Exmark VT651KA484 manual

V ANT AGE For Serial Nos. 312,000,000 & Higher Part No. 4501-211 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 arr ester mufer . It is a violation of Califor nia Public Resource Code (CPRC) Se[...]

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

Contents Introduction . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . 3 Safety .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. 5 Safety Alert 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; how ev er , failure to comply with the following instr uctions ma y 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 whic h 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 explosi ve. A re or e[...]

Safety Operation W ARNING Operating engine par ts, especially the mufer , become extremely hot. Sev ere bur ns can occur on contact and de bris, 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 debris from muf er and engine area. • Inst[...]

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 mow er or engine deck which may result in serious injur y , death or drowning . • Mow across slopes, nev er up and down. • Do Not mo w sl[...]

Safety DANGER Batter y electrolyte contains sulfuric acid, which is poisonous and can cause sev ere bur ns. Swallo wing electrolyte can be fatal or if it touches skin can cause severe bur ns. • W ear safety glasses to shield eyes, and r ub ber glo ves to protect skin and clothing when handling electrolyte. • Do Not s w allo w electrolyte. • I[...]

Safety Safety and Instructional Decals • Keep all safety signs legible. R emo v e all grease, dirt and debris from safety signs and instr uctional labels . • R eplace all w orn, 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 60 Inch Model 1 16-3267 1 16-3283 1 16-3290 1 16-4181 1 1[...]

Safety 1 16-5040 1. Forward position – faster 2. Backward position – slower 1 16-7217 1 16-1887 1. Fast 3. Neutral 2. Slow 4. Reverse 1 16-4647 12[...]

Safety 1 16-4648 All Units Except EFI 1. PTO-on 4. Slow 2. PTO-of f 5. Choke-on 3. Fast 6. Choke-off 1 16-5026 EFI Only 1. PTO-on 3. Fast 2. PTO-of f 4. Slow 13[...]

Specications Specications Model Numbers Serial Nos: 312,000,000 and Higher VT651KA484; VT691KA484CA; VT691KA524; VT691KA524CA; VT730EKC524; VT740EKC604; 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 Syste[...]

Specications T ransmission • T w o Hydro Gear v ariable displacement high efciency pumps independently coupled to tw o high efciency P arker/R oss wheel dri ve motors . • Hydraulic Oil: Use Exmark Premium Hydro Oil. • Hydraulic Oil Capacity: 2.4 qt. (2.2 L) • Hydraulic Filter is replaceable cartridg e type . P/N 109-4180: 25 micron[...]

Product Overview T read W idth: (Outside to Outside of Tires, W idthwise) 48 inch Deck 52 inch Deck 60 inch Deck 46.5 inches (118.1 cm) 46.5 inches (118.1 cm) 50.5 inches (128.3 cm) Curb Weight: 48 inch Deck 52 inch Deck 60 inch Deck 855 lb (388 kg) 875 lb (397 kg) 883 lb (401 kg) Note: W eights will v ar y slightly depending on engine . T orque Re[...]

Operation Operation Note: Deter mine the left and right sides of the machine from the normal operating position. Controls Motion Control Levers The motion control levers , located on eac h side of the top console , control the forw ard and rev erse motion of the mac hine. Moving the lev ers forward or backw ard turns the wheel on the same side forw[...]

Operation Park Brake Lever Located on left side of unit, just to the front of the LH motion control lev er (see Figure 5). The brake lev er engag es a parking brake on the dri v e wheels . Note: The LCD indicator appears in the message display on the front console when the park brak e is engag ed (see Figure 5 and Figure 7). T o engage the brake , [...]

Operation Fuel Gauge Located on the top left side of the tank (see Figure 5). The fuel g auge monitors the amount of fuel in the tank. Drive Wheel Release V alves Located on the right front corner of the h ydrostatic pumps . Driv e wheel release v alv es are used to release the hy drostatic dri v e system to allow the machine to be mov ed by hand w[...]

Operation 3. Push in (down) on the PTO switch to the “disengag e” position. 4. Place the throttle midw ay between 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 w ar m engine, lea ve the c hoke in the “OFF” position. 6. T urn 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 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 maximum forward speed. 1. Stop the m[...]

Operation W ARNING The operator platfor m is heavy and may cause injur y when lowering 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 piv ot area when lowering or raising the operator platfor m. • Make sure the platfor [...]

Operation Adjusting the Cutting Height The cutting height of the mo wer 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 loc k the deck to the 5 inc h (12.7 cm) transport position. The deck [...]

Operation W ARNING Loading a unit on a trailer or tr uck increases 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 indi vidual 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 star ting of the engine could seriously injure y ou or other bystander s. Remo ve the k ey from the ignition switch, engage parki[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedure Every 500 hours • R eplace the secondary air cleaner element. (Ma y need more often under sev ere conditions . See the Engine manual for additional infor mation.) • Change the h y draulic lter and uid (Ev er y 250 hours/yearly if using Mobil 1 15W50) • Chec k the wheel hu[...]

Maintenance V oltage Reading Percent Charge Maximum Charger Settings Charging Inter v al 12.0–12.2 25–50% 14.4 v olts/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 before perfor ming any welding on the equipment. R[...]

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 positiv e 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 130-160 ft-lb (176–217 N-m) 2. T orque [...]

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 switch (PTO) and release. The clutch should engage and the mower blades begin rotating . 7. Mov e or release the right side motion c[...]

Maintenance 1. Stop engine and w ait for all moving parts to stop , and remo v e k ey . Engage parking brak e . 2. Clean area around h ydraulic reser v oir 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 Hy dro Oil. Replace hy draulic reser voir cap and tighten until snug . D[...]

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 lock the spacer nuts to the axle . R emov e the axle (wit[...]

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 abo ve 32°F (0°C) or P/N 1-523541 for Winter use below 32°F (0°C) (R efer to T ransmission section in Specications for lter specications). 1. Stop engine, w [...]

Maintenance Figure 21 1. Charge pump cap 2. Loosen 1 1/2 turns only 1. Stop engine and w ait for all moving parts to stop . Raise the rear of the machine up onto jack stands high enough to raise the dri v e wheels off the g round. 2. Check oil lev el as stated in Check Hydraulic Oil Level section. 3. Start engine and mov e throttle control ahead to[...]

Maintenance Thread Locking Adhesives Thread loc king adhesi ves such as “Loctite 242” or “F el-Pro , Pro-Loc k 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 nuts . • 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 inc h (5 mm), an adjustment is required; contact an Authorized Ser vice Dealer . Figure 23 1. Blades side to side 2. Measure here 8. Low er the disc harge 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 locking nuts b y the same amount on both front adjusting rods . Tighten both rear locking nuts . Check the side to side lev el of the mow er again; refer to Deck Leveling . Note: Rak e adjustments may affect the motion con[...]

Maintenance Checking the Tire Pressure in Driv e System Maintenance. 4. Disengag e the park brak e. 5. Push do wn on the brake bar until it touc hes 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 h[...]

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 switch and adjust the switch. Electric Clutch Adjustment No adjustment necessar y . How ever when the clutc h brake has w orn to the point where the clutc h no longer engag es consistently , the shim[...]

Maintenance G011733 1 Figure 34 1. Feeler gauge Figure 35 1. Feeler gauge • If the gap 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 chec k in step F. F . P erfor m the follo wing safety c heck: a. Sit on the seat and start the engine. b . Mak e [...]

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 turns off . R otate the adjustment rod in the opposite direction half the n umber of turns counted. R elease the LH motion control lever and tighten the lock nuts on the right side . 8. T [...]

Maintenance 6. Check the alignment on the LH and RH neutral switches upper and lower surfaces (reference Figure 39). If they are not in alignment, loosen the hardware on the lo wer neutral switc h and adjust it forward or rearw ard as necessar y . Once aligned, tighten the hardware . Check the neutral switc h alignment ag ain as the dec k is mov ed[...]

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 lever switch needs to be c heck ed. 9. Check the gap between the control lev er and switch as shown in Figure 42. The gap needs to be an 1/8 inc h (3mm) with the right motion control lever in the neutral, operate p[...]

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 h ydraulic system to o verheat which can create a re hazard. Clean a[...]

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

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: star ting problems could be caused by an empty fuel tank. The following table lists some of the common causes o[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e 1. Reduce the g round speed. 2. Air cleaner is dirty . 2. Clean or replace the air cleaner element. 3. Oil lev el in the crankcase is lo w . 3. Add oil to the crankcase. 4. Cooling ns and air passages for the engine are plug ged. 4. Remov e the obstructions[...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Fuse is blown. 1. Replace fuse . Check coil resistance, batter y charge, c harging 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 Pr oducts Covered 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 EXMARK 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 DISCHARGE SUN SHADE TRA[...]