Exmark 000 & Higher manual

V ANT AGE ™ For Serial Nos. 850,000 & Higher Part No. 4500-648 Rev . D[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer , birth defects, or other reproductiv e har m. Important: The engine in this product is not equipped with a spark arr ester mufer . It is a violation of Califor nia Public Resource Code (CPRC) Sec[...]

Introduction CONGRATULATIONS on the purchase of y our Exmark Mow er . T his product has been carefully designed and manufactured to giv e you a maximum amount of dependability and years of trouble-free operation. This man ual contains operating, maintenance , adjustment, and safety instr uctions for your Exmark mow er . BEFORE OPERATING Y OUR MO WE[...]

Contents Introduction .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. 3 Safety .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . 5 Safety Alert Symbol . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 5[...]

Safety Safety Safety Alert Symbol This Safety Alert Symbol (Figure 2) is used both in this man ual and on the mac hine to identify important safety messages which m ust be follow ed to av oid accidents . This symbol means: ATTENTION! BECOME ALERT! Y OUR SAFETY IS INV OL VED! Figure 2 1. Safety alert symbol The safety alert symbol appears abo ve inf[...]

Safety DANGER In certain conditions gasoline is extremely ammable and v apors are explosi v e. A re or explosion from gasoline can bur n y ou, others, and cause proper ty damage. • Fill the fuel tank outdoors on lev el gr ound, in an open area, when the engine is cold. Wipe up an y gasoline that spills. • Never rell the fuel tank or dr[...]

Safety Operation W ARNING Operating engine par ts, especially the mufer, become extremely hot. Sev ere bur ns can occur on contact and debris, such as leav es, grass, br ush, etc. can catch re. • Allow engine parts, especially the mufer, to cool before touching . • Remo ve accumulated de bris from mufer and engine area. • Install [...]

Safety occur . The operator is responsible for safe operation on slopes . DANGER Operating on w et 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 ar m or leg getting under the mow er or engine deck which may result in serious injur y , death or drownin[...]

Safety DANGER Charging or jump star ting the batter y may produce explosi ve gases. Batter y gases can explode causing serious injur y . • Keep sparks, ames, or cigarettes aw ay from batter y . • V entilate when charging or using batter y in an enclosed space. • Make sure venting path of batter y is always open once batter y is lled wit[...]

Safety Safety and Instructional Decals • Keep all safety signs legible . R emov e all grease, dirt and debris from safety signs and instructional labels . • R eplace all w or n, damaged, or missing safety signs . • When replacement components are installed, be sure that cur rent safety signs are afx ed to the replaced components . • If a[...]

Safety 1 16-0404 1 16-2040 1 16-3076 1 16-3260 1. Forward position - faster 2. Backward position - slower 1 16-3267 1 16-3283 1 1[...]

Safety 1 16-3290 1 16-1886 1 16-1887 1. Fast 3. Neutral 2. Slow 4. Reverse 1 16-3067 1. PTO-on 4. Slow 2. PTO-of f 5. Choke-on 3. Fast 6. Choke-off 12[...]

Specications Specications Model Numbers Serial Nos: 850,000 and Higher VT20KAS484; VT20KAS524; VT24KAS484; VT24KAS524; VT24KAS484CA; VT24KAS524CA Systems Engine • Engine Specications: See y our Engine Owner’ s Manual • RPM: Full Speed: 3600 ±100 RPM (No Load) Fuel System • Capacity: 8.0 gal. (30.2 L) • T ype of Fuel: R egular un[...]

Specications Tires & Wheels Driv e Front Caster Pneumatic (Air-Filled) Semi- Pneumatic Quantity 2 2 T read T urf Master Smooth Size 20 x 10.00–8 11 x 4.00-5 Ply Rating 4 Pressure 14 psi (97 kP a) Cutting Deck • Cutting Width: – 48 inch Deck: 48 inches (121.9 cm) – 52 inc h Deck: 52.00 inc hes (132.1 cm) • Discharge: Side • Blade [...]

Product Overview T orque Requirements Bolt Location T orque Cutter Housing Spindle Nut 140-145 ft-lb (190-197 N-m) Blade Mounting Bolt (lubricate with anti-seize) 55-60 ft-lb (75-81 N-m) Engine Deck/Mo wer Deck Support Mount Bolts 30-35 ft-lb (41-47 N-m) Engine Mounting Bolts 15-20 ft-lb (20-27 N-m) Wheel Lug Nuts 90-95 ft-lb (122-129 N-m) Wheel Hu[...]

Operation Operation Note: Deter mine the left and right sides of the machine from the nor mal operating position. Controls Motion Control Levers The motion control lev ers , located on each side of the top console , control the forward and rev erse motion of the machine . Moving the lev ers forward or bac kward turns the wheel on the same side forw[...]

Operation The brak e lev er engages a parking brake on the dri ve wheels . Note: The LCD indicator appears in the message display on the front console when the park brake is engag ed (see Figure 5 and Figure 7). T o engag e the brak e, pull the lev er rearward and to the right to position into the engag ed position. T o release , pull the brake lev[...]

Operation The fuel gauge monitors the amount of fuel in the tank. Drive Wheel Release V alves Located on the left rear corner of the h ydrostatic pumps . Driv e wheel release v alves are used to release the hy drostatic driv e system to allow the machine to be mov ed b y hand without the engine running . With a 5/8 wrench, turn both valv es one tur[...]

Operation Important: Do Not crank the engine continuously for more than ten seconds at a time. If the engine does not star t, allow a 60 second cool-down period betw een star ting attempts. F ailure to follow these guidelines can bur n out the star ter motor . 7. If the chok e is in the “ON” position, gradually return c hoke to the “OFF” po[...]

Operation Important: T o begin mov ement (forward or backw ard), the brak e lev er must be disengaged (pushed forw ard) befor e the motion control levers can be mo ved or the engine will stop . When the RH motion control lev er is positioned fully outw ard (apart), the dri ve system is in the PTO disengag e position (Figure 8). Note: The “N” LC[...]

Operation Figure 10 T o turn left or right, release pressure on the motion control lev er tow ard the desired turn direction. 3. T o stop , position both motion control lev ers in the neutral operate position. Adjusting the Front Reference/Speed Control Bar Adjust the front reference/speed control bar for desired maxim um forward speed. 1. Stop the[...]

Operation W ARNING The operator platfor m is heavy and may cause injur y when low ering and raising the operator platfor m. The platfor m may suddenly drop if not suppor ted when the latch pin is pulled out. • Do Not put y our hands or ngers in the platfor m pi vot area when low ering or raising the operator platfor m. • Make sure the platfo[...]

Operation Adjusting the Cutting Height The cutting height of the mo wer dec k is adjusted from 1 to 5 inc hes (2.5 cm to 12.7 cm) in 1/4 inc h (6.4 mm) increments . 1. Stop the machine and mo ve the motion control levers to the neutral position. 2. Disengag e the PTO . 3. Raise and loc k the deck to the 5 inch (12.7 cm) transport position. The dec [...]

Operation W ARNING Loading a unit on a trailer or tr uck increases the possibility of backw ard tip-o ver . Backw ard tip-o ver could cause serious injur y or death. • Use extreme caution when operating a unit on a ramp . • Use only a single, full width ramp; Do Not use indi vidual ramps for each side of the unit. • If individual ramps must b[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the mac hine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystanders. Remo ve the k ey from the ignition s witch, engage parki[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedure Every 500 hours • R eplace the secondary air cleaner element (May need more often under severe conditions . See the Engine Owner’ s Man ual for additional infor mation.) • Change the h ydraulic lter and uid (Ev er y 250 hours/yearly if using Mobil 1 15W50) • Check the w[...]

Maintenance V oltage Reading Percent Charge Maximum Charger Settings Charging Inter v al 11.7–12.0 0–25% 14.4 volts/4 amps 3 Hours 11.7 or less 0% 14.4 volts/2 amps 6 Hours or More Recommended Jump Starting Procedure Service Interval: As required 1. Check the w eak batter y for terminal corrosion (white, green, or blue “snow”), it m ust be [...]

Maintenance Figure 16 1. Positive (+) cable on discharged battery 2. Positive (+) cable on booster battery 3. Negative (–) cable on the booster battery 4. Negative (–) cable on the engine block 5. Booster battery 6. Discharged battery 7. Engine block 4. Connect the other end of the positi ve cable to the positiv e ter minal of the booster batte[...]

Maintenance A. Install bushing through blade with bushing ange on bottom (grass) side of blade . Figure 18 1. Install bushing in blade prior to installing bushing in spindle. B . Install bushing/blade assembly into spindle . Figure 19 1. Use wrench here for blade installation. This nut has been torqued to 140–145 ft-lb (190–197 N-m) 2. T orq[...]

Maintenance 3. Mov e the motion control lev ers forward. The engine should initiate shutdown after momentar y pause. 4. Start the engine and release the parking brak e. 5. Mov e the right side motion control lev er to the center , operating position. 6. Continue holding the right side motion control lever in the center , operating position and pull[...]

Maintenance 1. Stop engine and wait for all mo ving parts to stop . Engag e parking brake . 2. Clean area around h ydraulic reservoir cap and remov e cap . Oil lev el should be to the top of the bafe inside the tank. If not, add oil. Use Exmark Premium Hydro oil. R eplace h ydraulic reser v oir cap and tighten until snug . Do Not ov ertighten. N[...]

Maintenance Figure 20 1. Seal guard 2. Spacer nut with wrench ats 2. R emov e caster wheel from caster forks . 3. R emov e seal guards from the wheel hub . 4. R emov e one of the spacer nuts from the axle assembly in the caster wheel. Note that thread locking adhesi ve has been applied to loc k the spacer n uts to the axle. Remo ve the axle (wit[...]

Maintenance 2. Carefully clean area around lter . It is important that no dir t or contamination enter hy draulic system. 3. Unscrew lter to remov e and allo w oil to drain from reser v oir . Important: Before reinstalling new lter , ll it with Exmark Premium Hydro oil and apply a thin coat of oil on the surface of the rubber seal. T ur[...]

Maintenance Note: It is necessary to lightly touc h the charge pump cap with your hand to chec k the pump temperature. If the cap is too hot to touc h, turn off engine . The pumps may be damaged if the pump becomes too hot. If either driv e wheel still does not rotate contin ue with step 4. 4. Thoroughly clean the area around eac h of the charge pu[...]

Maintenance • On clutc h ar m assembly betw een bearings and shaft and between low er sheav e and shaft. • Between pump shafts and sheav es . Dielectric Grease Dielectric grease is used on all blade type electrical connections to prev ent cor rosion and loss of contact. Adjustments Note: Disengag e PTO , shut off engine, wait for all mo ving pa[...]

Maintenance Figure 22 1. Blades front to rear 2. Measure here 7. Measure betw een the outside cutting edges and the at surface (Figure 23). If both measurements are not within 3/16 inch (5 mm), an adjustment is required; contact an A uthorized Ser vice Dealer . Figure 23 1. Blades side to side 2. Measure here 8. Low er the disc harg e deector[...]

Maintenance Figure 26 1. Rear lift points 2. Engine deck brackets 7. T o raise the front of the mo wing deck, tighten the front loc king nuts b y the same amount on both front adjusting rods . Tighten both rear locking nuts . Chec k the side to side lev el of the mo wer again; refer to Deck Lev eling . Note: Rak e adjustments ma y affect the motion[...]

Maintenance 4. T o adjust the brake , remo ve the hairpin, w asher, and clevis pin from the lo wer brake lev er and y oke as sho wn in Figure 28. Figure 28 1. Jam nut 4. Lower brake lever 2. Y oke 5. W asher 3. Clevis pin 6. Hairpin 5. Loosen the jam nut. 6. R otate the yok e. T o tighten the brake , rotate the yok e up . T o loosen the brak e, rot[...]

Maintenance Figure 30 1. Adjusting nut 3. Feeler gauge 2. Slot Motion Control Neutral Adjustment Check to see if an adjustment is required: 1. With the engine off, turn the ignition switc h to the “ON” position. 2. Locate the LCD indicator in the message display . Figure 31 1. Neutral LCD indicator 3. With the motion control levers in the neutr[...]

Maintenance Figure 33 1. Rotate to increase speed 2. T urnbuckle 3. Rotate to decrease speed 9. R einstall the rear cushion. Motion Control T racking Adjustment If the machine trav els or pulls to one side when the motion control lev ers are in the full forward position, adjust the trac king . 1. Push both control levers forw ard the same distance.[...]

Maintenance close together as possible without touc hing (approximately .06 inch (1.5 mm) gap is desirable). The switch mounting plate can be mo ved up or down to adjust the position of the low er neutral switch. 8. Check the function of the neutral switc hes by temporarily replacing the k ey . With the engine off, turn the ignition switc h to the [...]

Maintenance Figure 37 1. Switch 2. Cam 3. Right motion control lever in the neutral operate position 4. 1/8 inch (3mm) 10. If needed, loosen the screws holding the switch and adjust the switch. 11. Tighten the switc h screws . Caster Pivot Bearings Pre-Load Adjustment R emov e dust cap from caster and tighten nyloc nut until washers are at and b[...]

Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval: Before each use or daily (May be required more often in dry or dirty conditions.) CAUTION Excessi ve de bris around engine cooling air intake and exhaust system area can cause engine, exhaust area, and h y draulic system to o verheat which can create a re hazard. Clean a[...]

Maintenance Battery Disposal DANGER Batter y electrol yte contains sulfuric acid, which is poisonous and can cause severe bur ns. Sw allowing electrolyte can be fatal or if it touches skin can cause sev ere bur ns. • W ear safety glasses to shield eyes, and r ub ber g lov es to protect skin and clothing when handling electrolyte. • Do Not sw al[...]

T roubleshooting T roubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mow er use. When a problem occurs , do not o verlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The follo wing table lists some of the common causes [...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessive . 1. Reduce the ground speed. 2. Oil level in the crankcase is low . 2. Add oil to the crankcase . Engine ov erheats . 3. Cooling ns and air passages for the engine are plug ged. 3. Remo ve the obstructions from the cooling ns and air passages . 1. Tire p[...]

Schematics Schematics Electrical Diagram FUSE BLOCK KEY SWITCH I A Y X B S MA GNETO SOLENOID (-) SOLENOID (+) B+ REGULA TOR FUEL SOLENOID ENGINE G ROUND PTO CLUTCH NEUTRAL KEY SWITCH VIEWED FROM BA CK OF SWITCH KEY SW SWITCH PTO SWITCH OPERA TOR PRESENT SW P ARK BRAKE SWITCH HOUR METER RED RED RED RED VIOLET VIOLET BLUE GREEN ORANGE PINK PINK PINK [...]

Schematics Electrical Schematic 48[...]

Schematics Hydraulic Diagram 49[...]

General Warranty Conditions and Products Co vered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty 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 defec[...]

Notes: 51[...]

Notes: 52[...]

Service Record Date: Description of Work Done: Service Done By: 53[...]

54[...]

G01 1841 Figure 39 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 20 degrees . Use the slope indicator to determine the degree of slope of hills before operating. Do Not operate this machine on a slope greater than 20 degrees. Fold along the appropriate line to match the recommended slope. 2.[...]

MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF A CCESSORIES AND OPTIONS W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA T OR CONTROLLED[...]