to3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

6.UseoilrecommendedintheCheckEngineOil Levelsection.DoNotoverll.Starttheengine andcheckforleaks.Stopengineandrecheckoil level.

7.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

CheckHydraulicOilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop, andremovekey.Engageparkingbrake.

2.Cleanareaaroundhydraulicreservoircapand removecap.Oillevelshouldbetothetopofthe bafeinsidethetank.Ifnot,addoil.UseExmark

Maintenance

PremiumHydroOil.Replacehydraulicreservoir capandtightenuntilsnug.DoNotovertighten.

Note:Thebafeislabeled“HOT”and “COLD”.Theoillevelvarieswiththe temperatureoftheoil.The“HOT”levelshows thelevelofoilwhenitisat225°F(107°C).The “COLD”levelshowstheleveloftheoilwhen itisat75°F(24°C).Filltotheappropriatelevel dependinguponthetemperatureoftheoil.For example:Iftheoilisabout150°F(65°C),llto halfwaybetweenthe“HOT”and“COLD”levels. Iftheoilisatroomtemperature(about75°F (24°C)),llonlytothe“COLD”level.

CheckTirePressures

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto13psi(90kPa).

4.Semi-pneumaticcastertiresdonotneedtobe inated.

CheckConditionOfBelts

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lookonthetopsideofthecuttingdecktocheck themowerbladedrivebeltcondition.

3.Lookundertheenginedecktocheckthepump drivebeltcondition.

4.Checkallidlerarmstobesuretheypivotfreely.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.LubricatettingswithNGLIgrade#2 multi-purposegungrease.

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

LubricationChart(cont'd.)

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.LiftLinkage Pivots

1–2

Every50

hours

2.DeckBelt IdlerPivot

Yearly

3.FrontCaster WheelHubs

*Yearly

4.FrontCaster Pivots

*Yearly

*Seestep3forspeciallubricationinstructionson thefrontcasterpivots.

3.Lubricatefrontcasterpivotsonceayear.Remove hexplugandcap.Threadgreasezerkinholeand pumpwithgreaseuntilitoozesoutaroundtop bearing.Removegreasezerkandthreadplugback in.Placecapbackon.

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Maintenance

Figure17

1.Sealguard2.Spacernutwithwrench ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxle assemblyinthecasterwheel.Notethatthread lockingadhesivehasbeenappliedtolockthe spacernutstotheaxle.Removetheaxle(withthe otherspacernutstillassembledtoit)fromthe wheelassembly.

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1 multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Seals(ExmarkP/N103-0063)mustbe replaced.

8.Iftheaxleassemblyhashadbothspacernuts removed(orbrokenloose),applyathreadlocking adhesivetoonespacernutandthreadontothe axlewiththewrenchatsfacingoutward.Do Notthreadspacernutallofthewayontotheend oftheaxle.Leaveapproximately1/8inch(3mm) fromtheoutersurfaceofthespacernuttothe endoftheaxleinsidethenut.

9.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.

10.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof NGLIgrade#1multi-purposegrease.

11.Insertthesecondbearingandnewsealintothe wheel.

12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.

13.Torquethenutto75-80in-lb(8-9N-m),loosen, thenre-torqueto20-25in-lb(2-3N-m).Make sureaxledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully.

Important:Topreventsealandbearingdamage, checkthebearingadjustmentoften.Spinthe castertire.Thetireshouldnotspinfreely (morethan1or2revolutions)orhaveanyside play.Ifthewheelspinsfreely,adjusttorqueon spacernutuntilthereisaslightamountofdrag. Reapplythreadlockingadhesive.

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner's Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledinthefuellinebetweenthe fueltankandtheengine.Replacewhennecessary.

ForKohlerEFIUnits:

WARNING

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponentscan resultinsystemfailure,gasolineleakageand possibleexplosion.

Useonlyapprovedfuellinesandfuelltersfor highpressuresystems.

ReplacementFilters

KawasakiKawasaki

P/N49019-0014

KohlerEFIKohler

P/N2405003

ChangeHydraulicSystem FilterandFluid

ServiceInterval:Aftertherst250hours

Maintenance

Every500hours/Yearly (whichevercomes rst)thereafter (Every250hours/Yearlyif usingMobil115W50)

Note:UseonlyExmarkPartNo.109–4180for

Summeruseabove32°F(0°C)orP/N1-523541for Winterusebelow32°F(0°C)(RefertoTransmission sectioninSpecicationsforlterspecications).

1.Stopengine,waitforallmovingpartstostop,and removekeyorsparkplugwire(s).Engageparking brake.

2.Carefullycleanareaaroundlter.Itisimportant thatnodirtorcontaminationenterhydraulic system.

3.Unscrewltertoremoveandallowoiltodrain fromreservoir.

Important:Beforereinstallingnewlter,ll itwithExmarkPremiumHydrooilandapply athincoatofoilonthesurfaceoftherubber seal.

Turnlterclockwiseuntilrubbersealcontactsthe lteradapter,thentightenthelteranadditional 2/3to3/4turn.

4.FillreservoirasstatedinCheckHydraulicOil

Level.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ChangeInterval

ExmarkPremiumHydro Oil(Preferred)

500Hours

Mobil115W50

250Hours

5.Loosenlter1/2turnandallowasmallamount ofoiltoleakfromtheoillter(thisallowsairto bepurgedfromtheoillterandsupplyhosefrom thehydraulicreservoir).Turnlterclockwise untilrubbersealcontactsthelteradapter.Then tightenthelteranadditional2/3to3/4turn.

6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

CAUTION

Raisingthemowerforserviceormaintenance relyingsolelyonmechanicalorhydraulic jackscouldbedangerous.Themechanicalor hydraulicjacksmaynotbeenoughsupport ormaymalfunctionallowingtheunittofall, whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

7.Ifeitherdrivewheeldoesnotrotate,oneorboth ofthechargepumps(locatedonthetopofthe mainpumpasshowninFigure18)mayhavelost their“prime”.RefertoHydraulicSystemAir Purgesection.

Note:DoNotchangehydraulicsystemoil(except forwhatcanbedrainedwhenchanginglter),unless itisfelttheoilhasbeencontaminatedorbeen extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

HydraulicSystemAirPurge

ServiceInterval:Asrequired

Airmustbepurgedfromthehydraulicsystem whenanyhydrauliccomponents,includingoil lter,areremovedoranyofthehydrauliclinesare disconnected.

Thecriticalareaforpurgingairfromthehydraulic systemisbetweentheoilreservoirandeach chargepumplocatedonthetopofeachvariable displacementpump(Figure18).Airinotherpartsof thehydraulicsystemwillbepurgedthroughnormal operationoncethechargepumpis“primed”.

Maintenance

Figure18

1.Chargepumpcap2.Loosen11/2turnsonly

1.Stopengineandwaitforallmovingpartstostop. Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsoffthe ground.

2.CheckoillevelasstatedinCheckHydraulicOil Levelsection.

3.Startengineandmovethrottlecontrolaheadto fullthrottleposition.Movethespeedcontrol levertothemiddlepositionandplacethedrive leversinthe“drive”position.

Ifeitherdrivewheeldoesnotrotate,itispossible toassistthepurgingofthechargepumpby carefullyrotatingthetireintheforwardposition.

Note:Itisnecessarytolightlytouchthecharge pumpcapwithyourhandtocheckthepump temperature.Ifthecapistoohottotouch,turn offengine.Thepumpsmaybedamagedifthe pumpbecomestoohot.

Ifeitherdrivewheelstilldoesnotrotatecontinue withstep4.

4.Thoroughlycleantheareaaroundeachofthe chargepumphousings.

5.To“prime”chargepump,loosentwohexsocket headcapscrews(showninFigure18)11/2turns only.Makesureengineisnotrunning.Lift thechargepumphousingupwardandwaitfor asteadyowofoiltoowoutfromunderthe housing.Retightenthecapscrews.Dothisfor bothpumps.

Note:Hydraulicreservoircanbepressurizedup to5psitospeedthisprocess.

6.Ifeitherdrivewheelstilldoesnotrotate,stop andrepeatsteps4and5abovefortherespective

pump.Ifwheelsrotateslowly ,thesystemmay primeafteradditionalrunning.Checkoillevel asstatedinChecktheHydraulicOilLevel section.

7.Allowunittorunseveralminutesafterthecharge pumpsare“primed”withdrivesysteminthefull speedposition.CheckoillevelasstatedinCheck theHydraulicOilLevelsection.

8.Checkhydrodrivelinkageadjustmentasstatedin HydroDriveLinkageAdjustmentsectionin Adjustments.

WheelHubNutTorque Specication

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Torquethenutonthewheelmotortaperedshaftto 175-225ft-lb(237-305N-m).

Note:DoNotuseanti-seizecompoundonthe wheelhub.

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresult inpersonalinjuryorpropertydamage.

DoNotrefuelorrunengineunlesssparkarrester isinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacearrester.

4.Ifpluggingofthescreenisobserved,remove arresterandshakelooseparticlesoutofthe arresterandcleanscreenwithawirebrush(soak insolventifnecessary).Reinstallarresteron exhaustoutlet.

Maintenance

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242” or“Fel-Pro,Pro-LockNutType”areusedonthe followingfasteners:

•Pumpsheavesetscrews.

•Sheaveretainingboltinendofenginecrankshaft.

•Casterwheelspacernuts.

•Platformspringpin.

MobilHTSGrease(Or Food-GradeAnti-seize)

MobilHTSgrease(orfood-gradeanti-seize)isused inthefollowinglocations:

Betweensplinesofthecutterhousingspindleand sheave.

Copper-BasedAnti-seize

Copper-basedanti-seizeisusedinthefollowing locations:

•OnthreadsofBladeBolts.SeeCheckMower Bladessection.

•Betweenenginecrankshaft,pumpdrivesheave, andclutch.

•Betweenpumpshaftsandsheaves.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact. Dielectricgreaseshouldnotbeappliedtosealed connectors.

Adjustments

Note:DisengagePTO,shutoffengine,waitfor allmovingpartstostop,engageparkingbrake,and removekeybeforeservicing,cleaning,ormakingany adjustmentstotheunit.

CAUTION

Raisingthemowerforserviceormaintenance relyingsolelyonmechanicalorhydraulic jackscouldbedangerous.Themechanicalor hydraulicjacksmaynotbeenoughsupportor maymalfunctionallowingtheunittofall,which couldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstandsor equivalentsupport.

DeckLeveling

Note:Sidetosidedecklevelingshouldbedoneby

anAuthorizedServiceDealer.Smalladjustmentscan beaccomplishedbyincreasingthetirepressureinthe tireonthelowside.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checktheairpressureinthedrivetires.Ifneeded, adjusttotherecommendedination;referto CheckingtheTirePressureinDriveSystem Maintenancesection.

4.Settheheightofcutlevertothe3inch(7.6cm) position.

5.Raisethedischargedeector.

6.Carefullyrotatethebladesfronttorear.Measure fromthetipofthefrontbladetothelevelsurface (Figure19).Thebladesshouldmeasure3inches (7.6cm).

Maintenance

Figure19

1.Bladesfronttorear

2.Measurehere

7.Measurebetweentheoutsidecuttingedgesand theatsurface(Figure20).Ifbothmeasurements arenotwithin3/16inch(5mm),anadjustmentis required;contactanAuthorizedServiceDealer.

Figure20

1.Bladessidetoside2.Measurehere

8.Lowerthedischargedeector.

AdjustingtheCuttingDeck Rake

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checktheairpressureinthedrivetires.Ifneeded, adjusttotherecommendedination;referto CheckingtheTirePressureinDriveSystem Maintenancesection.

4.Checkandadjustthesidetosidebladelevelif youhavenotcheckedthesetting;refertoDeck Leveling.

5.Carefullyrotatethebladesfronttorear (Figure21).Measurefromthetipofthefront bladetothelevelsurfaceandthetipoftherear bladetothelevelsurfaceonallblades.Theblades shouldbe1/4inch(6.4mm)lowerinthefront thanintherear.

Figure21

1.Bladesfronttorear

2.Measurehere

6.Loosentherearlocknutsonbothadjustment rods(Figure22).

Figure22

1.Adjustmentrod3.Frontlocknut

2.Rearlocknut

Note:Makesuretheenginedeckbrackets arerestingrmlyontherearliftpoints(see Figure23).Ifitisliftingoff,tightenthefront locknutoftheadjustingrodontheoppositeside.

Maintenance

Figure23

1.Rearliftpoints

2.Enginedeckbrackets

7.Toraisethefrontofthemowingdeck,tightenthe frontlockingnutsbythesameamountonboth frontadjustingrods.Tightenbothrearlocking nuts.Checkthesidetosidelevelofthemower again;refertoDeckLeveling.

Note:Rakeadjustmentsmayaffecttheneutral position.SeetheNeutralAdjustmentsectionin Maintenance.

AdjustingtheRearofthe Deck

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checktheairpressureinthedrivetires.Ifneeded, adjusttotherecommendedination;referto CheckingtheTirePressureinDriveSystem Maintenancesection.

4.Settheheightofcuttothe3inch(7.6cm) position.

5.Carefullyrotatethebladesfronttorear.Measure fromthetipofthefrontbladetothelevelsurface. Thebladesshouldmeasure3inches(7.6cm).

6.Ifitdoesnotmeasurecorrectly,locatethe height-of-cutrodontherightsideofthemachine (seeFigure24).

Figure24

1.Adjustmentscrew

7.Turntheadjustmentscrewuntilthebladetips match3inches(7.6cm).

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

MowerDeckDriveBelt Tension

Self-tensioning-Noadjustmentnecessary.

ChecktheParkBrake

1.Parkthemachineonalevelsurface.

2.Shutoffengineandwaitforallmovingpartsto stop.

3.Whentheparkbrakeisreleased,thebrakebars shouldliftoffthetiresandthehandlevershould travelforwardtotheendoftheslotinthecontrol panel.Whenengagingthebrake,thehandlever shouldtravel3/4inch(19mm)atthecontrol panelslotwhenthebrakebarsrstcontactthe tire.Measurethegapfromthefrontofthelever totheendoftheslotinthecontrolpanelwhen thebrakebarcontactsthetire.

ParkBrakeAdjustment

Iftheparkingbrakedoesnotholdsecurely,an adjustmentisrequired.

1.Parkthemachineonalevelsurface.

2.Shutoffengineandwaitforallmovingpartsto stop.

3.Checktheairpressureinthedrivetires.Ifneeded, adjusttotherecommendedination;referto

Maintenance

CheckingtheTirePressureinDriveSystem Maintenance.

4.Disengagetheparkbrake.

5.Pushdownonthebrakebaruntilittouches thetires.Therewillbea3/4inch(19mm)gap betweentheparkbrakehandleandtheslotinthe controlpanel(seeFigure25).

Figure25

1.Brakebar

4.3/4inch(19mm)

2.Pushdown5.Parkbrakehandle

3.Slot

6.Therearetwomethodstoadjusttheparkbrake; oneorbothmethodsmaybeused.

A.Adjustingthelowerbrakelever:

a.Removethehairpin,washer,andclevispin

fromthelowerbrakeleverandyokeas showninFigure26.

Figure26

1.Jamnut4.Lowerbrakelever

2.Yoke5.Washer

3.Clevispin

6.Hairpin

b.Loosenthejamnut.

c.Rotatetheyoke.T otightenthebrake,

rotatetheyokeup.T oloosenthebrake, rotatetheyokedown.

d.Securetheyoketolowerbrakeleverwith

thehairpin,washer,andclevispin.

e.Tightenthejamnut.

f.Checkthebrakeoperationagain.

B.Adjustingtheupperbrakelinkage:

a.Loosenthetopjamnut.

b.Totightenthebrake,turnthebottom

jamnutclockwise(asviewedfromthe top)thenturnthetopjamnut.Move thelinkageupwardtoachievethedesired setting.

c.T oloosenthebrake,turnthetopjam

nutcounterclockwise(asviewedfrom thetop)thenturnthebottomnut counterclockwise.Movethelinkage downwardtoachievethedesiredsetting.

Figure27

1.Movedowntoloosen brake

4.Bottomjamnut

2.Moveuptotightenbrake5.Linkage

3.Topjamnut

d.Tightenthejamnuts.

e.Checkthebrakeoperationagain.

7.Afterthebrakeisadjusted,theleverswitchneeds tobechecked.

8.Checkthegapbetweenthebrakeleverandthe switchasshowninFigure26.Thegapneedsto bean1/8inch(3mm)withthebrakeengaged.

Maintenance

Figure28

1.Switch

3.Brakelever

2.1/8inch(3mm)gap neededbetweenswitch andbrakelever

9.Ifneeded,loosenthescrewsholdingtheswitch andadjusttheswitch.

ElectricClutchAdjustment

Noadjustmentnecessary.Howeverwhentheclutch brakehasworntothepointwheretheclutchno longerengagesconsistently ,theshimcanberemoved toextendtheclutchlife.

Figure29

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheShim:

1.Stopengine,waitforallmovingpartstostop, andremovekey.Engageparkingbrake.Allow themachinetocoolcompletelybeforestarting theseinstructions.

2.Usingapneumaticline,blowoutanydebris fromunderthebrakepoleandaroundthebrake spacers.

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

5.Measurethegapbetweentherotorandarmature. Ifthegapisgreaterthan.04inch(1mm),proceed withthefollowingsteps:

A.Loosenbothbrakemountingboltsone-half

toonefullturn(seeFigure30).

Note:DoNotremovethebrakepolefrom theeldshell/armature.Thebrakepolehas worntomatchthearmatureandneedsto continuetomatchaftertheshimisremoved toensureproperbraketorque.

Figure30

1.Brakemountingbolt

2.Shim

B.Usingneedlenosepliers,orbyhand,take

holdofthetabandremovetheshim(DoNot discardtheshimuntilproperclutchfunction hasbeenconrmed).

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe brakespacers.

D.Re-torqueeachbolt(M6x1)to10ft-lb(13

N-m)+/-0.5ft-lb(0.7N-m).

E.Usinga0.010inchthickfeelergauge,verify

thatagapispresentbetweentherotorand armaturefaceonbothsidesofthebrakepole asshown.(Duetothewaytherotorand armaturefaceswear(peaksandvalleys)itis sometimesdifculttomeasurethetruegap.)

Maintenance

G011733

Figure31

1.Feelergauge

Figure32

1.Feelergauge

•Ifthegapislessthan0.010inch,then reinstalltheshimandreferencethe Troubleshootingsection.

•Ifthegapissufcient,proceedtothe safetycheckinstepF.

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine. b.MakesurethebladesDoNotengagewith

thePTOswitch“off”andtheclutch disengaged.

Iftheclutchdoesnotdisengage, reinstalltheshimandreferencethe Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly .Iftheclutch doesnotengageproperly,referencethe Troubleshootingsection.

NeutralAdjustment

IfthemachinetravelsortheLCDindicatorlight doesnotilluminatewhenthespeedcontrolleverisin neutral,thenanadjustmentisrequired.

1.Stopengineandwaitforallmovingpartsto stop.Engageparkingbrake.Raisetherearofthe machineupontojackstandshighenoughtoraise thedrivewheelsoffoftheground.

2.Releasetherearcushionfromtherearofthe machine.

A.Checkthespeedcontrollinkageand

neutralsafetyswitch:

a.Withtheengineoff,turntheignition

switchtothe“ON”position.

b.LocatetheLCDindicatorinthemessage

display.

Figure33

1.NeutralLCDindicator

c.Withthespeedcontrolleverintheneutral

position,theneutralLCDindicatorshould appear.

d.Iftheindicatorilluminates,pushthelever

ahead;theindicatorshoulddisappear within3/4inch(19mm)amountoftravel. Ifitexceedsthisdistance,anadjustment totheneutralswitchisrequired.

e.Iftheindicatordoesnotilluminate,with

thespeedcontrolleverinthefullback position,anadjustmenttotheneutral switchisrequired.

f.Pullthespeedcontrolleverbackto

neutral.Checkthattheneutralsafety switchactuatingtabhasdepressedthe plungeroftheswitchsothatthereisabout 11/32inch(8.6mm)betweenthetaband theswitch(seeFigure34).Ifnecessary, movetheswitchforeandaft.

Maintenance

Figure34

1.11/32inch(8.6mm)

B.DriveWheelsAdjustment:

WARNING

Enginemustberunninganddrivewheels maybeturningwhenadjustmentis performed.Contactwithmovingpartsor hotsurfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

a.Starttheengineandreleasetheparking

brake.

b.Withthedriveleverrampssetand

tightened(seeAdjusttheNeutralRamp section),placethedriveleversinthe neutrallockposition.

c.MoveeitherOPClevertotheoperating

position.

Note:AtleastoneoftheOPClevers mustbehelddownandtheparkbrake mustbedisengagedwheneverthespeed controlleverismovedoutofneutralor theenginewillkill.

d.Pushthespeedcontrollevertothefull

forwardposition.

e.AdjustthelengthoftheLHandRH

steeringrodsuntilthewheelsarenot turning.

Figure35

1.LHdrivelever

2.Steeringrod

f.Movethedriveleverstothefullforward

andreverseandthenbacktoneutralto makesurewheelsarenotturning.Check withtheneutrallocklatchesengaged.

g.Tightentherodhardware.

Important:Rodsmustbefreetopivot onrodendballsafteradjustment.

C.SpeedControlLeverAdjustment:

a.Stopengineandwaitforallmovingparts

tostop.

b.Placethedriveleversintheneutrallock

position.

c.Loosentheupperandlowernutsonthe

speedcontrolrod(seeFigure36).

Maintenance

Figure36

1.Speedcontrollever4.Stud

2.Nut5.Trackingknob

3.Speedcontrolrod

6.Trackingrod

d.Pullthespeedcontrolleverintothefull

back(neutral)position.

e.Allowthespeedcontrolrodtositonthe

stud.

f.Adjustandtightenthenuts.

Note:Makesuretheatoftherodis perpendiculartothestud.

g.Adjustthetrackingrodbyturningtracking

knobuntiltherodissittingonthestud (referenceFigure36).

h.Starttheengineandreleasetheparking

brake.

i.MoveeitherOPClevertotheoperating

position.

j.Movethespeedcontrollevertothefull

forwardandthenbacktoneutraltomake surewheelsarenotturning.Checkwith theneutrallocklatchesengagedand disengaged.

k.Checkthetrackingandadjustasneeded

(seeTrackingAdjustmentsection).

D.NeutralRampAdjustment:

Note:Thisadjustmentshouldonlybeneeded ifcomponentshavebeenreplacedorifneutral lockandneutraldetentarenotaligned.Adjust

thespeedcontrolleveranddrivewheels beforeperformingthisadjustment.

a.Stopengineandwaitforallmovingparts

tostop.

b.Placethespeedcontrolleverintothefull

back(neutral)position.

c.Removethesteeringrodfromtheramp

arm.

d.Placethedriveleversintheneutrallock

position(seeFigure8).

e.Rotatetheramparmintoapositionwhere

therampcontactstheroller.Notethis position.

f.Loosentherampretainingboltandslide

therampuntilbothforwardandreverse rampsurfacescontacttheroller.Tighten theramphardware.

Figure37

1.LHdrivelever3.Roller

2.Driveleverrampsurface4.Steeringrod

g.Makethisadjustmentonbothsides.

h.Checktheneutrallocationbymovingthe

driveleversfromforwardtoneutral.Stop whenachangeinforceintothedetentis felt.Thethumblocklevershouldeasily engagewithlittlesteeringmovement;there shouldnotbeagapbetweenthelocklatch andthedrivelever.

Maintenance

Important:Afterallneutraladjustmentshave

beenmade,makesurethedrivewheelshave equalspeedinthefullforwardandreverse positions.

TrackingAdjustment

1.Stopengineandwaitforallmovingpartstostop.

2.Checkthedrivetirepressuresandtire circumferencesasstatedinChecktheTire PressuressectioninMaintenance.

3.Runtheunitandobservethetrackingonalevel, smooth,hardsurfacesuchasconcreteorasphalt.

4.Iftheunittrackstoonesideortheother,turnthe quicktrackknob.Turntheknobrightto“steer” right,turntheknobleftto“steer”left.

DriveLeverResistance Adjustment

Relocatingthehydropumpspringstoadifferent settingwillchangetheresistanceonthedrivelevers.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisetheplatform.

3.Unhookbothspringsfromthelowerbellcrank bolts(seeFigure38).

Figure38

1.Lowerbellcrankbolt

2.Spring

4.Lowertheplatform.

5.Releasetherearcushionfromtherearofthe machineandlowertotheplatform.

6.Relocatetheupperspringhooktothepreferred resistancesettingontheupperadjustablelink; refertoFigure39forsettings.

Figure39

1.RHupperadjustablelink4.Recommendedsetting

2.Higherresistance5.Lowerresistance

3.Upperspringhook

7.Reinstalltherearcushionandraisetheplatform.

8.Reinstallthespringlowerhookontothelower mountingbolts(referenceFigure38).

9.Lowertheplatform.

10.Starttheengine,releasetheparkingbrake,and drivethemachine.Iftheunitisslowtorespond ordoesnotperformonhillsasdesired,relocate theupperspringhooktoadifferentsetting (referenceFigure39).

Forheavydutydriveconditions,suchasoperation onsteepslopes,ahigherspringforcemaybe requiredtopreventthedrivesystemfromstalling. Locatetheupperspringhookontothebolt.

Note:Inheavydutyposition,thedrivelever resistancewillalsobeincreased.

Maintenance

CasterPivotBearings Pre-LoadAdjustment

Removedustcapfromcasterandtightennylocnut untilwashersareatandbackoff1/4ofaturn toproperlysetthepre-loadonthebearings.If disassembled,makesurethespringdiscwashersare reinstalledasshowninFigure40.

Figure40

1.Springdiscwashers

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancauseengine, exhaustarea,andhydraulicsystemtooverheat whichcancreatearehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea.

4.Cleanoilcoolers(ifequipped)ofalldebris,dirt, andoil.

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every80hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removecoolingshroudsfromengineandclean coolingns.Alsocleandust,dirt,andoilfrom externalsurfacesofenginewhichcancause impropercooling.

3.Makesurecoolingshroudsareproperlyreinstalled. Operatingtheenginewithoutcoolingshroudswill causeenginedamageduetooverheating.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

Maintenance

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanoffanyoil,debris,orgrassbuild-uponthe machineandcuttingdeck,especiallyunderdeck beltshields,aroundthefueltank,aroundengine andexhaustarea.

CleanGrassBuild-UpUnder Deck

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisedecktothetransport(maximumcutting height)position.Liftthefrontofunitandsupport unitusingjackstandsorequivalentsupport.

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which ispoisonousandcancausesevereburns. Swallowingelectrolytecanbefatalorifittouches skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber glovestoprotectskinandclothingwhen handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately .

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

Ifabatteryisbeingreplacedoriftheunitcontaining thebatteryisnolongeroperatingandisbeing scrapped,takethebatterytoalocalcertiedrecycling center.Ifnolocalrecyclingisavailablereturnthe batterytoanycertiedbatteryreseller.

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.PTOisengaged.

1.DisengagethePTO .

2.Speedcontrolleverisnotinneutrallock position.

2.Ensurethespeedcontrolleverisinthe neutrallockposition.

3.OPCleversarereleased.

3.DepressOPClevers.

4.Batterydoesnothaveafullcharge.

Chargethebattery.SeeCheckBattery

ChargeandRecommendedJump StartingProceduresectionsin

Maintenance.

5.Electricalconnectionsarecorroded,loose orfaulty.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

6.Fuseisblown.6.Replacetheblownfuse.

7.NeutralLCDindicatordoesnot illuminate.

7.Checkneutralswitch.

Starterdoesnotcrank.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

2.Openthefuelshutoffvalve.

3.Thethrottleandchokearenotinthe correctposition.

3.Besurethethrottlecontrolismidway betweenthe“SLOW”and“FAST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.

4.Dirtinfuellter.4.Replacethefuellter.

5.Dirt,water,orstalefuelisinthefuel system.

5.ContactanAuthorizedServiceDealer.

6.Aircleanerisdirty.

6.Cleanorreplacetheaircleanerelement.

7.Electricalconnectionsarecorroded,loose orfaulty.

7.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Faultysparkplug.

9.Clean,adjustorreplacesparkplug.

10.Sparkplugwireisnotconnected.

10.Checkthesparkplugwireconnection.

Enginewillnotstart,startshard,orfailsto keeprunning

11.MILilluminatesandblinks11.ContactanAuthorizedServiceDealer.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow .

3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe engineareplugged.

4.Removetheobstructionsfromthe coolingnsandairpassages.

5.Ventholeinthefuelcapisplugged.

5.Cleanorreplacethefuelcap.

6.Dirtinfuellter.6.Replacethefuellter.

Enginelosespower

7.Dirt,water,orstalefuelisinthefuel system.

7.ContactanAuthorizedServiceDealer.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

Engineoverheats

3.Coolingnsandairpassagesforthe engineareplugged.

3.Removetheobstructionsfromthe coolingnsandairpassages.

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

Mowerpullsleftorright(withleversfully forward).

2.Trackingneedsadjustment.2.Adjustthetrackingbyturningknob ontherighthydrocontrollinkagein thedirectionthatthemowerneedsto beadjustedto.Turntheknobin1/8 turnincrementsuntilthemowertracks correctly.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor

broken.

2.Changethebelt.

Machinedoesnotdrive.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.

2.Installnewcuttingblade(s).

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand front-to-rear.

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

Unevencuttingheight.

7.Tipsofadjacentbladesareatanuneven

cuttingheight.Bladestipsshouldbeeven within3/16inchwhichisapproximately onebladethickness.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

1.Cuttingblade(s)is/arebentorunbalanced.

1.Installnewcuttingblade(s).

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley ,idlerpulley ,orblade pulley.

4.Tightentheappropriatepulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

Abnormalvibration

7.Beltisdamaged.7.Installnewbelt.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Drivebeltisoffpulley .1.Checkbeltfordamage;replaceif necessary.Installdrivebeltandcheck adjustingshaftsandbeltguidesforcorrect position.

2.Deckbeltisworn,looseorbroken.2.Installnewdeckbelt.

3.Deckbeltisoffpulley .3.Installdeckpulleyandchecktheidler pulley,idlerarmandspringforcorrect positionandfunction.

4.Brokenormissingidlerspring.

4.Replacethespring.

5.Damagedelectricclutch.5.ContactanAuthorizedServiceDealer.

Bladesdonotrotate.

6.OPCleversarereleased.

6.DepressOPClevers.

1.Fuseisblown.

1.Replacefuse.Checkcoilresistance, batterycharge,chargingsystem,and wiringconnectionsandreplaceif necessary.

2.Lowvoltagesupplyattheclutch.

2.Checkcoilresistance,batterycharge, chargingsystem,andwiringconnections andreplaceifnecessary.

3.Damagedcoil.

3.Replaceclutch.

4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor electricalsystem.Cleanconnector contacts.

5.Rotor/armatureairgapistoolarge.

5.Removeshimorreplaceclutch.

Clutchwillnotengage.

6.OPCleversarereleased.

6.DepressOPClevers.

Schematics

ElectricalDiagram–AllUnitsExceptKohlerEFI

Schematics

ElectricalDiagram–KohlerEFI

Schematics

ElectricalSchematic–AllUnitsExceptKohlerEFI

Schematics

ElectricalSchematic–KohlerEFI

Schematics

HydraulicDiagram

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.

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.

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.

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.

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.

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.

Warranty Exceptions

 Warranty Exceptions Warranty Period

• Bags, Belts and Tires 90 days

• Battery 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.

• 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 as set forth in the maintenance section of the operator’s   manual.

• 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.

There are no other express warranties except for engine and special emission system coverage.

All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts.

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 www.exmark.com. U.S. or Canada customers may also call 402-223-6375.

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

 Exmark Customer Service Department  The Exmark Warranty Company  2101 Ashland Avenue  Beatrice, NE 68310  402-223-6375 or  service@exmark.com

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.

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.

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.

• 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.

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.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Exmark Lazer Z X-Series, Lazer Z S-Series, and Vantage Turf Equipment

3 Year Limited Commercial Warranty

5 Year or 750 Hours Limited Consumer Warranty

G4500-733_C

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

G011841

Figure41

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopeindicatortodeterminethe degreeofslopeofhillsbeforeoperating.DoNotoperatethismachineonaslopegreaterthan20degrees.Fold alongtheappropriatelinetomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

EXMARK ACCESSORIES AND OPTIONS*

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T- FRON T RIDING ACCESSORIES AND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

*Some accessories and options not available for some models.

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

PartNo.4502-224Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

*4502-224*A

www.exmark.com

Exmark VANTAGE X Series Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual