Exmark VT691KA524CA, VT691KA484CA, VT740EKC604, VT651KA484, VT730EKC524 User Manual

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V ANTAGE

ForSerialNos. 312,000,000&Higher

PartNo.4501-211Rev.A

WARNING

CALIFORNIA

Proposition65Warning

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.

Figure1

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

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

Ifadditionalinformationisneeded,orshould yourequiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor. Exmarkpartsmanualsareavailableonlineat http://www.exmark.com

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

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Contents

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

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

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

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

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

Specications........................................................14

ModelNumbers.............................................14

Systems..........................................................14

Dimensions....................................................15

TorqueRequirements.....................................16

ProductOverview.................................................16

Operation..............................................................17

Controls.........................................................17

Pre-Start.........................................................19

OperatingInstructions...................................19

Transporting..................................................24

Maintenance..........................................................26

RecommendedMaintenanceSchedule(s)............26

PeriodicMaintenance........................................27

CheckEngineOilLevel..................................27

CheckMowerBlades......................................29

CheckSafetyInterlockSystem........................30

CheckforLooseHardware.............................31

ServiceAirCleaner.........................................31

ChangeEngineOil.........................................31

CheckHydraulicOilLevel..............................31

CheckTirePressures......................................32

CheckConditionOfBelts...............................32

LubricateGreaseFittings................................32

LubricateCasterWheelHubs.........................32

CheckSparkPlugs..........................................33

ChangeHydraulicSystemFilterand

Fluid..........................................................33

WheelHubNutTorqueSpecication..............35

CheckSparkArrester(ifequipped)..................35

ThreadLockingAdhesives..............................36

MobilHTSGrease(OrFood-Grade

Anti-seize)..................................................36

Copper-BasedAnti-seize................................36

DielectricGrease............................................36

Adjustments......................................................36

DeckLeveling................................................36

AdjustingtheCuttingDeckRake....................37

AdjustingtheRearoftheDeck........................38

PumpDriveBeltTension................................38

MowerDeckDriveBeltTension.....................38

ChecktheParkBrake......................................38

ParkBrakeAdjustment...................................38

ElectricClutchAdjustment.............................40

MotionControlNeutralAdjustment...............41

MotionControlTrackingAdjustment.............42

ChecktheNeutralSwitchAlignment

..................................................................42

AdjustRHMotionControlHandle

Position......................................................43

CasterPivotBearingsPre-Load

Adjustment................................................44

Cleaning............................................................45

CleanEngineandExhaustSystem

Area...........................................................45

RemoveEngineShroudsandClean

CoolingFins...............................................45

CleanDebrisFromMachine...........................45

CleanGrassBuild-UpUnderDeck.................45

WasteDisposal...............................................45

Troubleshooting....................................................47

Schematics............................................................50

Safety

SafetyAlertSymbol

ThislawnmowermeetsorexceedstheB71.4 specicationsoftheAmericanNationalStandards Instituteineffectatthetimeofproduction.

Exmarkdesignedandtestedthislawnmowertooffer reasonablysafeservice;however,failuretocomply withthefollowinginstructionsmayresultinpersonal injury.

ThisSafetyAlertSymbol( thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

SafetyAlertSymbol

Figure2)isusedbothin

Figure2

SafeOperatingPractices

Training

•ReadtheOperator’ sManualandothertraining material.Iftheoperator(s)ormechanic(s)can notreadEnglishitistheowner’sresponsibilityto explainthismaterialtothem.

•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.

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Yellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses, substantialfootwear,longtrousers,andhearing protection.DoNotoperatewhenbarefootor whenwearingopensandals.Longhair,loose clothingorjewelrymaygettangledinmoving parts.

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.

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.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperator'spresencecontrols, 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.

•Installandmaintaininworkingordera sparkarresterbeforeusingequipment onforest-covered,grass-covered,or brush-coveredunimprovedland.

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•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.

•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.

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithgrasscatchersor attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.

•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.

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.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipmentparts andaccessoriesmayalterthewarranty,traction, andsafetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.Makingunauthorizedchangestothe engine,fuelorventingsystem,mayviolateEPA andCARBregulations.

Replaceallpartsincluding,butnotlimitedto, tires,belts,blades,andfuelsystemcomponents withoriginalExmarkparts.

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.

1-303508

109-3148

1-403005

115-4186

1.Interval

2.PowerT ake-off(PTO)

98-5954

3.Parkingbrake

4.Neutral

5.Operatorpresenceswitch

6.Battery

106-5517

1.Warning—donottouchthehotsurface.

Safety

116-0404

116-2040

116-3267

116-3283

60InchModel

116-3290

116-4181

116-3076

Safety

116-7217

116-5040

1.Forwardposition–faster

1.Fast3.Neutral

2.Slow

2.Backwardposition– slower

116-1887

116-4647

4.Reverse

116-4648

AllUnitsExceptEFI

1.PTO-on4.Slow

2.PTO-off5.Choke-on

3.Fast

Safety

6.Choke-off

116-5026

EFIOnly

1.PTO-on

2.PTO-off4.Slow

3.Fast

Specications

ModelNumbers

SerialNos:312,000,000andHigher

VT651KA484;VT691KA484CA;VT691KA524;VT691KA524CA;VT730EKC524;VT740EKC604;

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/N49019-7005

–KohlerEFI:

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.

•PTOmustbedisengagedandmotioncontrol leversinneutraltostartengine.(Itisnot necessaryfortheoperatortobeontheplatform tostarttheengine.)

•Mowerbladeswillstopiftherightsidemotion controlleverismovedorreleasedintothePTO disengageposition.

•Enginewillstopifthemotioncontrolleversare movedfromtheneutralpositionwiththepark brakeengaged.

KohlerP/N2505042

•FuelShut-OffValve:1/4turnincrements

ElectricalSystem(ElectricStart)

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:

OperatorControls

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

Specications

Transmission

•TwoHydroGearvariabledisplacementhigh efciencypumpsindependentlycoupledtotwo highefciencyParker/Rosswheeldrivemotors.

•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 motorswith1inch(25.4mm)taperedshaft.

•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)to5inches(12.7cm) in1/4inch(6.4mm)increments

•MulchingKit:Optional

•Bagger:Optional

Tires&Wheels

DriveFrontCaster

Pneumatic (Air-Filled)

Quantity

Tread

Size20x10.50–811x4.00-5

PlyRating

Pressure

K500

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)

Dimensions

OverallWidth:

SemiPneumatic

Smooth

Deector Up

Deector Down

OverallLength:

PlatformUp60.5inches

Platform Down

OverallHeight:

48inchDeck52inchDeck60inchDeck

50.0inches (127.0cm)

48inch Deck

51.8inches (131.6cm)

59.6inches (151.4cm)

48inch Deck

(153.7cm)

74.0inches (188.0cm)

50.0inches (127.0cm)

52inch Deck

56.3inches (143.0cm)

64.8inches (164.6cm)

52inch Deck

60.5inches (153.7cm)

74.0inches (188.0cm)

60inch Deck

63.9inches (162.3cm)

72.8inches (184.9cm)

60inch Deck

62.4inches (158.5cm)

75.9inches (192.8cm)

50.0inches (127.0cm)

ProductOverview

TreadWidth:(OutsidetoOutsideof Tires,Widthwise)

48inchDeck52inchDeck60inchDeck

46.5inches (118.1cm)

50.5inches (128.3cm)

CurbWeight:

48inchDeck52inchDeck60inchDeck

855lb (388kg)

875lb (397kg)

883lb (401kg)

Note:Weightswillvaryslightlydependingonengine.

TorqueRequirements

BoltLocation

CutterHousingSpindle Nut

BladeMountingBolt (lubricatewithanti-seize)

Torque

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

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

ProductOverview

Figure3

1.Platform

2.FuelCap5.EngineControls

3.Height-of-Cut Adjustment

4.Motioncontrollevers

6.ParkBrakeLever

EngineDeck/MowerDeck SupportMountBolts

EngineMountingBolts Kawasaki Kohler

WheelLugNuts

WheelHubNuts175-225ft-lb

WheelMotorMounting Bolts

HydroPumpRelease Valves

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

17-23ft-lb(23-31N-m) 27-33ft-lb(37-45N-m)

90-95ft-lb(122-129N-m)

(237-305N-m)

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

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

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrollevers,locatedoneachsideofthe topconsole,controltheforwardandreversemotion ofthemachine.

Movingtheleversforwardorbackwardturns thewheelonthesamesideforwardorreverse respectively.Wheelspeedisproportionaltothe amounttheleverismoved.

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

Figure5

Figure4

1.LHMotioncontrollever6.Neutral

2.RHMotioncontrollever7.Forward

3.RHMotioncontrol leverinPTOdisengage position

4.Reverse

5.Rearreferencebar

8.Frontreference/Speed controlbar

9.Frontofunit

Whenthemotioncontrolleversareintheneutral position,theLCDindicatorappearsinthemessage displayonthefrontcontrolconsole(seeFigure5and Figure7).

Whenthemotioncontrolleversareintheneutral positionandtheRHmotioncontrolleverismoved intothePTOdisengageposition,themowerblades willdisengage.

ChokeControl(AllUnitsExcept KohlerEFI)

Locatedonthefrontcontrolconsolerightofthe PTOengagementswitch.

1.Throttle8.Fuelgauge

2.RHMotioncontrollever

3.LHMotioncontrollever

4.FrontReference/Speed ControlBar

5.Messagedisplay12.Fuelcap

6.Parkbrakelever

7.Ignitionswitch

9.PTOengagementswitch

10.Choke

11.Decklifthandle

13.Height-of-cutpin

14.Platformlatch

ThrottleControl

LocatedontheRHsideofthefrontcontrolconsole (redlever)(seeFigure5).

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

FrontReference/SpeedControlBar

Locatedinfrontofthemotioncontrollevers(see Figure5).

Thefrontreference/speedcontrolbarcontrolsthe maximumforwardspeedandisinnitelyvariable fromapproximately4–8mph(6–13km/hr).

Operation

ParkBrakeLever

Locatedonleftsideofunit,justtothefrontofthe LHmotioncontrollever(seeFigure5).

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Note:TheLCDindicatorappearsinthemessage displayonthefrontconsolewhentheparkbrakeis engaged(see

Figure5andFigure7).

Toengagethebrake,pulltheleverrearwardandto therighttopositionintotheengagedposition.

Torelease,pullthebrakeleverbackandovertothe left,positionintotheslotandpushtheleverforward.

Whenparkingonasteepslope,thewheelsmustbe chockedorblockedinadditiontothebrakebeing engaged.Theunitmustbetieddownandbrake engagedwhentransporting.

Parkbrakemustbedisengagedbeforemovingmotion controloutofneutralorenginewillkill.

IgnitionSwitch

disengaged.(Itisnotnecessaryfortheoperatorto beontheplatform.)

HourMeter

LocatedontheLHsideofthefrontcontrolconsole inthemessagedisplay(see

Thehourmeterrecordsthenumberofhoursthat theenginehasrun.

1.LCDIndicators

2.Lowvoltageindicatorlight

3.Hour/Voltagedisplay

Figure5andFigure7).

Figure7

LocatedontheLHsideofthefrontcontrolconsole

Figure5).

(see

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:Tostarttheengine,placetheLHmotion controlleverinneutral,theRHmotioncontrol inPTOdisengageposition,andthePTOswitch

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.

Operation

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).

Pullthehandlerearwardandtotherighttolatch thecuttingdeckintotheraisedtransportposition (

Figure6).

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.

Switchmustbepulledout(up)toengagetheblades. Switchispushedintodisengagetheblades.

TheLCDindicatorwillappearwhenthePTOswitch isengaged(see

Figure7).

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.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

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

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethevalveandalignwiththefuellinetoopen.

StartingtheEngine

1.LeavetheLHmotioncontrolleverinneutraland theRHleverinthePTOdisengageposition(see Figure4).

2.Pulltheparkingbrakerearwardandovertothe righttoengagetheparkingbrake.

Operation

3.Pushin(down)onthePTOswitchtothe “disengage”position.

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

5.Onacoldengine,pushthechokeleverforward intothe“ON”position(exceptKohlerEFIunits).

Onawarmengine,leavethechokeinthe“OFF” position.

6.Turnignitionswitchtothe“START”position. Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine continuouslyformorethantensecondsata time.Iftheenginedoesnotstart,allowa60 secondcool-downperiodbetweenstarting attempts.Failuretofollowtheseguidelines canburnoutthestartermotor.

7.Ifthechokeisinthe“ON”position,gradually returnchoketothe“OFF”positionastheengine warmsup.

PTOEngagement

DANGER

3.Movetherightsidemotioncontrollevertothe center,operateposition.

4.Continueholdingtherightsidemotioncontrol leverinthecenter,operatepositionandpullup onthebladecontrolswitch(PTO)andrelease. Theclutchshouldengageandthemowerblades beginrotating.

5.Placethethrottleinthe“FAST”positiontobegin mowing.

DisengagingthePTO

1.Setthethrottlemidwaybetweenthe“SLOW”and “FAST”positions.

2.PushdownonthePTOswitchtodisengagethe blades.

Note:ThePTOwillbedisengagedbyreleasing therightsidemotioncontrolleverandallowingit tospringoutwardtothePTOdisengageposition. ThePTOwillnotre-engagewhentheRHmotion controlleverismovedoutofthePTOdisengage positionwithoutpullinguponthePTOswitch. TofullydisengagethePTO,continuetopushthe switchdownward.

Therotatingbladesunderthemowerdeckare dangerous.Bladecontactcancauseserious injuryorkillyou.

DoNotputhandsorfeetunderthemoweror mowerdeckwhenthebladesareengaged.

DANGER

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

Neveroperatethemowerwiththedischarge deectorraised,removed,oralteredunlessthere isagrasscollectionsystemormulchkitinplace andworkingproperly.

ThePTOswitchengagesthecuttingblades.Besure allpersonsareclearofmowerdeckanddischarge areabeforeengagingthePTO .

1.Setthrottleto“MIDW AY”position.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Movethemotioncontrolleverstotheneutral position;movetheRHcontrolleverouttothe PTOdisengageposition.

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

4.PushdownonthePTOswitchtodisengagethe blades.

5.Engagetheparkingbrake.

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

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

2.Releasetheparkingbrake.

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioningone levertoomuchaheadoftheother.Operatormay losecontrolofthemachine,whichmaycause damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

Important:Tobeginmovement(forwardor backward),thebrakelevermustbedisengaged (pushedforward)beforethemotioncontrol leverscanbemovedortheenginewillstop.

WhentheRHmotioncontrolleverispositioned fullyoutward(apart),thedrivesystemisinthePTO disengageposition(

Note:The“N”LCDindicatorappearswhenthe RHleverisinthePTOdisengageposition.

WhentheRHmotioncontrolleverismoveddirectly inward(together)thedrivesystemisintheneutral operateposition.

Figure8).

Operation

Figure9

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

Figure8

1.LHMotioncontrollever6.Neutral

2.RHMotioncontrollever7.Forward

3.RHMotioncontrol leverinPTOdisengage position

4.Reverse

5.Rearreferencebar

8.Frontreference/Speed controlbar

9.Frontofunit

DrivingForward

1.Makesurethemotioncontrolleversareinthe neutralposition.

2.Releasetheparkingbrake.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

DrivinginReverse

1.Movethemotioncontrolleverstotheneutral operateposition.

2.Tomoverearwardinastraightline,slowlymove bothleversrearwardwithequalpressure.

Operation

Figure10

Toturnleftorright,releasepressureonthe motioncontrollevertowardthedesiredturn direction.

3.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

AdjustingtheFrontReference/Speed ControlBar

Adjustthefrontreference/speedcontrolbarfor desiredmaximumforwardspeed.

1.Stopthemachineandmovethemotioncontrol leverstotheneutralposition.

2.DisengagethePTO.

3.Unlockthehandlesonbothsidesofthecontrol towerbypullingoutward(see

Figure11).

Figure11

1.Frontofthemachine

2.Controltower

3.Unlock6.Lock

4.Forwardposition— faster

5.Backwardposition— slower

4.Movethebarforwardtoobtainthefastestspeed.

Movethebarbackwardtoobtaintheslowest speed.

5.Onbothsides,rotateandpushthehandlesinward tolockthehandlesagainstthecontroltower.

Important:Makesurethehandlesarelocked inplacesothefrontreference/speedcontrol bardoesnotmoveduringoperation.

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.

Operation

Figure12

1.Platform

2.Raiseupward

3.Latchpinknobsnapsinward

OperatingtheMachinewiththe PlatformDown

Operatingthemachinewiththeplatformdownis recommendedwhen:

•Mowingmostareas

•Drivingdownslopes

Tolowertheplatform,pushtheplatformforward againstthecushiontoreleasepressureonthelatch pin,pulltheknoboutward,andlowertheplatform

Figure13).

(see

•Turningintightareaswhereplatformmaycontact obstacles.

Toraisetheplatform,pullthebottomupwardand pushittightagainstthecushion.Thelatchpinknob willsnapinwardtolocktheplatformintoplace(see Figure12).

Figure13

1.Pulllatchpinknoboutward

2.Platform

3.Lower

Operation

AdjustingtheCuttingHeight

Thecuttingheightofthemowerdeckisadjusted from1to5inches(2.5cmto12.7cm)in1/4inch (6.4mm)increments.

1.Stopthemachineandmovethemotioncontrol leverstotheneutralposition.

2.DisengagethePTO.

3.Raiseandlockthedecktothe5inch(12.7cm) transportposition.

Thedeckisraisedbypullingthedecklifthandle rearwardandtotherighttoplaceitintothe transportlockposition.

1.Heightadjustmentpin

2.Heightofcutholes

Transporting

Figure15

3.Decklifthandle

Figure14

1.Transportlockposition

2.RHMotioncontrollever

3.Frontreference/speed controlbar

4.Decklifthandle

Note:Whenchangingthecuttingheight positions,alwayscometoacompletestop anddisengagethePTO.

4.Inserttheheightadjustmentpinintothehole correspondingtothedesiredcuttingheight.

Seethedecalonthesideofthedeckliftplatefor cutheights(reference

Figure15).

5.Pullthedecklifthandlerearwardandtotheleft andslowlyallowthedecktolowertothecutting height.

TransportingaUnit

Useaheavy-dutytrailerortrucktotransportthe machine.Lockbrakeandblockwheels.Securely fastenthemachinetothetrailerortruckwithstraps, chains,cable,orropes.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.

Operation

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).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

Aftertherst250hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubtorquespecication.

•Checkthewheellugnuts.

•Changethehydrauliclteranduid.

WARNING

Theenginecanbecomeveryhot.T ouchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

Beforeeachuseordaily

Every50hours

Every80hours

Every100hours

Every160hours

Every250hours

•Checktheengineoillevel.

•Checkthemowerblades.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Cleantheengineandexhaustsystemarea.

•Cleanthegrassanddebrisbuild-upfromthemachineandcuttingdeck.

•Cleanthegrassbuild-upfromunderthedeck.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Greasetheliftlinkagepivots.

•Checksparkarrester(ifequipped).

•Removeengineshroudsandcleancoolingns.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Checkthesparkplugs.

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

Maintenance

MaintenanceService

Interval

Every500hours

Yearly

MaintenanceProcedure

•Replacethesecondaryaircleanerelement.(Mayneedmoreoftenundersevereconditions. SeetheEnginemanualforadditionalinformation.)

•Changethehydrauliclteranduid(Every250hours/yearlyifusingMobil115W50)

•Checkthewheelhubtorquespecication.

•Checkthewheellugnuts.

•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

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

Charging Interval

No Charging Required

30Minutes

1Hour

Maintenance

Voltage Reading

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

Maximum Charger Settings

14.4volts/4 amps

14.4volts/2 amps

Charging Interval

2Hours

3Hours

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.

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricaland/orEFIsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

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

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

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

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe engineorEFImayoccur.

DANGER

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

DoNotjumpstartaweakbatteryifthese conditionsexist.

2.Makesuretheboosterisagoodandfullycharged leadacidbatteryat12.6voltsorgreater.Use properlysizedjumpercables(4to6AWG)with shortlengthstoreducevoltagedropbetween systems.Makesurethecablesarecolorcodedor labeledforthecorrectpolarity .

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

Figure16.

Figure16

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

Maintenance

6.Raisethecushionandslideitontothepinson bothsidesofthemachine(

7.Pushtheplasticslidesintothecushionbracket andsecurethemwithahairpin.

Figure17).

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.

Figure17

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.

Figure18

1.Installbushinginbladepriortoinstallingbushingin spindle.

B.Installbushing/bladeassemblyintospindle.

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecan bedangerous.Failuretousealloriginal componentsandassembledasshowncould allowabladeorbladecomponenttobe thrownoutfromunderthedeckresultingin seriouspersonalinjuryordeath.

AlwaysinstalltheoriginalExmarkblades, bladebushings,andbladeboltsasshown.

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

CAUTION

Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitches beforeoperatingthemachine.

Figure19

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).

UnderstandingtheSafetyInterlockSystem

Thesafetyinterlocksystemisdesignedtopreventthe mowerbladesfromrotatingunless:

•Therightsidemotioncontrolleverismovedto thecenter,operatingposition.

•Thebladecontrolswitch(PTO)ispulledon.

Thesafetyinterlocksystemisdesignedtostop themowerbladesifyoumoveorreleasetheright sidemotioncontrolleverintothePTOdisengage position.

•Therightsidemotioncontrolleverismovedto thecenter,operatingposition,theparkingbrake isengaged,andthebladecontrolswitch(PTO)is pulledon.

CheckingtheSafetyInterlockSystem

1.Starttheengine.

2.Settheparkingbrake.

3.Movethemotioncontrolleversforward.

Theengineshouldinitiateshutdownafter momentarypause.

4.Starttheengineandreleasetheparkingbrake.

Maintenance

5.Movetherightsidemotioncontrollevertothe center,operatingposition.

6.Continueholdingtherightsidemotioncontrol leverinthecenter,operatingpositionandpullup onthebladecontrolswitch(PTO)andrelease. Theclutchshouldengageandthemowerblades beginrotating.

7.Moveorreleasetherightsidemotioncontrol leverintotheneutralposition.Theblades

shouldstoprotatingandtheengineshould continuerunning.

8.Pushthebladecontrolswitchdownandmove therightsidemotioncontrollevertothecenter, operatingposition.

9.Continueholdingtherightsidemotioncontrol leverinthecenter,operatingpositionandpullup onthebladecontrolswitch(PTO)andrelease. Theclutchshouldengageandthemowerblades beginrotating.

10.Pushthebladecontrolswitch(PTO)downtothe offposition.Thebladesshouldstoprotating.

11.Withtheenginerunning,pullupthebladecontrol switch(PTO)andreleasewithoutholdingright sidemotioncontrollevertothecenter,operating position.Thebladesshouldnotrotate.

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).

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

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

Maintenance

1.Stopengineandwaitforallmovingpartstostop, andremovekey.Engageparkingbrake.

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

2.LubricatettingswithNGLIgrade#2 multi-purposegungrease.

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Fitting

Locations

1.LiftLinkage Pivots

2.DeckBeltIdler Pivot

3.FrontCaster WheelHubs

4.FrontCaster Pivots

InitialPumpsNumberof

1–2

Places

Service

Interval

Every50

hours

Yearly

*Yearly

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.

*Seestep3forspeciallubricationinstructionson thefrontcasterpivots.

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

LubricateCasterWheelHubs

ServiceInterval:Yearly

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Figure20

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.

Maintenance

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.

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.

ForKohlerEFIUnits:

WARNING

Fuelsystemcomponentsareunderhigh pressure.Theuseofimpropercomponentscan resultinsystemfailure,gasolineleakageand possibleexplosion.

Useonlyapprovedfuellinesandfuelltersfor highpressuresystems.

ReplacementFilters

KawasakiKawasaki

P/N49019-7005

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.

CAUTION

Raisingthemowerforserviceormaintenance relyingsolelyonmechanicalorhydraulic jackscouldbedangerous.Themechanicalor hydraulicjacksmaynotbeenoughsupport ormaymalfunctionallowingtheunittofall, whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

7.Ifeitherdrivewheeldoesnotrotate,oneorboth ofthechargepumps(locatedonthetopofthe mainpumpasshowninFigure21)mayhavelost their“prime”.RefertoHydraulicSystemAir Purgesection.

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

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

HydraulicSystemAirPurge

4.FillreservoirasstatedinCheckHydraulicOil Level.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

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.

ChangeInterval

500Hours

250Hours

ServiceInterval:Asrequired

Airmustbepurgedfromthehydraulicsystem whenanyhydrauliccomponents,includingoil lter,areremovedoranyofthehydrauliclinesare disconnected.

Thecriticalareaforpurgingairfromthehydraulic systemisbetweentheoilreservoirandeach chargepumplocatedonthetopofeachvariable displacementpump( thehydraulicsystemwillbepurgedthroughnormal operationoncethechargepumpis“primed”.

Figure21).Airinotherpartsof

Figure21

Maintenance

pump.Ifwheelsrotateslowly,thesystemmay primeafteradditionalrunning.Checkoillevel asstatedinChecktheHydraulicOilLevel section.

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

8.Checkhydrodrivelinkageadjustmentasstatedin HydroDriveLinkageAdjustmentsectionin Adjustments.

1.Chargepumpcap2.Loosen11/2turnsonly

1.Stopengineandwaitforallmovingpartstostop. Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsoffthe ground.

2.CheckoillevelasstatedinCheckHydraulicOil Levelsection.

3.Startengineandmovethrottlecontrolaheadto fullthrottleposition.MoveRHmotioncontrol leverinward(together)andmovebothlevers forwardwithequalpressure.

Ifeitherdrivewheeldoesnotrotate,itispossible toassistthepurgingofthechargepumpby carefullyrotatingthetireintheforwardposition.

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

Ifeitherdrivewheelstilldoesnotrotatecontinue withstep

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.

4.Thoroughlycleantheareaaroundeachofthe chargepumphousings.

5.To“prime”chargepump,loosentwohexsocket headcapscrews(showninFigure21)11/2turns only.Makesureengineisnotrunning.Lift thechargepumphousingupwardandwaitfor asteadyowofoiltoowoutfromunderthe housing.Retightenthecapscrews.Dothisfor bothpumps.

Note:Hydraulicreservoircanbepressurizedup to5psitospeedthisprocess.

6.Ifeitherdrivewheelstilldoesnotrotate,stop andrepeatsteps4and5abovefortherespective

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:

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.

•OnthreadsofBladeBolts.SeeCheckMower Bladessection.

•Betweenenginecrankshaft,pumpdrivesheave, andclutch.

•Betweenpumpshaftsandsheaves.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact. Dielectricgreaseshouldnotbeappliedtosealed connectors.

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

Figure22).Thebladesshouldmeasure3inches

( (7.6cm).

Figure22

Maintenance

4.Checkandadjustthesidetosidebladelevelif youhavenotcheckedthesetting;refertoDeck Leveling.

5.Carefullyrotatethebladesfronttorear (Figure24).Measurefromthetipofthefront bladetothelevelsurfaceandthetipoftherear bladetothelevelsurfaceonallblades.Theblades shouldbe1/4inch(6.4mm)lowerinthefront thanintherear.

1.Bladesfronttorear

2.Measurehere

7.Measurebetweentheoutsidecuttingedgesand theatsurface(

Figure23).Ifbothmeasurements arenotwithin3/16inch(5mm),anadjustmentis required;contactanAuthorizedServiceDealer.

Figure23

1.Bladessidetoside2.Measurehere

Figure24

1.Bladesfronttorear

6.Loosentherearlocknutsonbothadjustment rods(Figure25).

2.Measurehere

8.Lowerthedischargedeector.

AdjustingtheCuttingDeck Rake

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

Figure25

1.Adjustmentrod3.Frontlocknut

2.Rearlocknut

Note:Makesuretheenginedeckbrackets arerestingrmlyontherearliftpoints(see Figure26).Ifitisliftingoff,tightenthefront locknutoftheadjustingrodontheoppositeside.

Maintenance

Figure27

1.Adjustmentscrew

Figure26

1.Rearliftpoints

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

Note:Rakeadjustmentsmayaffectthemotion controlneutralposition.SeetheMotionControl

NeutralAdjustmentandMotionControl TrackingAdjustmentsectionsinMaintenance.

2.Enginedeckbrackets

AdjustingtheRearofthe Deck

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

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.

4.Settheheightofcuttothe3inch(7.6cm) position.

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

6.Ifitdoesnotmeasurecorrectly,locatethe height-of-cutrodontherightsideofthemachine

Figure27).

(see

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(see

1.Brakebar

2.Pushdown5.Parkbrakehandle

3.Slot

Figure28).

Figure28

4.3/4inch(19mm)

b.Loosenthejamnut.

c.Rotatetheyoke.Totightenthebrake,

rotatetheyokeup.Toloosenthebrake, 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.

6.Therearetwomethodstoadjusttheparkbrake; oneorbothmethodsmaybeused.

A.Adjustingthelowerbrakelever:

a.Removethehairpin,washer,andclevispin

fromthelowerbrakeleverandyokeas shownin

1.Jamnut4.Lowerbrakelever

2.Yoke5.Washer

3.Clevispin

Figure29.

Figure29

6.Hairpin

Figure30

1.Movedowntoloosen brake

2.Moveuptotightenbrake5.Linkage

3.Topjamnut

4.Bottomjamnut

d.Tightenthejamnuts.

e.Checkthebrakeoperationagain.

7.Afterthebrakeisadjusted,theleverswitchneeds tobechecked.

8.Checkthegapbetweenthebrakeleverandthe switchasshowninFigure29.Thegapneedsto bean1/8inch(3mm)withthebrakeengaged.

Maintenance

Figure31

1.Switch

2.1/8inch(3mm)gap neededbetweenswitch andbrakelever

3.Brakelever

9.Ifneeded,loosenthescrewsholdingtheswitch andadjusttheswitch.

ElectricClutchAdjustment

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

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

A.Loosenbothbrakemountingboltsone-half

toonefullturn(see

Figure33).

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

Noadjustmentnecessary.Howeverwhentheclutch brakehasworntothepointwheretheclutchno longerengagesconsistently,theshimcanberemoved toextendtheclutchlife.

Figure32

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheShim:

Figure33

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).

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

2.Usingapneumaticline,blowoutanydebris fromunderthebrakepoleandaroundthebrake spacers.

E.Usinga0.010inchthickfeelergauge,verify

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

G011733

1.Feelergauge

Maintenance

1.Withtheengineoff,turntheignitionswitchto the“ON”position.

2.LocatetheLCDindicatorinthemessagedisplay.

Figure34

Figure36

1.NeutralLCDindicator

3.Withthemotioncontrolleversintheneutral position(seeFigure4)(withnoforceonthelever eitherforwardorback),theneutralLCDindicator shouldappear.

Figure35

1.Feelergauge

•Ifthegapislessthan0.010inch,then reinstalltheshimandreferencethe Troubleshootingsection.

•Ifthegapissufcient,proceedtothe safetycheckinstep

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengagewith

thePTOswitch“off”andtheclutch disengaged.

Iftheclutchdoesnotdisengage, reinstalltheshimandreferencethe Troubleshootingsection.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly,referencethe Troubleshootingsection.

4.Iftheindicatorilluminates,movetheRHlever rstforward,thenbackward,notingtheposition ofthecontrolleverwhentheindicatordisappears. Theamountofmovement,bothforwardand back,shouldbeapproximatelythesame;ifnot, gotostep

5.Iftheindicatordoesnotilluminate,moveboth motioncontrolleversforwardandthenbackward. Continuetowatchthemessagedisplayandnote thepositionofthecontrolswhenitappears.

6.LoosenthelocknutsontheRHmotioncontrol linkage(asviewedfromtherearofthemachine —seeFigure37).Withtherightmotioncontrol inthePTOdisengageposition,holdtheLH motioncontrolinthepositiondeterminedinstep 4or5.RotatetheadjustmentroduntiltheLCD indicatorcomeson.

MotionControlNeutral Adjustment

Checktoseeifanadjustmentisrequired:

Maintenance

Figure37

1.Locknut

2.Adjustmentrod

7.Continuetorotatetheadjustmentrod,counting theturns,untiltheLCDindicatorturnsoff. Rotatetheadjustmentrodintheopposite directionhalfthenumberofturnscounted. ReleasetheLHmotioncontrolleverandtighten thelocknutsontherightside.

8.TurntheadjustmentrodontheLHside(as viewedfromtherearofthemachine—see Figure38)untiltheleftcontrolhasapproximately thesamenaturalneutralpositionastheright.If moreadjustmentisneeded,contactanAuthorized ServiceDealer.Finaladjustmentoftheleftside isdoneinthetrackingadjustmentsection.Ifno adjustmentisrequired,seeChecktheNeutral SwitchAlignmentsection.

3.Locknut(LHthread)

MotionControlTracking Adjustment

Ifthemachinetravelsorpullstoonesidewhenthe motioncontrolleversareinthefullforwardposition, adjustthetracking.

1.Pushbothcontrolleversforwardthesame distance.

2.Checkifthemachinepullstooneside.Ifitdoes, stopthemachineandsettheparkingbrake.

3.Releasetherearcushionfromtherearofthe machine.

4.Placethefrontreference/speedcontrolbarin themaximumforwardposition.SeeAdjusting theFrontReference/SpeedControlBarin Operation.

5.RotatetheadjustmentrodontheLHsideofthe machine(asviewedfromtherearofthemachine —see

6.Lookingdowntowardstheadjustmentrod— rotateitcounterclockwise,in1/4turnincrements, toincreasespeedorclockwisetodecreasespeed.

7.Drivethemachineandcheckthefullforward tracking.

8.Repeatsteps5through7untildesiredtracking isobtained.

9.Withthemotioncontrolleversintheneutral position(seeFigure4)(withnoforceonthelever eitherforwardorback),theneutralLCDindicator shouldappear..Ifitdoesnotappear,refertothe Troubleshootingsection.

10.Reinstalltherearcushion.

Figure38).

1.Rotatetoincreasespeed

2.Adjustmentrod

3.Rotatetodecreasespeed

9.Reinstalltherearcushion.

Figure38

ChecktheNeutralSwitch Alignment

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Stopengine,waitforallmovingpartstostop,and removethekeyorsparkplugwire(s).

3.Settheheightofcuttothe3inch(7.6cm) position.

4.PerformtheMotionControlNeutral

AdjustmentandMotionControlTracking AdjustmentasstatedintheMaintenancesection.

5.Releasetherearcushionfromtherearofthe machineandlowertotheplatform.

Maintenance

6.CheckthealignmentontheLHandRHneutral switchesupperandlowersurfaces(reference Figure39).Iftheyarenotinalignment,loosenthe hardwareonthelowerneutralswitchandadjustit forwardorrearwardasnecessary.Oncealigned, tightenthehardware.Checktheneutralswitch alignmentagainasthedeckismovedthroughthe highestandlowestcutheightsetting;adjustthe lowerneutralswitchsurfaceifnecessary.

B.Iftheindicatordoesnotstaylitwhilemoving

thedeckupanddown,contactanAuthorized ServiceDealer.Removethekey.

AdjustRHMotionControl HandlePosition

Ifthemotioncontrolleversdonotalignhorizontally, adjusttherightsidemotioncontrollever.

Note:Adjustthehorizontalalignmentbeforethe fronttobackalignment.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Pushtherightmotioncontrolleverdownoutof lockedneutralposition.

3.Checkifitalignshorizontallywiththeleftmotion controllever.

Figure39

1.Alignmentreference

2.Upperneutralswitch surface

3.Switchmountingplate

4.Lowerneutralswitch surface

5.Hardware

7.Adjusttheupperneutralswitchsurfaceleft orrightifside-to-sidealignmentisneeded. Theupperandlowerswitchesshouldbeas closetogetheraspossiblewithouttouching (approximately.06inch(1.5mm)gapisdesirable). Theswitchmountingplatecanbemovedupor downtoadjustthepositionofthelowerneutral switch.

8.Checkthefunctionoftheneutralswitchesby temporarilyreplacingthekey .Withtheengineoff, turntheignitionswitchtothe“ON”position. LocatetheLCDindicatorinthemessagedisplay. Raiseandlowerthedeck.

A.Iftheindicatordisplayswhilemovingthedeck

upanddown,theneutralswitcheshavebeen adjustedproperlyandnofurtheradjustment isnecessary.

Figure40

1.LHMotioncontrollever

2.RHMotioncontrollever

3.RHMotioncontrolleverinPTOdisengagedposition

4.Checkthehorizontalalignmenthere

4.Toadjusttherightmotioncontrollever horizontally,thecamneedstobeadjusted.

5.Releasethecushionfromtherearofthemachine.

6.Loosenthenutandboltholdingthecam.

7.Adjustthecamuntilitalignswiththeleftmotion controlleverandtightenthenutandboltforthe cam.

Maintenance

Figure41

1.Switchscrews

2.Nutandbolt

3.Cam

4.Frontreference/speedcontrolhandle

8.Afterthecamisadjusted,theleverswitchneeds tobechecked.

9.Checkthegapbetweenthecontrolleverand switchasshowninFigure42.Thegapneeds tobean1/8inch(3mm)withtherightmotion controlleverintheneutral,operateposition.

CasterPivotBearings Pre-LoadAdjustment

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

Figure43.

Figure42

1.Switch

2.Cam

3.Rightmotioncontrolleverintheneutraloperateposition

4.1/8inch(3mm)

Figure43

1.Springdiscwashers

10.Ifneeded,loosenthescrewsholdingtheswitch andadjusttheswitch.

11.Tightentheswitchscrews.

Maintenance

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.

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.

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

3.Cleanoutanygrassbuild-upfromundersideof deckandindischargedeector.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

Maintenance

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

Starterdoesnotcrank.

Enginewillnotstart,startshard,orfailsto keeprunning

1.PTOisengaged.

2.Oneofthespeedcontrolleversarenot inneutralposition.

3.Batterydoesnothaveafullcharge.

4.Electricalconnectionsarecorroded,loose orfaulty.

5.Fuseisblown.5.Replacetheblownfuse.

6.NeutralLCDindicatordoesnot illuminate.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Thethrottleandchokearenotinthe correctposition.

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

5.Dirt,water,orstalefuelisinthefuel system.

6.Aircleanerisdirty.

7.Electricalconnectionsarecorroded,loose orfaulty.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Faultysparkplug.

10.Sparkplugwireisnotconnected.

11.MILilluminatesandblinks11.ContactanAuthorizedServiceDealer.

1.DisengagethePTO.

2.Ensurethespeedcontrolleverisinthe neutralposition.

Chargethebattery.SeeCheck

BatteryChargeandRecommended JumpStartingProceduresectionsin

Maintenance.

4.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

6.Checkreedswitch.

2.Openthefuelshutoffvalve.

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

5.ContactanAuthorizedServiceDealer.

6.Cleanorreplacetheaircleanerelement.

7.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

9.Clean,adjustorreplacesparkplug.

10.Checkthesparkplugwireconnection.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Enginelosespower

Engineoverheats

Mowerpullsleftorright(withleversfully forward).

Machinedoesnotdrive.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

5.Ventholeinthefuelcapisplugged.

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

7.Dirt,water,orstalefuelisinthefuel system.

1.Engineloadisexcessive1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Coolingnsandairpassagesforthe engineareplugged.

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

2.Trackingneedsadjustment.2.AdjustthetrackingbyturningtheLH

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

2.Addoiltothecrankcase.

3.Removetheobstructionsfromthecooling nsandairpassages.

adjustmentrodinthedirectionthatthe mowerneedstobeadjustedto.Rotatethe adjustmentrodin1/4turnincrements untilthemowertrackscorrectly.

2.Changethebelt.

Unevencuttingheight.

Abnormalvibration

Bladesdonotrotate.

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

2.Cuttingblade(s)is/arebent.

3.Mowerdeckisnotlevel.3.Levelmowerdeckfromside-to-sideand

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureindrivetiresnotcorrect.5.Adjusttirepressureinthedrivetires.

6.Bladespindlebent.6.ContactanAuthorizedServiceDealer.

7.Tipsofadjacentbladesareatanuneven cuttingheight.Bladestipsshouldbeeven within3/16inchwhichisapproximately onebladethickness.

1.Cuttingblade(s)is/arebentorunbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley ,idlerpulley ,orblade pulley.

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

7.Beltisdamaged.7.Installnewbelt.

1.Drivebeltisoffpulley.1.Checkbeltfordamage;replaceif

2.Deckbeltisworn,looseorbroken.2.Installnewdeckbelt.

3.Deckbeltisoffpulley .3.Installdeckpulleyandchecktheidler

4.Brokenormissingidlerspring.

5.Damagedelectricclutch.5.ContactanAuthorizedServiceDealer.

2.Installnewcuttingblade(s).

front-to-rear.

7.Replaceblades,spindlesand(or)check fordamagetomowerdeck.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

necessary.Installdrivebeltandcheck adjustingshaftsandbeltguidesforcorrect position.

pulley,idlerarmandspringforcorrect positionandfunction.

4.Replacethespring.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Clutchwillnotengage.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.

4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

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

2.Checkcoilresistance,batterycharge, chargingsystem,andwiringconnections andreplaceifnecessary.

3.Replaceclutch.

electricalsystem.Cleanconnector contacts.

5.Removeshimorreplaceclutch.

Schematics

ElectricalDiagram–AllUnitsExceptKohlerEFI

ElectricalDiagram–KohlerEFI

Schematics

ElectricalSchematic–AllUnitsExceptKohlerEFI

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.

• 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_B

Notes:

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

G011841

Figure44

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-FRONT R IDING ACCESSORIES A ND 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

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

www.exmark.com

PartNo.4501-211Rev.A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

Exmark VT691KA524CA, VT691KA484CA, VT740EKC604, VT651KA484, VT730EKC524 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual