Exmark 920 Lawn Mower User Manual

VANTAGE™
36 INCH MODELS
For Serial Nos.
920,000 & Higher
Part No. 4500-897 Rev. A
WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
Important: The engine in this product is not
equipped with a spark arrester muffler. It is a
violation of California Public Resource Code
(CPRC) Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126.
Other states or federal areas may have similar
laws.
To acquire a spark arrester for your unit, see your
Engine Service Dealer.
This spark ignition system complies with the
Canadian standard ICES-002. Ce système d’allumage
par ètincelle de vèhicule est conforme à la norme
NMB-002 du Canada.
The enclosed Engine Owner’s Manual is
supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and
the California Emission Control Regulation of
emission systems, maintenance and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become
damaged or illegible, replace immediately.
Replacements may be ordered through the
engine manufacturer.
Exmark reserves the right to make changes or
add improvements to its products at any time
without incurring any obligation to make such
changes to products manufactured previously.
Exmark, or its distributors and dealers, accept
no responsibility for variations which may be
evident in the actual specifications of its products
and the statements and descriptions contained
in this publication.
©2011 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
2
Contact us at www.Exmark.com.
Printed in the USA
All Rights Reserved
Introduction
CONGRATULATIONS on the purchase of your
Exmark Mower. This product has been carefully
designed and manufactured to give you a maximum
amount of dependability and years of trouble-free
operation.
This manual contains operating, maintenance,
adjustment, and safety instructions for your Exmark
mower.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
Figure 1
1. Model and serial number location
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
Model No.
If additional information is needed, or should you
require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
Exmark parts manuals are available online at
http://www.exmark.com/manuals.htm
Serial No.
All Exmark equipment dealers and distributors are
kept informed of the latest methods of servicing
and are equipped to provide prompt and efficient
service in the field or at their service stations. They
carry ample stock of service parts or can secure them
promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.
3
Contents
Forward Speed Adjustment ........................... 37
Motion Control Tracking Adjustment ............ 38
Adjust RH Motion Control Handle
Position..................................................... 39
Caster Pivot Bearings Pre-Load
Adjustment ............................................... 40
Cleaning ........................................................... 40
Clean Engine and Exhaust System
Area .......................................................... 40
Remove Engine Shrouds and Clean Cooling
Fins........................................................... 40
Clean Debris From Machine .......................... 40
Clean Grass Build-Up Under Deck ................ 41
Waste Disposal .............................................. 41
Troubleshooting ................................................... 42
Schematics ........................................................... 45
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ..................... 10
Specifications ....................................................... 13
Model Numbers ............................................ 13
Systems ......................................................... 13
Dimensions................................................... 14
Torque Requirements .................................... 14
Product Overview ................................................ 15
Operation ............................................................. 15
Controls ........................................................ 15
Pre-Start........................................................ 18
Operating Instructions .................................. 18
Transporting ................................................. 23
Maintenance ......................................................... 24
Recommended Maintenance Schedule(s) ........... 24
Periodic Maintenance ....................................... 25
Check Engine Oil Level ................................. 25
Check Battery Charge .................................... 25
Check Mower Blades ..................................... 27
Check Safety Interlock System ....................... 28
Check for Loose Hardware ............................ 28
Service Air Cleaner ........................................ 28
Change Engine Oil ........................................ 29
Check Hydraulic Oil Level ............................. 29
Check Tire Pressures ..................................... 29
Check Condition Of Belts.............................. 29
Lubricate Grease Fittings............................... 29
Lubricate Caster Wheel Hubs ........................ 30
Check Spark Plugs ......................................... 31
Change Hydraulic System Filter and
Fluid ......................................................... 31
Wheel Hub Nut Torque Specification............. 32
Check Spark Arrester (if equipped)................. 32
Thread Locking Adhesives............................. 33
Mobil HTS Grease (Or Food-Grade
Anti-seize)................................................. 33
Copper-Based Anti-seize ............................... 33
Dielectric Grease........................................... 33
Adjustments ..................................................... 34
Deck Leveling ............................................... 34
Overall Height Adjustment............................ 35
Deck Lift Handle Force ................................. 35
Pump Drive Belt Tension............................... 35
Mower Deck Drive Belt Tension .................... 35
Park Brake Adjustment.................................. 35
Electric Clutch Adjustment............................ 36
4
Safety
Safety
Safe Operating Practices
Safety Alert Symbol
Training
• Read the Operator’s Manual and other training
material. If the operator(s) or mechanic(s) can
not read English it is the owner’s responsibility to
explain this material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
• Never let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.
• Only adults and mature teenagers should operate
a mower, and even mature teenagers should have
adult supervision. Be sure a teenager:
1. has read and understands the Operator’s
Manual and recognizes the risks involved;
2. is sufficiently mature to use caution; and
3. is of sufficient size and weight to operate
the controls comfortably and to manage the
mower without taking risks.
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
This lawn mower meets or exceeds the B71.4
specifications of the American National Standards
Institute in effect at the time of production.
Exmark designed and tested this lawn mower to offer
reasonably safe service; however, failure to comply
with the following instructions may result in personal
injury.
This Safety Alert Symbol (Figure 2) is used both in
this manual and on the machine to identify important
safety messages which must be followed to avoid
accidents.
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
Figure 2
Safety Alert Symbol
The safety alert symbol appears above information
which alerts you to unsafe actions or situations
and will be followed by the word DANGER,
WARNING, or CAUTION.
Preparation
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
• Evaluate the terrain to determine what accessories
and attachments are needed to properly and
safely perform the job. Only use accessories and
attachments approved by Exmark.
• Wear appropriate clothing including safety glasses,
substantial footwear, long trousers, and hearing
protection. Do Not operate when barefoot or
when wearing open sandals. Long hair, loose
clothing or jewelry may get tangled in moving
parts.
WARNING: Black lettering / Orange background.
Indicates a potentially hazardous situation which, if
not avoided, Could result in death or serious injury.
CAUTION: Black lettering / Yellow background.
Indicates a potentially hazardous situation which, if
not avoided, May result in minor or moderate injury.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
CAUTION
This machine produces sound levels in excess
of 85 dBA at the operator’s ear and can cause
hearing loss through extended periods of
exposure.
Wear hearing protection when operating this
machine.
5
Safety
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
DANGER
In certain conditions during fueling, static
electricity can be released causing a spark
which can ignite gasoline vapors. A fire or
explosion from gasoline can burn you and
others and cause property damage.
DANGER
• Always place gasoline containers on the
ground away from your vehicle before
filling.
In certain conditions gasoline is extremely
flammable and vapors are explosive.
A fire or explosion from gasoline can burn
you, others, and cause property damage.
• Do Not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the
loss of any static charge.
• Fill the fuel tank outdoors on level ground,
in an open area, when the engine is cold.
Wipe up any gasoline that spills.
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• Do Not fill the fuel tank completely full.
Fill the fuel tank to the bottom of the filler
neck. The empty space in the tank allows
gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine
or emission system.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• If a gasoline dispenser nozzle must be
used, keep the nozzle in contact with the
rim of the fuel tank or container opening
at all times until fueling is complete.
• Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by spark.
• Store gasoline in an approved container
and keep it out of the reach of children.
WARNING
• Add fuel before starting the engine. Never
remove the cap of the fuel tank or add
fuel when engine is running or when the
engine is hot.
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors has caused
cancer in laboratory animals. Failure to use
caution may cause serious injury or illness.
• If fuel is spilled, Do Not attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Do Not operate without entire exhaust
system in place and in proper working
condition.
• Keep away from eyes and skin.
• Never siphon by mouth.
• Check that the operator’s presence controls,
safety switches, and shields are attached and
functioning properly. Do Not operate unless they
are functioning properly.
6
Safety
Operation
damage and make repairs before restarting
and operating the mower).
WARNING
– Before clearing blockages.
Operating engine parts, especially the muffler,
become extremely hot. Severe burns can occur
on contact and debris, such as leaves, grass,
brush, etc. can catch fire.
• Allow engine parts, especially the muffler, to
cool before touching.
• Remove accumulated debris from muffler
and engine area.
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered, or
brush-covered unimproved land.
– Whenever you leave the mower.
• Stop engine, wait for all moving parts to stop, and
engage parking brake:
– Before refueling.
– Before dumping the grass catcher.
– Before making height adjustments.
WARNING
Hands, feet, hair, clothing, or accessories can
become entangled in rotating parts. Contact
with the rotating parts can cause traumatic
amputation or severe lacerations.
WARNING
• Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can kill
you.
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
Do Not run engine indoors or in a small confined
area where dangerous carbon monoxide fumes
can collect.
• DO NOT operate the mower when people,
especially children, or pets are in the area.
• Operate only in daylight or good artificial light,
keeping away from holes and hidden hazards.
• Be sure all drives are in neutral and parking brake
is engaged before starting engine.
• Never raise deck with blades running.
• Never operate the mower with damaged guards,
shields, or covers. Always have safety shields,
guards, switches and other devices in place and in
proper working condition.
• Never mow with the discharge deflector raised,
removed or altered unless there is a grass
collection system or mulch kit in place and
working properly.
• Do Not change the engine governor setting or
overspeed the engine.
• Park machine on level ground. Stop engine, wait
for all moving parts to stop, remove key and
engage parking brake:
– Before checking, cleaning or working on the
mower.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• Stop the blades, slow down, and use caution when
crossing surfaces other than grass and when
transporting the mower to and from the area to
be mowed.
• Be aware of the mower discharge path and direct
discharge away from others.
• Do Not operate the mower under the influence
of alcohol or drugs.
• Use extreme care when loading or unloading the
machine into a trailer or truck.
• Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure vision.
Slope Operation
Use Extreme caution when mowing and/or turning
on slopes as loss of traction and/or tip-over could
occur. The operator is responsible for safe operation
on slopes.
7
Safety
• Keep engine and engine area free from
accumulation of grass, leaves, excessive grease
or oil, and other debris which can accumulate
in these areas. These materials can become
combustible and may result in a fire.
DANGER
Operating on wet grass or steep slopes can
cause sliding and loss of control. Loss of control
and/or loss of operator’s footing could result in a
fall with an arm or leg getting under the mower
or engine deck which may result in serious
injury, death or drowning.
• Let engine cool before storing and do not store
near flame or any enclosed area where open pilot
lights or heat appliances are present.
• Mow across slopes, never up and down.
• Shut off fuel while storing or transporting. Do
Not store fuel near flames or drain indoors.
• Do Not mow slopes when grass is wet.
• Do Not mow near drop-offs or near water.
• Do Not mow slopes greater than 20 degrees.
• Park machine on level ground. Never allow
untrained personnel to service machine.
• Reduce speed and use extreme caution on
slopes.
• Use jack stands to support components when
required.
• Avoid sudden turns or rapid speed changes.
• Carefully release pressure from components with
stored energy.
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
• Disconnect battery or remove spark plug wire
before making any repairs. Disconnect the
negative terminal first and the positive last.
Reconnect positive first and negative last.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Use care when checking blades. Wrap the blade(s)
or wear gloves, and use caution when servicing
them. Only replace damaged blades. Never
straighten or weld them.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Keep hands and feet away from moving parts.
If possible, do not make adjustments with the
engine running.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
• Be aware that operating on wet grass, across steep
slopes or downhill may cause the mower to lose
traction. Loss of traction to the drive wheels may
result in sliding and a loss of braking and steering.
• Charge batteries in an open well ventilated area,
away from spark and flames. Unplug charger
before connecting or disconnecting from battery.
Wear protective clothing and use insulated tools.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
DANGER
Charging or jump starting the battery may
produce explosive gases. Battery gases can
explode causing serious injury.
• Follow the manufacturer’s recommendations for
wheel weights or counter weights to improve
stability.
• Keep sparks, flames, or cigarettes away
from battery.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control.
• Ventilate when charging or using battery
in an enclosed space.
Maintenance and Storage
• Make sure venting path of battery is
always open once battery is filled with
acid.
• Disengage drives, lower implement, set parking
brake, stop engine and remove key or disconnect
spark plug wire. Wait for all movement to stop
before adjusting, cleaning or repairing.
• Always shield eyes and face from battery.
8
Safety
DANGER
WARNING
Battery electrolyte contains sulfuric acid,
which is poisonous and can cause severe
burns. Swallowing electrolyte can be fatal or
if it touches skin can cause severe burns.
Hydraulic fluid escaping under pressure
can penetrate skin and cause injury. Fluid
accidentally injected into the skin must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene may
result.
• Wear safety glasses to shield eyes, and
rubber gloves to protect skin and clothing
when handling electrolyte.
• If equipped, make sure all hydraulic fluid
hoses and lines are in good condition and all
hydraulic connections and fittings are tight
before applying pressure to hydraulic system.
• Do Not swallow electrolyte.
• In the event of an accident, flush with
water and call a doctor immediately.
• Keep body and hands away from pinhole
leaks or nozzles that eject high pressure
hydraulic fluid.
CAUTION
• Use cardboard or paper, not your hands, to
find hydraulic leaks.
If the ignition is in the “ON” position there
is potential for sparks and engagement
of components. Sparks could cause an
explosion or moving parts could accidentally
engage causing personal injury.
• Safely relieve all pressure in the hydraulic
system by placing the motion control levers
in neutral and shutting off the engine before
performing any work on the hydraulic system.
Be sure ignition switch is in the “OFF”
position before charging the battery.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
• Check all bolts frequently to maintain proper
tightness.
• Frequently check for worn or deteriorating
components that could create a hazard.
WARNING
Removing standard original equipment parts
and accessories may alter the warranty, traction,
and safety of the machine. Failure to use original
Exmark parts could cause serious injury or
death. Making unauthorized changes to the
engine, fuel or venting system, may violate EPA
and CARB regulations.
Replace all parts including, but not limited to,
tires, belts, blades, and fuel system components
with original Exmark parts.
9
Safety
Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.
• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• Safety signs may be affixed by peeling off the
backing to expose the adhesive surface. Apply
only to a clean, dry surface. Smooth to remove
any air bubbles.
• Familiarize yourself with the following safety signs
and instruction labels. They are critical to the safe
operation of your Exmark commercial mower.
1-303508
109-3148
1-403005
115-4186
1.
2.
3.
4.
5.
6.
106-5517
1. Warning—do not touch the hot surface.
10
Interval
Power Take-off (PTO)
Parking brake
Neutral
Operator presence switch
Battery
Safety
116-4270
116-0404
116-4271
116-3267
116-3290
116-4298
11
Safety
116-1887
1. Fast
2. Slow
3. Neutral
4. Reverse
116-4647
116-4648
1. PTO-on
2. PTO-off
3. Fast
4. Slow
5. Choke-on
6. Choke-off
12
Specifications
Specifications
Model Numbers
Serial Nos: 920,000 and Higher
VT18KA363; VT18KA363CA
Systems
• PTO must be disengaged and motion control
levers in neutral to start engine. (It is not
necessary for the operator to be on the platform
to start the engine.)
• Mower blades will stop if the right side motion
control lever is moved or released into the PTO
disengage position.
• Engine will stop if the motion control levers are
moved from the neutral position with the park
brake engaged.
Engine
• Engine Specifications: See your Engine Owner’s
Manual
• Engine Oil Type: Exmark 4–Cycle Premium
Engine Oil
• RPM: Full Speed: 3600 ±100 RPM (No Load)
Fuel System
• Capacity: 8.0 gal. (30.2 L)
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher; containing no more than 10%
methanol or ethanol.
• Fuel Filter: Replaceable In-line
• Fuel Shut-Off Valve: 1/4 turn increments
Operator Controls
Steering Control: Fingertip drive control levers
provide independent speed control, braking and
neutral to each drive wheel for moving forward or
reverse, stopping, and power turning.
Transmission
Electrical System (Electric Start)
•
•
•
•
•
•
• Two Hydro Gear variable displacement high
efficiency pumps independently coupled to two
high efficiency Parker/Ross wheel drive motors.
• Hydraulic Oil: Use Exmark Premium Hydro Oil.
• Hydraulic Oil Capacity: 2.4 qt. (2.2 L)
• Hydraulic Filter is replaceable cartridge type.
Charging System: Flywheel Alternator
Charging Capacity: Kawasaki: 15 amps
Battery Type: BCI Group U1
Battery Voltage: 12 Volt
Polarity: Negative Ground
Fuses:
– 30 amp main fuse
– 25 amp charging system fuse
– 10 amp PTO fuse
– 15 amp accessory fuse
P/N 109-4180: 25 microns, 10 psi bypass
(Summer use above 32°F (0°C))
P/N 1-523541: 40 microns, 18 psi bypass (Winter
use below 32°F (0°C))
• Speeds:
– 0-8.0 mph (13 km/hr) forward.
– 0-4.0 mph (6 km/hr) reverse.
• Drive wheels release valves allow machine to be
moved when engine is not running.
Safety Interlock System
• LCD indicators appear for the park brake, drive
levers, and operator presence in the message
display on the front control panel.
Wheel Drive System
Note: Because the PTO must be disengaged
to start the engine, the LCD indicator will not
illuminate at this time.
Drive wheels are direct coupled to Parker wheel drive
motors with 1 inch (25.4 mm) tapered shaft.
13
Specifications
Tires & Wheels
Overall Height:
Drive
Front Caster
Pneumatic
(Air-Filled)
SemiPneumatic
Quantity
2
2
Tread Width: (Outside to Outside of
Tires, Widthwise)
Tread
Kenda K500
Smooth
37.6 inches (95.5 cm)
Size
18x 8.50–8
11 x 4.00-5
Ply Rating
4
Curb Weight:
Pressure
14 psi
(97 kPa)
800 lb (363 kg)
51.5 inches (130.8 cm)
Note: Weights will vary slightly depending on
engine.
Cutting Deck
•
•
•
•
•
•
•
•
Cutting Width: 36 inches (91.4 cm)
Discharge: Side
Blade Size: (2 ea.): 18.00 inches (45.7 cm)
Blade Spindles: Solid steel spindles with 1.00 inch
(25.4 mm) I.D. bearings.
Deck Drive:
– Electric clutch mounted on engine shaft.
– Blades driven by one belt (w/self-tensioning
idlers).
Deck: Full floating deck is attached to support
frame, removable for service. Deck design allows
for bagging, mulching or side discharge.
Deck Depth: 5.0 inches (12.7 cm)
Cutting Height Adjustment:
Torque Requirements
Adjusts from 1 inch (2.5 cm) to 5 inches (12.7 cm)
in 1/4 inch (6.4 mm) increments
• Mulching Kit: Optional
• Bagger: Optional
Dimensions
Overall Width:
Deflector Up
39.1 inches (99.3 cm)
Deflector Down
48.0 inches (121.9 cm)
Overall Length:
Platform Up
61.5 inches (156.2 cm)
Platform Down
74.0 inches (188.0 cm)
14
Bolt Location
Torque
Cutter Housing Spindle
Nut
130-160 ft-lb
(176-217 N-m)
Blade Mounting Bolt
(lubricate with anti-seize)
50-60 ft-lb (68-81 N-m)
Engine Deck/Mower
Deck Support Mount
Bolts
30-35 ft-lb (41-47 N-m)
Engine Mounting Bolts
17-23 ft-lb (23-31 N-m)
Wheel Lug Nuts
90-95 ft-lb (122-129 N-m)
Wheel Hub Nuts
175-225 ft-lb
(237-305 N-m)
Wheel Motor Mounting
Bolts
67-83 ft-lb (91-113 N-m)
Operation
Product Overview
Operation
Note: Determine the left and right sides of the
machine from the normal operating position.
Controls
Motion Control Levers
The motion control levers, located on each side of the
top console, control the forward and reverse motion
of the machine.
Moving the levers forward or backward turns
the wheel on the same side forward or reverse
respectively. Wheel speed is proportional to the
amount the lever is moved.
Figure 3
1. Platform
2. Fuel Cap
3. Height-of-Cut
Adjustment
4. Motion control levers
5. Engine Controls
6. Park Brake Lever
Figure 4
1. LH Motion control lever
2. RH Motion control lever
3. RH Motion control
lever in PTO disengage
position
4. Reverse
5. Rear reference bar
6. Neutral
7. Forward
8. Front reference/Speed
control bar
9. Front of unit
When the motion control levers are in the neutral
position, the LCD indicator appears in the message
display on the front control console (see Figure 5
and Figure 7).
When the motion control levers are in the neutral
position and the RH motion control lever is moved
into the PTO disengage position, the mower blades
will disengage.
15
Operation
Choke Control
The front reference/speed control bar controls the
maximum forward speed and is infinitely variable
from approximately 4–8 mph (6–13 km/hr).
Located on the front control console right of the
PTO engagement switch.
Park Brake Lever
The choke is used to aid in starting a cold engine.
Moving the choke lever forward will put the choke in
the “ON” position and moving the choke lever to the
rear, to the detent, will put the choke in the “OFF”
position. Do Not run a warm engine with choke in
the “ON” position.
Located on left side of unit, just to the front of the
LH motion control lever (see Figure 5).
The brake lever engages a parking brake on the drive
wheels.
Note: The LCD indicator appears in the message
display on the front console when the park brake is
engaged (see Figure 5 and Figure 7).
To engage the brake, pull the lever rearward.
To release, push the lever forward.
When parking on a steep slope, the wheels must be
chocked or blocked in addition to the brake being
engaged. The unit must be tied down and brake
engaged when transporting.
Park brake must be disengaged before moving
motion control out of neutral or engine will kill.
Ignition Switch
Figure 5
1.
2.
3.
4.
Choke
RH Motion control lever
LH Motion control lever
Front Reference/Speed
Control Bar
5. Park brake lever
6. Message display
7. Ignition switch
8.
9.
10.
11.
Located on the LH side of the front control console
(see Figure 5).
Fuel gauge
PTO engagement switch
Throttle
Deck lift handle
The ignition switch is used to start and stop the
engine. The switch has three positions “OFF”, “ON”
and “START”. Insert key into switch and rotate
clockwise to the “ON” position. Rotate clockwise to
the next position to engage the starter (key must be
held against spring pressure in this position). Allow
the key to return to the “ON” position immediately
after the engine starts.
12. Fuel cap
13. Height-of-cut pin
14. Platform latch
Throttle Control
Located on the RH side of the front control console
(red lever) (see Figure 5).
The throttle is used to control engine speed. Moving
the throttle lever forward will increase engine speed
and moving the throttle lever to the rear will decrease
engine speed. Moving the throttle forward into the
detent is full throttle.
Figure 6
1. Off
2. On
Front Reference/Speed Control Bar
Located in front of the motion control levers (see
Figure 5).
3. Start
Note: To start the engine, place the LH motion
control lever in neutral, the RH motion control
16
Operation
Fuel Gauge
in PTO disengage position, and the PTO switch
disengaged. (It is not necessary for the operator to
be on the platform.)
Located on the top left side of the tank (see Figure 5).
The fuel gauge monitors the amount of fuel in the
tank.
Hour Meter
Located on the LH side of the front control console
in the message display (see Figure 5 and Figure 7).
Drive Wheel Release Valves
Located on the right front corner of the hydrostatic
pumps.
The hour meter records the number of hours that
the engine has run.
Drive wheel release valves are used to release the
hydrostatic drive system to allow the machine to be
moved by hand without the engine running.
With a 5/8 wrench, turn both valves one turn
counterclockwise to release the drive system.
Turn clockwise to reset the drive system. Do Not
overtighten. Do Not tow machine.
PTO Engagement Switch
Figure 7
1. LCD Indicators
2. Low voltage indicator light
3. Hour/Voltage display
Located on front control panel (see Figure 5).
Switch must be pulled out (up) to engage the blades.
Switch is pushed in to disengage the blades.
The hour meter is recording when the decimal point
is flashing in Hour/Voltage display.
The LCD indicator will appear when the PTO switch
is engaged (see Figure 7).
Hours are displayed when the key is off or when the
machine is running.
Low Voltage Indicator
Note: If the ignition key is turned to the “ON”
position for a few seconds before cranking the
engine, the battery voltage will display in the area
where the hours are normally displayed.
Located on the front control panel in the message
display (see Figure 5 and Figure 7).
A low voltage condition (less than 12.3 volts) exists
when the low voltage indicator light appears on the
message display while the engine is running.
Note: The LCD indicators appear when each
control meets the “safe to start” mode. Because the
PTO must be disengaged to start the engine, the
LCD indicator will not illuminate at this time.
If the ignition key is turned to the “ON” position for
a few seconds before cranking the engine, the battery
voltage will display in the area where the hours are
normally displayed.
Fuel Shut-Off Valve
Note: The indicator normally appears when the
engine is off and the key switch is turned to the
“ON” position.
Located on the RH side of the control tower behind
the knee cushion.
The fuel shut-off valve is used to shut off the fuel
when the machine will not be used for a few days,
during transport to and from the jobsite, and when
parked inside a building.
Deck Lift Handle
Located on the RH of the front control panel.
Pull the handle rearward to raise the cutting deck.
Allow the handle to move forward to lower the
cutting deck to the cut height that has been set.
Align valve handle with the fuel line to open. Rotate
90° to close.
17
Operation
Important: Do Not crank the engine
continuously for more than ten seconds at a
time. If the engine does not start, allow a 60
second cool-down period between starting
attempts. Failure to follow these guidelines
can burn out the starter motor.
Pull the handle rearward and to the right to latch
the cutting deck into the raised transport position
(Figure 5).
Pre-Start
Fill fuel tank on level ground. For best results use
only clean, fresh regular grade unleaded gasoline with
an octane rating of 87 or higher.
7. If the choke is in the “ON” position, gradually
return choke to the “OFF” position as the engine
warms up.
Important: Never use methanol, gasoline
containing methanol, gasohol containing more
than 10% ethanol, premium gasoline, or white
gas because the fuel system could be damaged.
PTO Engagement
DANGER
Do Not add oil to gasoline.
The rotating blades under the mower deck are
dangerous. Blade contact can cause serious
injury or kill you.
Do Not overfill fuel tank. Fill the fuel tank to the
bottom of the filler neck. The empty space in the
tank allows gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine or emission
system.
Do Not put hands or feet under the mower or
mower deck when the blades are engaged.
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
DANGER
An uncovered discharge opening will allow
objects to be thrown in an operator’s or
bystander’s direction. Also, contact with the
blade could occur. Thrown objects or blade
contact can cause serious injury or death.
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
Operating Instructions
Never operate the mower with the discharge
deflector raised, removed, or altered unless there
is a grass collection system or mulch kit in place
and working properly.
Open the Fuel Shut-Off Valve
Rotate the valve and align with the fuel line to open.
Starting the Engine
The PTO switch engages the cutting blades. Be sure
all persons are clear of mower deck and discharge
area before engaging the PTO.
1. Leave the LH motion control lever in neutral and
the RH lever in the PTO disengage position (see
Figure 4).
2. Pull the parking brake lever rearward to engage
the parking brake.
3. Push in (down) on the PTO switch to the
“disengage” position.
4. Place the throttle midway between the “SLOW”
and “FAST” positions.
5. On a cold engine, push the choke lever forward
into the “ON” position.
1. Set throttle to “MIDWAY” position.
2. Release the parking brake.
3. Move the right side motion control lever to the
center, operate position.
4. Continue holding the right side motion control
lever in the center, operate position and pull up
on the blade control switch (PTO) and release.
The clutch should engage and the mower blades
begin rotating.
On a warm engine, leave the choke in the “OFF”
position.
6. Turn ignition switch to the “START” position.
Release the switch as soon as the engine starts.
5. Place the throttle in the “FAST” position to begin
mowing.
18
Operation
Disengaging the PTO
(pushed forward) before the motion control
levers can be moved or the engine will stop.
1. Set the throttle midway between the “SLOW”
and “FAST” positions.
2. Push down on the PTO switch to disengage the
blades.
When the RH motion control lever is positioned
fully outward (apart), the drive system is in the PTO
disengage position (Figure 8).
Note: The PTO will be disengaged by releasing
the right side motion control lever and allowing it
to spring outward to the PTO disengage position.
The PTO will not re-engage when the RH motion
control lever is moved out of the PTO disengage
position without pulling up on the PTO switch.
To fully disengage the PTO, continue to push the
switch downward.
Note: The “N” LCD indicator appears when the
RH lever is in the PTO disengage position.
When the RH motion control lever is moved directly
inward (together) the drive system is in the neutral
operate position.
Stopping the Engine
1. Bring the unit to a full stop.
2. Move the motion control levers to the neutral
position; move the RH control lever out to the
PTO disengage position.
3. Place the throttle midway between the “SLOW”
and “FAST” positions.
4. Push down on the PTO switch to disengage the
blades.
5. Engage the parking brake.
6. Allow the engine to run for a minimum of 15
seconds, then turn the ignition switch to the
“OFF” position to stop the engine.
7. Remove the key to prevent children or other
unauthorized persons from starting engine.
8. Close the fuel shut-off valve when the machine
will not be in use for a few days, when
transporting, or when the unit is parked inside
a building.
Figure 8
1. LH Motion control lever
2. RH Motion control lever
3. RH Motion control
lever in PTO disengage
position
4. Reverse
5. Rear reference bar
6. Neutral
7. Forward
8. Front reference/Speed
control bar
9. Front of unit
Driving Forward
1. Make sure the motion control levers are in the
neutral position.
2. Release the parking brake.
3. To move forward in a straight line, move both
levers forward with equal pressure.
Driving the Machine
CAUTION
Machine can spin very rapidly by positioning one
lever too much ahead of the other. Operator may
lose control of the machine, which may cause
damage to the machine or injury.
• Use caution when making turns.
• Slow the machine down before making sharp
turns.
Important: To begin movement (forward or
backward), the brake lever must be disengaged
19
Operation
Figure 10
To turn left or right, release pressure on the
motion control lever toward the desired turn
direction.
Figure 9
3. To stop, position both motion control levers in
the neutral operate position.
To turn left or right, pull the motion control lever
back toward neutral in the desired turn direction.
Adjusting the Front Reference/Speed
Control Bar
The machine will move faster the farther the
motion control levers are moved from the neutral
position.
Adjust the front reference/speed control bar for
desired maximum forward speed.
4. To stop, position both motion control levers in
the neutral operate position.
1. Stop the machine and move the motion control
levers to the neutral position.
Driving in Reverse
2. Disengage the PTO.
1. Move the motion control levers to the neutral
operate position.
3. Unlock the handles on both sides of the control
tower by pulling outward (see Figure 11).
2. To move rearward in a straight line, slowly move
both levers rearward with equal pressure.
20
Operation
WARNING
The operator platform is heavy and may cause
injury when lowering and raising the operator
platform. The platform may suddenly drop if not
supported when the latch pin is pulled out.
• Do Not put your hands or fingers in the
platform pivot area when lowering or raising
the operator platform.
• Make sure the platform is supported when
the latch pin is pulled out.
• Make sure the latch secures the platform
when folding it in the up position. Push it
tight against the cushion for the latch pin to
lock into place.
Figure 11
1. Front of the machine
2. Control tower
3. Unlock
4. Forward position —
faster
5. Backward position —
slower
6. Lock
Operating the Machine with the
Platform Up
Operating the machine with the platform up is
recommended when:
4. Move the bar forward to obtain the fastest speed.
• Mowing near drop-off ’s
Move the bar backward to obtain the slowest
speed.
• Mowing small areas where the machine is too long
5. On both sides, rotate and push the handles inward
to lock the handles against the control tower.
• Areas with low over hanging branches or obstacles
• Loading the machine for transport
Important: Make sure the handles are locked
in place so the front reference/speed control
bar does not move during operation.
• Unloading the machine after transport
• Driving up or backing down slopes or ramps.
• Turning in tight areas where platform may contact
obstacles.
Operating the Platform
The machine can be used with the platform in the
up or down position. It is the operator’s preference
on which position to use.
To raise the platform, pull the bottom upward and
push it tight against the cushion. The latch pin knob
will snap inward to lock the platform into place (see
Figure 12).
21
Operation
Adjusting the Cutting Height
The cutting height of the mower deck is adjusted
from 1 to 5 inches (2.5 cm to 12.7 cm) in 1/4 inch
(6.4 mm) increments.
1. Stop the machine and move the motion control
levers to the neutral position.
2. Disengage the PTO.
3. Raise and lock the deck to the 5 inch (12.7 cm)
transport position.
The deck is raised by pulling the deck lift handle
rearward and to the right to place it into the
transport lock position.
Figure 12
1. Platform
2. Raise upward
3. Latch pin knob snaps inward
Operating the Machine with the
Platform Down
Operating the machine with the platform down is
recommended when:
• Mowing most areas
Figure 14
• Driving down slopes
1. Transport lock position
To lower the platform, push the platform forward
against the cushion to release pressure on the latch
pin, pull the knob outward, and lower the platform
(see Figure 13).
2. RH Motion control lever
3. Front reference/speed
control bar
4. Deck lift handle
Note: When changing the cutting height
positions, always come to a complete stop
and disengage the PTO.
4. Insert the height adjustment pin into the hole
corresponding to the desired cutting height.
See the decal on the side of the deck lift plate for
cut heights (reference Figure 15).
5. Pull the deck lift handle rearward and to the left
and slowly allow the deck to lower to the cutting
height.
Figure 13
1. Pull latch pin knob outward
2. Platform
3. Lower
22
Operation
WARNING
Loading a unit on a trailer or truck increases
the possibility of backward tip-over. Backward
tip-over could cause serious injury or death.
• Use extreme caution when operating a unit
on a ramp.
• Use only a single, full width ramp; Do Not
use individual ramps for each side of the unit.
• If individual ramps must be used, use enough
ramps to create an unbroken ramp surface
wider than the unit.
Figure 15
1. Height adjustment pin
2. Height of cut holes
• Do Not exceed a 20 degree angle between
ramp and ground or between ramp and trailer
or truck.
3. Deck lift handle
Transporting
• Avoid sudden acceleration while driving unit
up a ramp to avoid tipping backward.
Transporting a Unit
• Avoid sudden deceleration while backing unit
down a ramp to avoid tipping backward.
Use a heavy-duty trailer or truck to transport the
machine. Lock brake and block wheels. Securely
fasten the machine to the trailer or truck with straps,
chains, cable, or ropes. Be sure that the trailer or truck
has all necessary lighting and marking as required by
law. Secure a trailer with a safety chain.
Loading a Unit
Use extreme caution when loading units on trailers or
trucks. One full width ramp that is wide enough to
extend beyond the rear tires is recommended instead
of individual ramps for each side of the unit. With
the platform up, a full width ramp provides a surface
to walk on behind the unit. If it is not possible to use
one full width ramp, use enough individual ramps to
simulate a full width continuous ramp.
CAUTION
This unit does not have proper turn signals,
lights, reflective markings, or a slow moving
vehicle emblem. Driving on a street or roadway
without such equipment is dangerous and
can lead to accidents causing personal injury.
Driving on a street or roadway without such
equipment may also be a violation of State laws
and the operator may be subject to traffic tickets
and/or fines.
Ramp should be long enough so that the angles
between the ramp and the ground and the ramp
and the trailer or truck do not exceed 20 degrees. A
steeper angle may cause mower deck components
to get caught as the unit moves from ramp to trailer
or truck. Steeper angles may also cause the unit to
tip backward. If loading on or near a slope, position
the trailer or truck so it is on the down side of the
slope and the ramp extends up the slope. This will
minimize the ramp angle. The trailer or truck should
be as level as possible.
Do Not drive a unit on a public street or roadway.
Important: Do Not attempt to turn the unit
while on the ramp, you may lose control and
drive off the side.
Avoid sudden acceleration when driving up a ramp
and sudden deceleration when backing down a ramp.
Both maneuvers can cause the unit to tip backward.
23
Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could seriously
injure you or other bystanders.
The engine can become very hot. Touching a hot
engine can cause severe burns.
Allow the engine to cool completely before
service or making repairs around the engine area.
Remove the key from the ignition switch, engage
parking brake, and pull the wire(s) off the spark
plug(s) before you do any maintenance. Also
push the wire(s) aside so it does not accidentally
contact the spark plug(s).
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 5 hours
• Change the engine oil.
After the first 100 hours
• Check the wheel hub torque specification.
• Check the wheel lug nuts.
After the first 250 hours
• Change the hydraulic filter and fluid.
Before each use or daily
•
•
•
•
•
•
•
Check the engine oil level.
Check the mower blades.
Check the safety interlock system.
Check for loose hardware.
Clean the engine and exhaust system area.
Clean the grass and debris build-up from the machine and cutting deck.
Clean the grass build-up from under the deck.
Every 40 hours
• Check the hydraulic oil level.
• Check the condition of the belts.
Every 50 hours
• Check the tire pressures.
• Check spark arrester (if equipped).
Every 80 hours
• Remove engine shrouds and clean cooling fins.
Every 100 hours
• Change the engine oil. (May need more often under severe conditions.)
Every 160 hours
• Check the spark plugs.
Every 200 hours
• Grease the lift linkage pivots.
Every 250 hours
• Replace the primary air cleaner element — check secondary air cleaner element; replace if
dirty. (May need more often under severe conditions. See the Engine manual for additional
information.)
Every 500 hours
• Replace the secondary air cleaner element. (May need more often under severe conditions.
See the Engine manual for additional information.)
• Change the hydraulic filter and fluid (Every 250 hours/yearly if using Mobil 1 15W50)
• Check the wheel hub torque specification.
• Check the wheel lug nuts.
24
Maintenance
Maintenance Service
Interval
Monthly
Yearly
Maintenance Procedure
• Check the battery charge.
• Grease the front caster pivots.
• Grease the deck belt idler pivot.
• Lubricate the caster wheel hubs.
Periodic Maintenance
storage when the open circuit voltage drops to 12.4
volts.
Check Engine Oil Level
Note: To prevent damage due to freezing, battery
should be fully charged before putting away for
winter storage.
Service Interval: Before each use or daily
1. Stop engine and wait for all moving parts to stop.
Make sure unit is on a level surface.
2. Check with engine cold.
3. Clean area around dipstick. Remove dipstick and
wipe oil off. Reinsert the dipstick and push it all
the way down into the tube. Do Not screw into
place. Remove the dipstick and read the oil level.
4. If the oil level is low, wipe off the area around the
oil fill cap, remove cap and add oil to the “FULL”
mark on the dipstick. Exmark 4-Cycle Premium
Engine Oil is recommended; refer to the Engine
Owner’s manual for an acceptable alternative. Do
Not overfill.
Check the voltage of the battery with a digital
voltmeter. Locate the voltage reading of the battery in
the table and charge the battery for the recommended
time interval to bring the charge up to a full charge
of 12.6 volts or greater.
Important: Make sure the negative battery cable
is disconnected and the battery charger used for
charging the battery has an output of 16 volts and
7 amps or less to avoid damaging the battery (see
chart for recommended charger settings).
Important: Do Not operate the engine with the
oil level below the “LOW” (or “ADD”) mark on
the dipstick, or over the “FULL” mark.
Check Battery Charge
Service Interval: Monthly
WARNING
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the State of
California to cause cancer and reproductive
harm. Wash hands after handling.
Voltage
Reading
Percent
Charge
Maximum
Charger
Settings
Charging
Interval
12.6 or
greater
100%
16 volts/7
amps
No
Charging
Required
12.4 – 12.6
75–100%
16 volts/7
amps
30 Minutes
12.2 – 12.4
50–75%
16 volts/7
amps
1 Hour
12.0–12.2
25–50%
14.4 volts/4 2 Hours
amps
11.7–12.0
0–25%
14.4 volts/4 3 Hours
amps
11.7 or less
0%
14.4 volts/2 6 Hours or
More
amps
Recommended Jump
Starting Procedure
Allowing batteries to stand for an extended period of
time without recharging them will result in reduced
performance and service life. To preserve optimum
battery performance and life, recharge batteries in
Service Interval: As required
1. Check the weak battery for terminal corrosion
(white, green, or blue “snow”), it must be cleaned
25
Maintenance
Note: Be sure the vent caps are tight and level.
Place a damp cloth, if available, over any vent
caps on both batteries. Be sure the vehicles do
not touch and that both electrical systems are
off and at the same rated system voltage. These
instructions are for negative ground systems only.
off prior to jump starting. Clean and tighten
connections as necessary.
CAUTION
Corrosion or loose connections can cause
unwanted electrical voltage spikes at anytime
during the jump starting procedure.
3. Connect the positive (+) cable to the positive (+)
terminal of the discharged battery that is wired to
the starter or solenoid as shown in Figure 16.
Do Not attempt to jump start with loose or
corroded battery terminals or damage to the
engine may occur.
DANGER
Jump starting a weak battery that is cracked,
frozen, has low electrolyte level, or an
open/shorted battery cell, can cause an
explosion resulting in serious personal injury.
Do Not jump start a weak battery if these
conditions exist.
Figure 16
1.
2.
3.
4.
5.
6.
7.
2. Make sure the booster is a good and fully charged
lead acid battery at 12.6 volts or greater. Use
properly sized jumper cables (4 to 6 AWG) with
short lengths to reduce voltage drop between
systems. Make sure the cables are color coded or
labeled for the correct polarity.
CAUTION
Positive (+) cable on discharged battery
Positive (+) cable on booster battery
Negative (–) cable on the booster battery
Negative (–) cable on the engine block
Booster battery
Discharged battery
Engine block
4. Connect the other end of the positive cable to the
positive terminal of the booster battery.
Connecting the jumper cables incorrectly
(wrong polarity) can immediately damage the
electrical system.
5. Connect the black negative (–) cable to the other
terminal (negative) of the booster battery.
Be certain of battery terminal polarity and
jumper cable polarity when hooking up
batteries.
6. MAKE THE FINAL CONNECTION ON
THE ENGINE BLOCK OF THE STALLED
VEHICLE (NOT TO THE NEGATIVE POST)
AWAY FROM THE BATTERY. STAND BACK.
Note: The following instructions are adapted
from the SAE J1494 Rev. Dec. 2001 – Battery
Booster Cables – Surface Vehicle Recommended
Practice (SAE – Society of Automotive
Engineers).
7. Start the vehicle and remove the cables in the
reverse order of connection (the engine block
(black) connection is the first to disconnect).
Release the Cushion for Rear
Access
WARNING
Batteries contain acid and produce explosive
gases.
Service Interval: As required
• Shield the eyes and face from the batteries
at all times.
The cushion can be released for rear access to the
machine for maintenance or adjustment.
• Do Not lean over the batteries.
1. Lower the platform.
26
Maintenance
2. Remove the hairpin on each side of the cushion.
3. Push the plastic slides to the inside.
4. Remove the cushion and lower it to the platform.
5. Perform any maintenance or adjustment on the
machine.
6. Raise the cushion and slide it onto the pins on
both sides of the machine (Figure 17).
7. Push the plastic slides into the cushion bracket
and secure them with a hairpin.
Figure 18
1. Install bushing in blade prior to installing bushing in
spindle.
B. Install bushing/blade assembly into spindle.
Figure 17
1.
2.
3.
4.
Cushion bracket
Plastic slide
Pin
Hairpin
Check Mower Blades
Service Interval: Before each use or daily
Figure 19
1. Use wrench here for
blade installation. This
nut has been torqued to
130-160 ft-lb (176–217
N-m)
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Lift deck and secure in raised position as stated in
the Clean Grass Build-Up Under Deck section.
3. Inspect blades and sharpen or replace as required.
4. Reinstall the blades (if they were removed) in the
following order:
2. Torque to 50-60 ft-lb
(68-81 N-m) Apply
lubricant to threads
as needed to prevent
seizing. Copper-based
anti-seize preferable.
Grease acceptable
substitute.
C. Apply lubricant to threads of blade bolt as
needed to prevent seizing. Copper-based
anti-seize preferable. Grease acceptable
substitute. Install blade bolt finger tight. Place
wrench on the top spindle nut then torque the
blade bolts to 50-60 ft-lb (68-81 N-m).
A. Install bushing through blade with bushing
flange on bottom (grass) side of blade.
27
Maintenance
5. Move the right side motion control lever to the
center, operating position.
6. Continue holding the right side motion control
lever in the center, operating position and pull up
on the blade control switch (PTO) and release.
The clutch should engage and the mower blades
begin rotating.
7. Move or release the right side motion control
lever into the neutral position. The blades
should stop rotating and the engine should
continue running.
8. Push the blade control switch down and move
the right side motion control lever to the center,
operating position.
9. Continue holding the right side motion control
lever in the center, operating position and pull up
on the blade control switch (PTO) and release.
The clutch should engage and the mower blades
begin rotating.
10. Push the blade control switch (PTO) down to the
off position. The blades should stop rotating.
11. With the engine running, pull up the blade control
switch (PTO) and release without holding right
side motion control lever to the center, operating
position. The blades should not rotate.
WARNING
Incorrect installation of the blade or
components used to retain the blade can
be dangerous. Failure to use all original
components and assembled as shown could
allow a blade or blade component to be
thrown out from under the deck resulting in
serious personal injury or death.
Always install the original Exmark blades,
blade bushings, and blade bolts as shown.
Check Safety Interlock
System
Service Interval: Before each use or daily
CAUTION
If safety interlock switches are disconnected
or damaged the machine could operate
unexpectedly causing personal injury.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches
before operating the machine.
Understanding the Safety Interlock System
Check for Loose Hardware
The safety interlock system is designed to prevent the
mower blades from rotating unless:
• The right side motion control lever is moved to
the center, operating position.
• The blade control switch (PTO) is pulled on.
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Visually inspect machine for any loose hardware
or any other possible problem. Tighten hardware
or correct the problem before operating.
The safety interlock system is designed to stop
the mower blades if you move or release the right
side motion control lever into the PTO disengage
position.
• The right side motion control lever is moved to
the center, operating position, the parking brake
is engaged, and the blade control switch (PTO) is
pulled on.
Service Air Cleaner
Service Interval: Every 250 hours—Replace
the primary air cleaner
element — check
secondary air cleaner
element; replace if dirty.
(May need more often
under severe conditions.
See the Engine manual for
additional information.)
Every 500 hours—
Replace the secondary
air cleaner element. (May
Checking the Safety Interlock System
1. Start the engine.
2. Set the parking brake.
3. Move the motion control levers forward.
The engine should initiate shutdown after
momentary pause.
4. Start the engine and release the parking brake.
28
Maintenance
need more often under
severe conditions. See
the Engine manual for
additional information.)
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. See the Engine Owner’s Manual for maintenance
instructions.
1. Stop engine and wait for all moving parts to stop,
and remove key. Engage parking brake.
2. Clean area around hydraulic reservoir cap and
remove cap. Oil level should be to the top of the
baffle inside the tank. If not, add oil. Use Exmark
Premium Hydro Oil. Replace hydraulic reservoir
cap and tighten until snug. Do Not overtighten.
Note: The baffle is labeled “HOT” and
“COLD”. The oil level varies with the
temperature of the oil. The “HOT” level shows
the level of oil when it is at 225°F (107°C). The
“COLD” level shows the level of the oil when
it is at 75°F (24°C). Fill to the appropriate level
depending upon the temperature of the oil. For
example: If the oil is about 150°F (65°C), fill to
halfway between the “HOT” and “COLD” levels.
If the oil is at room temperature (about 75°F
(24°C)), fill only to the “COLD” level.
Change Engine Oil
Service Interval: After the first 5 hours
Every 100 hours (May
need more often under
severe conditions.)
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Drain oil while engine is warm from operation.
3. The oil drain valve is located on the left side of
the engine.
4.
5.
6.
7.
Check Tire Pressures
Service Interval: Every 50 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Check tire pressure in drive tires.
3. Inflate drive tires to 12–14 psi (83–97 kPa).
4. Semi-pneumatic caster tires do not need to be
inflated.
Place the pan under the machine to catch the
oil. Install the clear plastic tube, located in the
literature pack, onto the oil drain valve. Loosen
the oil drain valve and allow the oil to drain.
Tighten the oil drain valve and remove and retain
the clear plastic tube.
Replace the oil filter per the Engine Owner’s
Manual. Clean around the oil filter and carefully
remove the filter by unscrewing it. Make sure no
oil drains onto the belt drive or clutch through
the holes in the engine deck. Before the new
filter is installed, apply a thin coating of Exmark
4–Cycle Premium Engine Oil on the surface of
the rubber seal. Turn filter clockwise until rubber
seal contacts the filter adapter, then tighten filter
an additional 2/3 to 3/4 turn.
Clean around oil fill cap and remove cap. Fill to
specified capacity and replace cap.
Use oil recommended in the Check Engine Oil
Level section. Do Not overfill. Start the engine
and check for leaks. Stop engine and recheck oil
level.
Wipe up any spilled oil from engine deck
mounting surfaces.
Check Condition Of Belts
Service Interval: Every 40 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Look on the top side of the cutting deck to check
the mower blade drive belt condition.
3. Look under the engine deck to check the pump
drive belt condition.
4. Check all idler arms to be sure they pivot freely.
Lubricate Grease Fittings
Note: See chart for service intervals.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Lubricate fittings with NGLI grade #2
multi-purpose gun grease.
Check Hydraulic Oil Level
Service Interval: Every 40 hours
29
Maintenance
Refer to the following chart for fitting locations
and lubrication schedule.
Lubrication Chart
Fitting
Locations
Initial
Pumps
Number of
Places
Service
Interval
1–2
3
Every 200
hours
2. Deck Belt Idler
Pivot
1
1
Yearly
3. Front Caster
Wheel Hubs
*0
2
*Yearly
4. Front Caster
Pivots
*0
1. Lift Linkage
Pivots
Figure 20
1. Seal guard
2
*Yearly
2. Spacer nut with wrench
flats
2. Remove caster wheel from caster forks.
3. Remove seal guards from the wheel hub.
4. Remove one of the spacer nuts from the axle
assembly in the caster wheel. Note that thread
locking adhesive has been applied to lock the
spacer nuts to the axle. Remove the axle (with
the other spacer nut still assembled to it) from
the wheel assembly.
5. Pry out seals, and inspect bearings for wear or
damage and replace if necessary.
6. Pack the bearings with a NGLI grade #1
multi-purpose grease.
7. Insert one bearing, one new seal into the wheel.
* See step 3 for special lubrication instructions on
the front caster pivots.
Note: Seals (Exmark P/N 103-0063) must be
replaced.
8. If the axle assembly has had both spacer nuts
removed (or broken loose), apply a thread locking
adhesive to one spacer nut and thread onto the
axle with the wrench flats facing outward. Do
Not thread spacer nut all of the way onto the end
of the axle. Leave approximately 1/8 inch (3 mm)
from the outer surface of the spacer nut to the
end of the axle inside the nut.
9. Insert the assembled nut and axle into the wheel
on the side of the wheel with the new seal and
bearing.
10. With the open end of the wheel facing up, fill
the area inside the wheel around the axle full of
NGLI grade #1 multi-purpose grease.
11. Insert the second bearing and new seal into the
wheel.
12. Apply a thread locking adhesive to the 2nd spacer
nut and thread onto the axle with the wrench flats
facing outward.
3. Lubricate front caster pivots once a year. Remove
hex plug and cap. Thread grease zerk in hole and
pump with grease until it oozes out around top
bearing. Remove grease zerk and thread plug back
in. Place cap back on.
Lubricate Caster Wheel Hubs
Service Interval: Yearly
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
30
Maintenance
13. Torque the nut to 75-80 in-lb (8-9 N-m), loosen,
then re-torque to 20-25 in-lb (2-3 N-m). Make
sure axle does not extend beyond either nut.
2. Carefully clean area around filter. It is important
that no dirt or contamination enter hydraulic
system.
14. Reinstall the seal guards over the wheel hub and
insert wheel into caster fork. Reinstall caster bolt
and tighten nut fully.
3. Unscrew filter to remove and allow oil to drain
from reservoir.
Important: Before reinstalling new filter, fill
it with Exmark Premium Hydro oil and apply
a thin coat of oil on the surface of the rubber
seal.
Important: To prevent seal and bearing damage,
check the bearing adjustment often. Spin the
caster tire. The tire should not spin freely
(more than 1 or 2 revolutions) or have any side
play. If the wheel spins freely, adjust torque on
spacer nut until there is a slight amount of drag.
Reapply thread locking adhesive.
Turn filter clockwise until rubber seal contacts the
filter adapter, then tighten the filter an additional
2/3 to 3/4 turn.
4. Fill reservoir as stated in Check Hydraulic Oil
Level.
Check Spark Plugs
Exmark Premium Hydro Oil is recommended.
Refer to the chart for an acceptable alternative:
Service Interval: Every 160 hours
Remove spark plugs, check condition and reset gaps,
or replace with new plugs. See Engine Owner’s
Manual.
Change Fuel Filter
Change Interval
Exmark Premium Hydro
Oil (Preferred)
500 Hours
Mobil 1 15W50
250 Hours
5. Loosen filter 1/2 turn and allow a small amount
of oil to leak from the oil filter (this allows air to
be purged from the oil filter and supply hose from
the hydraulic reservoir). Turn filter clockwise
until rubber seal contacts the filter adapter. Then
tighten the filter an additional 2/3 to 3/4 turn.
Service Interval: As required
A fuel filter is installed in the fuel line between the
fuel tank and the engine. Replace when necessary.
Replacement Filters
Kawasaki
Hydro Oil
Kawasaki
P/N 49019-7005
6. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
Change Hydraulic System
Filter and Fluid
CAUTION
Raising the mower for service or maintenance
relying solely on mechanical or hydraulic
jacks could be dangerous. The mechanical or
hydraulic jacks may not be enough support
or may malfunction allowing the unit to fall,
which could cause injury.
Service Interval: After the first 250 hours
Every 500 hours/Yearly
(whichever comes
first) thereafter
(Every 250 hours/Yearly if
using Mobil 1 15W50)
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
Note: Use only Exmark Part No. 109–4180 for
Summer use above 32°F (0°C) or P/N 1-523541 for
Winter use below 32°F (0°C) (Refer to Transmission
section in Specifications for filter specifications).
7. If either drive wheel does not rotate, one or both
of the charge pumps (located on the top of the
main pump as shown in Figure 21) may have lost
their “prime”. Refer to Hydraulic System Air
Purge section.
1. Stop engine, wait for all moving parts to stop, and
remove key or spark plug wire(s). Engage parking
brake.
31
Maintenance
Note: Do Not change hydraulic system oil (except
for what can be drained when changing filter), unless
it is felt the oil has been contaminated or been
extremely hot.
Changing oil unnecessarily could damage hydraulic
system by introducing contaminates into the system.
Note: It is necessary to lightly touch the charge
pump cap with your hand to check the pump
temperature. If the cap is too hot to touch, turn
off engine. The pumps may be damaged if the
pump becomes too hot.
If either drive wheel still does not rotate continue
with step 4.
Hydraulic System Air Purge
4. Thoroughly clean the area around each of the
charge pump housings.
5. To “prime” charge pump, loosen two hex socket
head capscrews (shown in Figure 21) 1 1/2 turns
only. Make sure engine is not running. Lift
the charge pump housing upward and wait for
a steady flow of oil to flow out from under the
housing. Retighten the capscrews. Do this for
both pumps.
Service Interval: As required
Air must be purged from the hydraulic system
when any hydraulic components, including oil
filter, are removed or any of the hydraulic lines are
disconnected.
The critical area for purging air from the hydraulic
system is between the oil reservoir and each
charge pump located on the top of each variable
displacement pump (Figure 21). Air in other parts of
the hydraulic system will be purged through normal
operation once the charge pump is “primed”.
Note: Hydraulic reservoir can be pressurized up
to 5 psi to speed this process.
6. If either drive wheel still does not rotate, stop
and repeat steps 4 and 5 above for the respective
pump. If wheels rotate slowly, the system may
prime after additional running. Check oil level
as stated in Check the Hydraulic Oil Level
section.
7. Allow unit to run several minutes after the charge
pumps are “primed” with drive system in the full
speed position. Check oil level as stated in Check
the Hydraulic Oil Level section.
8. Check hydro drive linkage adjustment as stated in
Hydro Drive Linkage Adjustment section in
Adjustments.
Figure 21
1. Charge pump cap
2. Loosen 1 1/2 turns only
Wheel Hub Nut Torque
Specification
1. Stop engine and wait for all moving parts to stop.
Raise the rear of the machine up onto jack stands
high enough to raise the drive wheels off the
ground.
2. Check oil level as stated in Check Hydraulic Oil
Level section.
3. Start engine and move throttle control ahead to
full throttle position. Move RH motion control
lever inward (together) and move both levers
forward with equal pressure.
Service Interval: After the first 100 hours
Every 500 hours thereafter
Torque the nut on the wheel motor tapered shaft to
175-225 ft-lb (237-305 N-m).
Note: Do Not use anti-seize compound on the
wheel hub.
Check Spark Arrester
(if equipped)
If either drive wheel does not rotate, it is possible
to assist the purging of the charge pump by
carefully rotating the tire in the forward position.
Service Interval: Every 50 hours
32
Maintenance
Dielectric Grease
WARNING
Hot exhaust system components may ignite
gasoline vapors even after the engine is stopped.
Hot particles exhausted during engine operation
may ignite flammable materials. Fire may result
in personal injury or property damage.
Dielectric grease is used on all blade type electrical
connections to prevent corrosion and loss of contact.
Do Not refuel or run engine unless spark arrester
is installed.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Wait for muffler to cool.
3. If any breaks in the screen or welds are observed,
replace arrester.
4. If plugging of the screen is observed, remove
arrester and shake loose particles out of the
arrester and clean screen with a wire brush (soak
in solvent if necessary). Reinstall arrester on
exhaust outlet.
Thread Locking Adhesives
Thread locking adhesives such as “Loctite 242”
or “Fel-Pro, Pro-Lock Nut Type” are used on the
following fasteners:
• Pump sheave setscrews.
• Sheave retaining bolt in end of engine crankshaft.
• Caster wheel spacer nuts.
• Platform spring pin.
Mobil HTS Grease (Or
Food-Grade Anti-seize)
Mobil HTS grease (or food-grade anti-seize) is used
in the following locations:
• Between splines of the cutter housing spindle and
sheave.
Copper-Based Anti-seize
Copper-based anti-seize is used in the following
locations:
• On threads of Blade Bolts. See Check Mower
Blades section.
• Between engine crankshaft, pump drive sheave,
and clutch.
• Between pump shafts and sheaves.
33
Maintenance
Adjustments
Note: Disengage PTO, shut off engine, wait for
all moving parts to stop, engage parking brake, and
remove key before servicing, cleaning, or making any
adjustments to the unit.
CAUTION
Raising the mower for service or maintenance
relying solely on mechanical or hydraulic
jacks could be dangerous. The mechanical or
hydraulic jacks may not be enough support or
may malfunction allowing the unit to fall, which
could cause injury.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands or
equivalent support.
Figure 22
1. 3 1/4 inches (8.3 cm)
2. Back blade tip
3. Front blade tip
4. 3 inches (7.6 cm)
5. Level surface
Deck Leveling
7. Use the fine tune adjustments on the front deck
lift arms to adjust the height of the front blade
tips. Loosen the whizlock nut on the side of
the yoke and the jam nut on top. Fine tune
the screw adjuster by turning it to get 3 inches
(7.6 mm) height. To increase the height, turn
the adjuster screw clockwise; to decrease, turn
counterclockwise (see Figure Figure 23).
Note: Small adjustments can be accomplished by
increasing the tire pressure in the tire on the low side.
1. Park the machine on a level surface and disengage
the blade control switch.
2. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
3. Check the air pressure in the drive tires. If needed,
adjust to the recommended inflation; refer to
Checking the Tire Pressure in Drive System
Maintenance section.
4. Set the height of cut lever to the 3 inch (7.6 cm)
position.
5. Raise the discharge deflector.
6. Carefully rotate the blades front to rear. Measure
from the tip of the front blade to the level surface
(Figure 22). The blades should measure 3 inches
(7.6 cm).
Note: In most conditions, the back tips should
be adjusted 1/4 inch (6.4 mm) higher than the
front.
Figure 23
1. Adjuster screw
2. Jam nut
34
3. Whizlock nut
4. Yoke
Maintenance
Deck Lift Handle Force
8. The back tips of the blades should measure 3
1/4 inches (8.3 cm). Fine tune rear adjusters as
required.
Tighten or loosen the bolt to adjust the amount of
force it takes to move the deck lift handle.
9. Re-measure until all four sides are the correct
height. Tighten all the nuts on the deck lift arm
assemblies.
Turning the bolt clockwise transfers some of the
deck weight from the lift handle to the helper spring
(see Figure 25). This makes the deck easier to lift;
however, it may allow the deck to float or become
bouncy which may cause an uneven cut.
10. Lower the discharge deflector.
Overall Height Adjustment
1. Park the machine on a level surface and disengage
the blade control switch.
2. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
3. Check the air pressure in the drive tires. If needed,
adjust to the recommended inflation; refer to
Checking the Tire Pressure in Drive System
Maintenance section.
4. Set the height of cut to the 3 inch (7.6 cm)
position.
5. Carefully rotate the blades front to rear. Measure
from the tip of the front blade to the level surface.
The blades should measure 3 inches (7.6 cm).
Figure 25
6. If it does not measure correctly, locate the
height-of-cut adjustment rod on the right side of
the machine (see Figure 24).
1. Deck lift handle
2. Helper spring
3. Bolt
Pump Drive Belt Tension
Self-tensioning - No adjustment necessary.
Mower Deck Drive Belt
Tension
Self-tensioning - No adjustment necessary.
Park Brake Adjustment
If the parking brake does not hold securely, an
adjustment is required.
Figure 24
1. Jam nuts
1. Park the machine on a level surface.
2. Height–of–cut
adjustment rod
2. Shut off engine and wait for all moving parts to
stop.
7. Loosen the jam nuts and turn the adjustment rod
until the blade tips match 3 inches (7.6 cm).
3. When the park brake is released, the brake bars
should lift off the tires and the hand lever should
travel forward to the end of the slot in the control
8. Tighten jam nuts.
35
Maintenance
panel. When the brake is disengaged, the gap
between the brake cross-tube and drive tire
should measure 5/8–3/4 inch (16–19 mm) (see
Figure 26).
Figure 27
1.
2.
3.
4.
Armature
Field shell
Rotor
Brake mounting bolt
5. Brake spacer
6. Re-gap shim
7. Brake pole
Removing the Shim:
1. Stop engine, wait for all moving parts to stop,
and remove key. Engage parking brake. Allow
the machine to cool completely before starting
these instructions.
Figure 26
1. Drive tire
2. Brake cross tube
3. Gap measures 5/8–3/4
inch (16–19 mm)
4. Brake linkage rod
5. Jam nut
2. Using a pneumatic line, blow out any debris
from under the brake pole and around the brake
spacers.
4. If the parking brake does not hold securely an
adjustment is required. To adjust the brake,
loosen the jam nuts on the brake linkage rod.
Turn the brake linkage rod clockwise to decrease
the gap and counterclockwise to increase the gap
(seeFigure 26).
3. Check the condition of the wire harness leads,
connectors, and terminals. Clean or repair as
necessary.
4. Verify that 12V is present at the clutch connector
when the PTO switch is engaged.
5. Tighten the jam nuts.
5. Measure the gap between the rotor and armature.
If the gap is greater than .04 inch (1 mm), proceed
with the following steps:
Electric Clutch Adjustment
A. Loosen both brake mounting bolts one-half
to one full turn (see Figure 28).
No adjustment necessary. However when the clutch
brake has worn to the point where the clutch no
longer engages consistently, the shim can be removed
to extend the clutch life.
Note: Do Not remove the brake pole from
the field shell/armature. The brake pole has
worn to match the armature and needs to
continue to match after the shim is removed
to ensure proper brake torque.
36
Maintenance
Figure 30
Figure 28
1. Brake mounting bolt
1. Feeler gauge
2. Shim
• If the gap is less than 0.010 inch, then
reinstall the shim and reference the
Troubleshooting section.
• If the gap is sufficient, proceed to the
safety check in step F.
F. Perform the following safety check:
a. Sit on the seat and start the engine.
b. Make sure the blades Do Not engage
with the PTO switch “off ” and the clutch
disengaged.
B. Using needle nose pliers, or by hand, take
hold of the tab and remove the shim (Do Not
discard the shim until proper clutch function
has been confirmed).
C. Using a pneumatic line, blow out any debris
from under the brake pole and around the
brake spacers.
D. Re-torque each bolt (M6 x 1) to 10 ft-lb (13
N-m) +/-0.5 ft-lb (0.7 N-m).
E. Using a 0.010 inch thick feeler gauge, verify
that a gap is present between the rotor and
armature face on both sides of the brake pole
as shown. (Due to the way the rotor and
armature faces wear (peaks and valleys) it is
sometimes difficult to measure the true gap.)
If the clutch does not disengage,
reinstall the shim and reference the
Troubleshooting section.
c. Engage and disengage the PTO switch
ten consecutive times to ensure the clutch
is functioning properly. If the clutch
does not engage properly, reference the
Troubleshooting section.
Forward Speed Adjustment
1. Park the machine on a level surface.
2. Shut off engine and wait for all moving parts to
stop. Engage parking brake.
3. Release and lower the rear cushion from the rear
of the machine.
4. Place the front reference/speed control bar in
the maximum forward position. See Adjusting
the Front Reference/Speed Control Bar in
Operation.
5. Push the RH control lever all the way forward to
the front reference/speed control bar.
6. Loosen the jam nuts on the turnbuckle on the RH
motion control (as viewed from the rear of the
G011733
1
Figure 29
1. Feeler gauge
37
Maintenance
Motion Control Tracking
Adjustment
machine — see Figure 31). Rotate the turnbuckle
counterclockwise (as viewed from the top of the
machine) until there is a gap between the control
lever and the front reference/speed control bar.
If the machine travels or pulls to one side when the
motion control levers are in the full forward position,
adjust the tracking.
1. Push both control levers forward the same
distance.
2. Check if the machine pulls to one side. If it does,
stop the machine and set the parking brake.
3. Release the rear cushion from the rear of the
machine.
4. Place the front reference/speed control bar in
the maximum forward position. See Adjusting
the Front Reference/Speed Control Bar in
Operation.
Figure 31
1. Lock nut
2. Turnbuckle
5. Rotate the adjustment rod on the LH side
of the machine. Looking down towards the
adjustment rod, rotate clockwise to decrease
speed or counterclockwise to increase speed (see
Figure 33).
3. Lock nut (LH thread)
7. With the RH control lever all the way forward,
make sure the RH pump arm bottoms out on the
forward stop, located by the hydraulic hoses, as
shown in Figure 32.
Figure 33
Figure 32
1. RH control lever
2. Forward stop
1. Rotate to increase speed
2. Turnbuckle
3. Rotate to decrease speed
3. RH pump arm
8. Holding the RH control lever forward, rotate the
turnbuckle clockwise until there is a minimal gap
or contact between the RH control lever and the
front reference/speed control bar.
6. Drive the machine and check the full forward
tracking.
7. Repeat steps 5 and 6 until desired tracking is
obtained.
9. Tighten the jam nuts.
8. Reinstall the rear cushion.
10. Reinstall the rear cushion.
38
Maintenance
Adjust RH Motion Control
Handle Position
If the motion control levers do not align horizontally,
adjust the right side motion control lever.
Note: Adjust the horizontal alignment before the
front to back alignment.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Figure 35
2. Push the right motion control lever down out of
locked neutral position.
1.
2.
3.
4.
3. Check if it aligns horizontally with the left motion
control lever.
Switch screws
Nut and bolt
Cam
Front reference/speed control handle
8. After the cam is adjusted, the lever switch needs
to be checked.
9. Check the gap between the control lever and
switch as shown in Figure 36. The gap needs
to be an 1/8 inch (3mm) with the right motion
control lever in the neutral, operate position.
Figure 34
1.
2.
3.
4.
LH Motion control lever
RH Motion control lever
RH Motion control lever in PTO disengaged position
Check the horizontal alignment here
4. To adjust the right motion control lever
horizontally, the cam needs to be adjusted.
5. Release the cushion from the rear of the machine.
6. Loosen the nut and bolt holding the cam.
7. Adjust the cam until it aligns with the left motion
control lever and tighten the nut and bolt for the
cam.
Figure 36
1.
2.
3.
4.
Switch
Cam
Right motion control lever in the neutral operate position
1/8 inch (3mm)
10. If needed, loosen the screws holding the switch
and adjust the switch.
11. Tighten the switch screws.
39
Maintenance
Caster Pivot Bearings
Pre-Load Adjustment
Cleaning
Clean Engine and Exhaust
System Area
Remove dust cap from caster and tighten nyloc nut
until washers are flat and back off 1/4 of a turn
to properly set the pre-load on the bearings. If
disassembled, make sure the spring disc washers are
reinstalled as shown in Figure 37.
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
conditions.)
CAUTION
Excessive debris around engine cooling air
intake and exhaust system area can cause engine,
exhaust area, and hydraulic system to overheat
which can create a fire hazard.
Clean all debris from engine and exhaust system
area.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Clean all debris from rotating engine air intake
screen, around engine shrouding, and exhaust
system area.
3. Wipe up any excessive grease or oil around the
engine and exhaust system area.
Figure 37
1. Spring disc washers
Remove Engine Shrouds and
Clean Cooling Fins
Service Interval: Every 80 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Remove cooling shrouds from engine and clean
cooling fins. Also clean dust, dirt, and oil from
external surfaces of engine which can cause
improper cooling.
3. Make sure cooling shrouds are properly
reinstalled. Operating the engine without
cooling shrouds will cause engine damage due to
overheating.
Clean Debris From Machine
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Clean off any oil, debris, or grass build-up on the
machine and cutting deck, especially under deck
40
Maintenance
belt shields, around the fuel tank, around engine
and exhaust area.
Federal law states that batteries should not be placed
in the garbage. Management and disposal practices
must be within relevant federal, state, or local laws.
Clean Grass Build-Up Under
Deck
If a battery is being replaced or if the unit containing
the battery is no longer operating and is being
scrapped, take the battery to a local certified recycling
center. If no local recycling is available return the
battery to any certified battery reseller.
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Raise deck to the transport (maximum cutting
height) position. Lift the front of unit and support
unit using jack stands or equivalent support.
CAUTION
Raising the mower for service or maintenance
relying solely on mechanical or hydraulic
jacks could be dangerous. The mechanical or
hydraulic jacks may not be enough support
or may malfunction allowing the unit to fall,
which could cause injury.
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
3. Clean out any grass build-up from underside of
deck and in discharge deflector.
Waste Disposal
Motor Oil Disposal
Engine oil and hydraulic oil are both pollutants to
the environment. Dispose of used oil at a certified
recycling center or according to your state and local
regulations.
Battery Disposal
DANGER
Battery electrolyte contains sulfuric acid, which
is poisonous and can cause severe burns.
Swallowing electrolyte can be fatal or if it touches
skin can cause severe burns.
• Wear safety glasses to shield eyes, and rubber
gloves to protect skin and clothing when
handling electrolyte.
• Do Not swallow electrolyte.
• In the event of an accident, flush with water
and call a doctor immediately.
41
Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, do not overlook the simple causes. For example: starting problems could be caused
by an empty fuel tank.
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.
Problem
Starter does not crank.
Possible Cause
1. PTO is engaged.
1. Disengage the PTO.
2. One of the speed control levers are not
in neutral position.
3. Battery does not have a full charge.
2. Ensure the speed control lever is in the
neutral position.
3. Charge the battery. See Check
Battery Charge and Recommended
Jump Starting Procedure sections in
Maintenance.
4. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
5. Replace the blown fuse.
6. Check reed switch.
4. Electrical connections are corroded, loose
or faulty.
5. Fuse is blown.
6. Neutral LCD indicator does not
illuminate.
7. Relay or switch is defective.
Engine will not start, starts hard, or fails to
keep running
7. Contact an Authorized Service Dealer.
1. Fuel tank is empty.
1. Fill the fuel tank.
2. Fuel shutoff valve is closed.
3. The throttle and choke are not in the
correct position.
2. Open the fuel shutoff valve.
3. Be sure the throttle control is midway
between the “SLOW” and “FAST”
positions, and the choke is in the “ON”
position for a cold engine or the “OFF”
position for a warm engine.
4. Replace the fuel filter.
5. Contact an Authorized Service Dealer.
4. Dirt in fuel filter.
5. Dirt, water, or stale fuel is in the fuel
system.
6. Air cleaner is dirty.
7. Electrical connections are corroded, loose
or faulty.
Engine loses power
Corrective Action
8. Relay or switch is defective.
9. Faulty spark plug.
10. Spark plug wire is not connected.
6. Clean or replace the air cleaner element.
7. Check the electrical connections for
good contact. Clean connector terminals
thoroughly with electrical contact cleaner,
apply dielectric grease and reconnect.
8. Contact an Authorized Service Dealer.
9. Clean, adjust or replace spark plug.
10. Check the spark plug wire connection.
1. Engine load is excessive
1. Reduce the ground speed.
2. Air cleaner is dirty.
3. Oil level in the crankcase is low.
4. Cooling fins and air passages for the
engine are plugged.
5. Vent system filter plugged.
6. Dirt in fuel filter.
7. Dirt, water, or stale fuel is in the fuel
system.
2. Clean or replace the air cleaner element.
3. Add oil to the crankcase.
4. Remove the obstructions from the cooling
fins and air passages.
5. Inspect vent filter; replace if dirty.
6. Replace the fuel filter.
7. Contact an Authorized Service Dealer.
42
Troubleshooting
Problem
Engine overheats
Possible Cause
Corrective Action
1. Engine load is excessive
1. Reduce the ground speed.
2. Oil level in the crankcase is low.
3. Cooling fins and air passages for the
engine are plugged.
2. Add oil to the crankcase.
3. Remove the obstructions from the cooling
fins and air passages.
Mower pulls left or right (with levers fully
forward).
1. Tire pressure in drive tires not correct.
1. Adjust tire pressure in the drive tires.
2. Tracking needs adjustment.
2. Adjust the tracking by turning turnbuckle
on the LH turnbuckle in the direction that
the mower needs to be adjusted to. Rotate
the turnbuckle in 1/4 turn increments
until the mower tracks correctly.
Machine does not drive.
1. Bypass valve is not closed tight.
1. Tighten the bypass valve.
2. Drive or pump belt is worn, loose or
broken.
3. Drive or pump belt is off a pulley.
2. Change the belt.
1. Blade(s) not sharp.
1. Sharpen the blade(s).
2. Cutting blade(s) is/are bent.
3. Mower deck is not level.
2. Install new cutting blade(s).
3. Level mower deck from side-to-side and
front-to-rear.
4. Clean the underside of the mower.
5. Adjust tire pressure in the drive tires.
6. Contact an Authorized Service Dealer.
7. Replace blades, spindles and (or) check
for damage to mower deck.
Uneven cutting height.
4.
5.
6.
7.
Abnormal vibration
Blades do not rotate.
Underside of mower is dirty.
Tire pressure in drive tires not correct.
Blade spindle bent.
Tips of adjacent blades are at an uneven
cutting height. Blades tips should be even
within 3/16 inch which is approximately
one blade thickness.
3. Change the belt.
1. Cutting blade(s) is/are bent or unbalanced.
1. Install new cutting blade(s).
2. Blade mounting bolt is loose.
3. Engine mounting bolts are loose.
4. Loose engine pulley, idler pulley, or blade
pulley.
5. Engine pulley is damaged.
6. Blade spindle is bent.
7. Belt is damaged.
2. Tighten the blade mounting bolt.
3. Tighten the engine mounting bolts.
4. Tighten the appropriate pulley.
5. Contact an Authorized Service Dealer.
6. Contact an Authorized Service Dealer.
7. Install new belt.
1. Drive belt is off pulley.
1. Check belt for damage; replace if
necessary. Install drive belt and check
adjusting shafts and belt guides for correct
position.
2. Deck belt is worn, loose or broken.
3. Deck belt is off pulley.
2. Install new deck belt.
3. Install deck pulley and check the idler
pulley, idler arm and spring for correct
position and function.
4. Replace the spring.
5. Contact an Authorized Service Dealer.
4. Broken or missing idler spring.
5. Damaged electric clutch.
43
Troubleshooting
Problem
Clutch will not engage.
Possible Cause
Corrective Action
1. Fuse is blown.
1. Replace fuse. Check coil resistance,
battery charge, charging system, and
wiring connections and replace if
necessary.
2. Low voltage supply at the clutch.
2. Check coil resistance, battery charge,
charging system, and wiring connections
and replace if necessary.
3. Replace clutch.
4. Repair or replace clutch lead wire or
electrical system. Clean connector
contacts.
5. Remove shim or replace clutch.
3. Damaged coil.
4. Inadequate current supply.
5. Rotor/armature airgap is too large.
44
Schematics
Schematics
Electrical Diagram
45
Schematics
Electrical Schematic
46
Schematics
Hydraulic Diagram
47
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
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.
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
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.
Owner’s Responsibilities
If your product requires warranty service it must be returned to an
authorized Exmark service dealer within the warranty period. This
warranty extends only to turf equipment operated under normal
conditions. You must read the operator’s manual. You must also properly
service and maintain your Exmark product as described in the operator’s
manual. Such routine maintenance, whether performed by a dealer or by
you, is at your expense.
Consumer Warranty Conditions
This warranty applies to Exmark Lazer Z X-Series, Lazer Z S-Series, and
Vantage turf equipment sold in the U.S. or Canada for a period of five
years or 750 hours (whichever occurs first) for residential usage.
Residential usage means use of the product on the same lot as your home.
Use at more than one location is considered commercial use, and the
commercial use warranty detailed above would apply.
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.
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.
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.
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.
There are no other express warranties except for engine and special
emission system coverage.
This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
All warranty work must be performed by an authorized Exmark Service
Dealer using Exmark approved replacement parts.
G4500-733_B
48
Service Record
Date:
Description of Work Done:
49
Service Done By:
50
G011841
Figure 38
This page may be copied for personal use.
1. The maximum slope you can safely operate the machine on is 20 degrees. Use the slope indicator to determine the
degree of slope of hills before operating. Do Not operate this machine on a slope greater than 20 degrees. Fold
along the appropriate line to match the recommended slope.
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.
3. Example of how to compare slope with folded edge.
51
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS
MID-MOUNT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
OPERATOR CONTROLLED DISCHARGE
FULL SUSPENSION SEAT
ROLL OVER PROTECTION SYSTEM (ROPS)
DECK LIFT ASSIST KIT
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
TURF STRIPER
12V POWER PORT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
OUT-FRONT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
SNOW BLADE
DUAL-TAIL WHEEL
SNOWBLOWER
FLOOR PAN EXTENDER
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
WEATHER CAB
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
TURF STRIPER
MICRO-MULCH SYSTEM
STANDON
Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Model No.
Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Serial No.
©2011 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
All Rights Reserved
Part No. 4500-897 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com