Exmark 4500-759 Rev A manual

V ANT AGE™ 48/52 INCH MODELS For Serial Nos. 920,000 & Higher Part No. 4500-759 Rev . A[...]

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 , bir th defects, or other reproductiv e har m. Important: The engine in this product is not equipped with a spark ar rester mufer . It is a violation of Califor nia Public Resource Code (CPRC) Se[...]

Introduction CONGRATULATIONS on the purc hase of your Exmark Mo w er . T his product has been carefully designed and man ufactured to gi ve you a maxim um amount of dependability and years of trouble-free operation. This manual contains operating, maintenance, adjustment, and safety instr uctions for your Exmark mow er . BEFORE OPERATING Y OUR MO W[...]

Contents Introduction . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . 3 Safety .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. 5 Safety Aler t Symbol . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. [...]

Safety Safety Safety Alert Symbol This lawn mow er meets or ex ceeds the B71.4 specications of the American National Standards Institute in effect at the time of production. Exmark designed and tested this lawn mo wer to offer reasonably safe ser vice; howev er , failure to comply with the following instr uctions may result in personal injur y .[...]

Safety • Inspect the area where the equipment is to be used and remov e all rocks , to ys , stic ks , wires , bones , and other foreign objects which can be thrown b y the machine and ma y cause personal injur y to the operator or bystanders . DANGER In cer tain conditions gasoline is extremely ammable and v apors are explosiv e. A re or ex[...]

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

Safety DANGER Operating on wet g rass 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 mo wer or engine deck which may r esult in serious injur y , death or drowning . • Mow acr oss slopes, nev er up and down. • Do Not mow slop[...]

Safety DANGER Batter y electrolyte contains sulfuric acid, which is poisonous and can cause sev ere bur ns. Swallo wing electrolyte can be f atal or if it touches skin can cause sev ere bur ns. • W ear safety glasses to shield ey es, and r ub ber g lov es to protect skin and clothing when handling electrolyte. • Do Not s w allow electrolyte. ?[...]

Safety Safety and Instructional Decals • Keep all safety signs legible. R emo v e all g rease , dirt and debris from safety signs and instructional labels . • R eplace all w orn, damaged, or missing safety signs . • When replacement components are installed, be sure that current safety signs are afxed to the replaced components . • If an[...]

Safety 1 16-0404 1 16-2040 1 16-3267 1 16-3283 1 16-3290 1 16-1887 1. Fast 3. Neutral 2. Slow 4. Reverse 1 1[...]

Safety 1 16-4181 1 16-4647 1 16-5040 1. Forward position – faster 2. Backward position – slower 1 16-4648 All Units Except EFI 1. PT O-on 4. Slow 2. PT O-off 5. Choke-on 3. Fast 6. Choke-of f 12[...]

Safety 1 16-5026 EFI Only 1. PT O-on 3. Fast 2. PT O-off 4. Slow 13[...]

Specications Specications Model Numbers Serial Nos: 920,000 and Higher VT20KA484; VT24KA484; VT24KA484CA; VT24KA524; VT24KA524CA; VT25EKC524 Systems Engine • Engine Specications: See your Engine Owner’ s Manual • Engine Oil T ype: Exmark 4–Cycle Premium Engine Oil • RPM: Full Speed: 3600 ±100 RPM (No Load) Fuel System • Capaci[...]

Specications – 0-4.0 mph (6 km/hr) rev erse. • Driv e wheels release v alv es allo w machine to be mov ed when engine is not r unning . Wheel Drive System Driv e wheels are direct coupled to P arker wheel driv e motors with 1 inch (25.4 mm) tapered shaft. Tires & Wheels Driv e Front Caster Pneumatic (Air-Filled) Semi- Pneumatic Quantity [...]

Product Overview T orque Requirements Bolt Location T orque 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 Dec k/Mow er Deck Support Mount Bolts 30-35 ft-lb (41-47 N-m) Engine Mounting Bolts K a wasaki Kohler 17-23 ft-lb (23-31 N-m) 27-33 ft-lb (37-45 N-m) Wheel [...]

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 eac h side of the top console , control the forward and rev erse motion of the machine . Moving the lev ers forward or backw ard turns the wheel on the same side for[...]

Operation The brake lever eng ages a parking brake on the driv e 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 rearw ard 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 right front cor ner of the hy drostatic pumps . Driv e wheel release valv es are used to release the hy drostatic dri ve system to allow the mac hine to be mov ed b y hand without the engine r unning . With a 5/8 wrenc h, turn both v alv es [...]

Operation 3. Push in (down) on the PTO switch to the “disengag e” position. 4. Place the throttle midway betw een the “SLO W” and “F AST” positions . 5. On a cold engine , push the chok e lev er forward into the “ON” position (ex cept Kohler EFI units). On a war m engine, leave the c hoke in the “OFF” position. 6. T ur n ignitio[...]

Operation Driving the Machine CAUTION Machine can spin ver y 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 injur y . • Use caution when making tur ns. • Slow the machine down before making shar p tur ns. Important: T o begin mov ement (forw ard o[...]

Operation Figure 10 T o turn left or right, release pressure on the motion control lever toward the desired turn direction. 3. T o stop , position both motion control levers in the neutral operate position. Adjusting the Front Reference/Speed Control Bar Adjust the front reference/speed control bar for desired maximum forw ard speed. 1. Stop the ma[...]

Operation W ARNING The operator platf or m is heavy and may cause injur y when lo wering and raising the operator platfor m. T he 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 piv ot ar ea when lowering or raising the operator platf or m. • Make sure the pla[...]

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 mac hine and mov e the motion control levers to the neutral position. 2. Disengag e the PTO . 3. Raise and lock the deck to the 5 inc h (12.7 cm) transport position. The deck is[...]

Operation W ARNING Loading a unit on a trailer or tr uck incr eases the possibility of backw ard tip-ov er . Backw ard tip-ov er 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 individual ramps for each side of the unit. • If individual ramps must be[...]

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 starting of the engine could seriousl y injure you or other bystanders. Remo ve the key fr om the ignition s witch, enga ge parki[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedur e Every 500 hours • Replace the secondary air cleaner element. (May need more often under sev ere conditions . See the Engine man ual for additional infor mation.) • Chang e the hydraulic lter and uid (Every 250 hours/yearly if using Mobil 1 15W50) • Check the wheel hub to[...]

Maintenance V oltage Reading Percent Charge Maximum Charger Settings Charging Inter v al 12.0–12.2 25–50% 14.4 volts/4 amps 2 Hours 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 Important: F or Kohler EFI units: Unplug the har ness from the ECU befor e perfor ming an y welding on the equipment. [...]

Maintenance 4. Connect the other end of the positiv e cable to the positiv e terminal of the booster battery . 5. Connect the black negativ e (–) cable to the other ter minal (negativ e) of the booster battery . 6. MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE (NOT TO THE NEGA TIVE POST) A W A Y FROM THE B ATTER Y . STAND B[...]

Maintenance 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 130-160 ft-lb (176–217 N-m) 2. T orque to 50-60 ft-lb (68-81 N-m) Apply lubricant to threads as needed to prevent seizing. Copp[...]

Maintenance 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 up on the blade control switc h (PTO) and release. The clutch should eng age and the mo wer blades begin rotating . 7. Mov e or release the right side motion[...]

Maintenance 1. Stop engine and wait for all mo ving parts to stop , and remo ve key . Engage parking brake . 2. Clean area around hy draulic reser voir cap and remov e cap . Oil level should be to the top of the bafe inside the tank. If not, add oil. Use Exmark Premium Hy dro Oil. R eplace h ydraulic reser voir cap and tighten until snug . Do No[...]

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 adhesiv e has been applied to loc k the spacer nuts to the axle . R emo ve the axle (wi[...]

Maintenance Every 500 hours/Y early (whichever comes rst) thereafter (Every 250 hours/Y early if using Mobil 1 15W50) Note: Use only Exmark P art 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 T ransmission section in Specications for lter specications). 1. Stop engine, wait[...]

Maintenance Figure 21 1. Charge pump cap 2. Loosen 1 1/2 turns only 1. Stop engine and wait for all mo ving par ts to stop . Raise the rear of the mac hine up onto jac k stands high enough to raise the driv e wheels off the g round. 2. Check oil lev el as stated in Check Hy draulic Oil Level section. 3. Start engine and move throttle control ahead [...]

Maintenance Thread Locking Adhesives Thread loc king adhesi ves such as “Loctite 242” or “F el-Pro , Pro-Lock Nut T ype” are used on the following fasteners: • Pump sheav e setscrews . • Sheav e retaining bolt in end of engine crankshaft. • Caster wheel spacer n uts . • Platfor m spring pin. Mobil HTS Grease (Or Food-Grade Anti-seiz[...]

Maintenance Figure 22 1. Blades front to rear 2. Measure here 7. Measure between 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 discharge deector . [...]

Maintenance Figure 26 1. Rear lift points 2. Engine deck brackets 7. T o raise the front of the mowing dec k, tighten the front locking n uts by the same amount on both front adjusting rods . Tighten both rear locking nuts . Chec k the side to side level of the mow er again; refer to Deck Lev eling . Note: Rak e adjustments ma y affect the motion c[...]

Maintenance Checking the Tir e Pressure in Dri ve System Maintenance. 4. Disengag e the park brake . 5. Push do wn on the brak e bar until it touches the tires . There will be a 3/4 inch (19 mm) gap between the park brake handle and the slot in the control panel (see Figure 28). Figure 28 1. Brake bar 4. 3/4 inch (19 mm) 2. Push down 5. Park brake [...]

Maintenance Figure 31 1. Switch 3. Brake lever 2. 1/8 inch (3mm) gap needed between switch and brake lever 9. If needed, loosen the screws holding the switc h and adjust the switch. Electric Clutch Adjustment No adjustment necessar y . Ho wev er when the clutch brake has w orn to the point where the clutch no longer engag es consistently , the shim[...]

Maintenance G011733 1 Figure 34 1. Feeler gauge Figure 35 1. Feeler gauge • If the g ap is less than 0.010 inc h, then reinstall the shim and reference the T roubleshooting section. • If the g ap is sufcient, proceed to the safety check in step F. F . P erfor m the following safety c hec k: a. Sit on the seat and start the engine. b . Make s[...]

Maintenance Figure 37 1. Lock nut 3. Lock nut (LH thread) 2. Adjustment rod 7. Continue to rotate the adjustment rod, counting the turns, until the LCD indicator tur ns off . R otate the adjustment rod in the opposite direction half the n umber of turns counted. R elease the LH motion control lev er and tighten the lock n uts on the right side. 8. [...]

Maintenance 6. Check the alignment on the LH and RH neutral switches upper and lo wer surfaces (reference Figure 39). If they are not in alignment, loosen the hardware on the lo wer neutral switch and adjust it forward or rearward as necessary . Once aligned, tighten the hardware. Chec k the neutral switch alignment again as the dec k is mo ved thr[...]

Maintenance Figure 41 1. Switch screws 2. Nut and bolt 3. Cam 4. Front reference/speed control handle 8. After the cam is adjusted, the lev er switc h needs to be chec ked. 9. Check the gap between the control lever and switch as sho wn in Figure 42. The gap needs to be an 1/8 inch (3mm) with the right motion control lev er in the neutral, operate [...]

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 v e de bris around engine cooling air intake and exhaust system area can cause engine, exhaust area, and hydraulic system to o v erheat which can create a re hazard. Clean a[...]

Maintenance F ederal law states that batteries should not be placed in the garbag e . Management and disposal practices must be within relevant federal, state , or local la ws . If a batter y is being replaced or if the unit containing the batter y is no longer operating and is being scrapped, take the batter y to a local certied recycling cente[...]

T roubleshooting T roubleshooting 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 ov erlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The following table lists some of the common causes of[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e 1. Reduce the ground speed. 2. Air cleaner is dir ty . 2. Clean or replace the air cleaner element. 3. Oil level in the crankcase is low . 3. Add oil to the crankcase. 4. Cooling ns and air passages for the engine are plugg ed. 4. Remov e the obstructions f[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Fuse is blown. 1. Replace fuse. Check coil resistance, batter y c harge, charging system, and wiring connections and replace if necessar y . 2. Low voltage supply at the clutch. 2. Check coil resistance, battery charge, charging system, and wiring connections and replace if necessary . [...]

Schematics Schematics Electrical Diagram–All Units Except Kohler EFI 50[...]

Schematics Electrical Diagram–Kohler EFI 51[...]

Schematics Electrical Schematic–All Units Except Kohler EFI 52[...]

Schematics Electrical Schematic–Kohler EFI 53[...]

Schematics Hydraulic Diagram 54[...]

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: 56[...]

Service Record Date: Description of W ork Done: Service Done By: 57[...]

58[...]

G01 1841 Figure 44 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 20 degrees . Use the slope indicator to determine the degree of slope of hills before operating. Do Not operate this machine on a slope greater than 20 degrees. Fold along the appropriate line to match the recommended slope. 2.[...]

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[...]