Page 2 - WARNING
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 aviolation of Cali...
Page 3 - Introduction; CONGRATULATIONS; on the purchase of your
Introduction CONGRATULATIONS on the purchase of your Exmark Mower. This product has been carefullydesigned and manufactured to give you a maximumamount of dependability and years of trouble-freeoperation. This manual contains operating, maintenance,adjustment, and safety instructions for your Exmark...
Page 4 - Contents; Adjust RH Motion Control Handle
Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...
Page 5 - Safety; Safety Alert Symbol; Safe Operating Practices; Training
Safety Safety Safety Alert Symbol This lawn mower meets or exceeds the B71.4specifications of the American National StandardsInstitute in effect at the time of production. Exmark designed and tested this lawn mower to offerreasonably safe service; however, failure to complywith the following instruc...
Page 6 - DANGER; Avoid prolonged breathing of vapors.
Safety • Inspect the area where the equipment is to beused and remove all rocks, toys, sticks, wires,bones, and other foreign objects which can bethrown by the machine and may cause personalinjury to the operator or bystanders. DANGER In certain conditions gasoline is extremelyflammable and vapors a...
Page 7 - Operation; NEVER; Slope Operation; Extreme
Safety Operation WARNING Operating engine parts, especially the muffler,become extremely hot. Severe burns can occuron contact and debris, such as leaves, grass,brush, etc. can catch fire. • Allow engine parts, especially the muffler, tocool before touching. • Remove accumulated debris from muffler ...
Page 8 - Do Not mow slopes when grass is wet.; Maintenance and Storage; Always shield eyes and face from battery.
Safety DANGER Operating on wet grass or steep slopes cancause sliding and loss of control. Loss of controland/or loss of operator's footing could result in afall with an arm or leg getting under the moweror engine deck which may result in serious injury,death or drowning. • Mow across slopes, never ...
Page 9 - Do Not swallow electrolyte.; CAUTION
Safety DANGER Battery electrolyte contains sulfuric acid,which is poisonous and can cause severeburns. Swallowing electrolyte can be fatal orif it touches skin can cause severe burns. • Wear safety glasses to shield eyes, andrubber gloves to protect skin and clothingwhen handling electrolyte. • Do N...
Page 10 - Safety and Instructional Decals
Safety Safety and Instructional Decals • Keep all safety signs legible. Remove all grease,dirt and debris from safety signs and instructionallabels. • Replace all worn, damaged, or missing safetysigns. • When replacement components are installed, besure that current safety signs are affixed to there...
Page 14 - Specifications; Model Numbers; Engine; Do Not; Safety Interlock System
Specifications Specifications Model Numbers Serial Nos: 312,000,000 and Higher VT651KA484; VT691KA484CA; VT691KA524; VT691KA524CA; VT730EKC524; VT740EKC604; Systems Engine • Engine Specifications: See your Engine Owner’sManual • Engine Oil Type: Exmark 4–Cycle PremiumEngine Oil • RPM: Full Speed: 36...
Page 15 - Transmission; Hydraulic Oil: Use Exmark Premium Hydro Oil.; Wheel Drive System; Cutting Deck; – Electric clutch mounted on engine shaft.; Dimensions
Specifications Transmission • Two Hydro Gear variable displacement highefficiency pumps independently coupled to twohigh 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 typ...
Page 16 - Weights will vary slightly depending on engine.; Torque Requirements; Product Overview
Product Overview Tread Width: (Outside to Outside ofTires, Widthwise) 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: Weights will vary slig...
Page 17 - Determine the left and right sides of the; Controls; Motion Control Levers; Throttle Control
Operation 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 thetop console, control the forward and reverse motionof the machine. Moving the levers forward or backwar...
Page 18 - Park Brake Lever; The LCD indicator appears in the message; Ignition Switch; To start the engine, place the LH motion; Hour Meter; If the ignition key is turned to the “ON”
Operation Park Brake Lever Located on left side of unit, just to the front of theLH motion control lever (see Figure 5). The brake lever engages a parking brake on the drivewheels. Note: The LCD indicator appears in the message display on the front console when the park brake isengaged (see Figure 5...
Page 19 - Fuel; Operating Instructions
Operation Fuel Gauge Located on the top left side of the tank (see Figure 5). The fuel gauge monitors the amount of fuel in thetank. Drive Wheel Release Valves Located on the right front corner of the hydrostaticpumps. Drive wheel release valves are used to release thehydrostatic drive system to all...
Page 20 - Do Not crank the engine; PTO Engagement
Operation 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 (except Kohler EFI units). On a warm engine, leave the choke in the “OFF”position....
Page 21 - Driving the Machine; Use caution when making turns.; Driving Forward; Driving in Reverse
Operation Driving the Machine CAUTION Machine can spin very rapidly by positioning onelever too much ahead of the other. Operator maylose control of the machine, which may causedamage to the machine or injury. • Use caution when making turns. • Slow the machine down before making sharpturns. Importa...
Page 22 - Make sure the handles are locked; Operating the Platform
Operation Figure 10 To turn left or right, release pressure on themotion control lever toward the desired turndirection. 3. To stop, position both motion control levers in the neutral operate position. Adjusting the Front Reference/SpeedControl Bar Adjust the front reference/speed control bar fordes...
Page 24 - Adjusting the Cutting Height; Stop the machine and move the motion control; When changing the cutting height; Insert the height adjustment pin into the hole; Transporting; Transporting a Unit; Do Not drive a unit on a public street or roadway.
Operation Adjusting the Cutting Height The cutting height of the mower deck is adjustedfrom 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...
Page 25 - Do Not attempt to turn the unit
Operation WARNING Loading a unit on a trailer or truck increasesthe possibility of backward tip-over. Backwardtip-over could cause serious injury or death. • Use extreme caution when operating a uniton a ramp. • Use only a single, full width ramp; Do Notuse individual ramps for each side of the unit...
Page 26 - Maintenance
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING While maintenance or adjustments are beingmade, someone could start the engine.Accidental starting of the engine could seriouslyinjure you or other bystanders. Remove the key f...
Page 27 - Periodic Maintenance; Check Engine Oil Level; Service Interval: Before each use or daily; Check Battery Charge; Service Interval: As required
Maintenance Maintenance Service Interval Maintenance Procedure 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 ...
Page 28 - For Kohler EFI units: Unplug the; Check the weak battery for terminal corrosion; Make sure the booster is a good and fully charged; The following instructions are adapted; Do Not lean over the batteries.; Be sure the vent caps are tight and level.
Maintenance VoltageReading PercentCharge MaximumChargerSettings ChargingInterval 12.0–12.2 25–50% 14.4 volts/4amps 2 Hours 11.7–12.0 0–25% 14.4 volts/4amps 3 Hours 11.7 or less 0% 14.4 volts/2amps 6 Hours orMore Important: For Kohler EFI units: Unplug the harness from the ECU before performing anywe...
Page 29 - Check Mower Blades
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 positive cable to...
Page 30 - A. Install bushing through blade with bushing; Do not tamper with the interlock switches.; Move the motion control levers forward.
Maintenance A. Install bushing through blade with bushing flange on bottom (grass) side of blade. Figure 18 1. Install bushing in blade prior to installing bushing inspindle. B. Install bushing/blade assembly into spindle. Figure 19 1. Use wrench here forblade installation. Thisnut has been torqued ...
Page 31 - Check for Loose Hardware; Service Air Cleaner; Service Interval: Every 250 hours—Replace; Change Engine Oil; Service Interval: After the first 5 hours; Check Hydraulic Oil Level; Service Interval: Every 50 hours
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 upon the blade control switch (PTO) and release.The clutch should engage and the mower bladesbegin rotating. 7...
Page 32 - Check Tire Pressures; Check Condition Of Belts; Lubricate Grease Fittings; See chart for service intervals.; Lubricate Caster Wheel Hubs; Service Interval: Yearly
Maintenance 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 thebaffle inside the tank. If not, add oil. Use ExmarkPremium Hydro Oil. Replace hydraulic reservoirc...
Page 33 - To prevent seal and bearing damage,; Check Spark Plugs; Service Interval: Every 160 hours; Change Fuel Filter; Service Interval: After the first 250 hours
Maintenance Figure 20 1. Seal guard 2. Spacer nut with wrenchflats 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 threadlocking adhesive has been applied to lock thespacer nuts...
Page 34 - Hydraulic System Air; Hydraulic System Air Purge
Maintenance Every 500 hours/Yearly(whichever comesfirst) thereafter(Every 250 hours/Yearly ifusing Mobil 1 15W50) Note: Use only Exmark Part No. 109–4180 for Summer use above 32°F (0°C) or P/N 1-523541 forWinter use below 32°F (0°C) (Refer to Transmission section in Specifications for filter specifi...
Page 35 - Service Interval: After the first 100 hours; Check Spark Arrester
Maintenance Figure 21 1. Charge pump cap 2. Loosen 1 1/2 turns only 1. Stop engine and wait for all moving parts to stop. Raise the rear of the machine up onto jack standshigh enough to raise the drive wheels off theground. 2. Check oil level as stated in Check Hydraulic Oil Level section. 3. Start ...
Page 36 - Thread Locking Adhesives; Check Mower; Dielectric Grease; Adjustments; Deck Leveling; Checking the Tire Pressure
Maintenance Thread Locking Adhesives Thread locking adhesives such as “Loctite 242”or “Fel-Pro, Pro-Lock Nut Type” are used on thefollowing fasteners: • Pump sheave setscrews. • Sheave retaining bolt in end of engine crankshaft. • Caster wheel spacer nuts. • Platform spring pin. Mobil HTS Grease (Or...
Page 38 - Pump Drive Belt Tension
Maintenance Figure 26 1. Rear lift points 2. Engine deck brackets 7. To raise the front of the mowing deck, tighten the front locking nuts by the same amount on bothfront adjusting rods. Tighten both rear lockingnuts. Check the side to side level of the moweragain; refer to Deck Leveling . Note: Rak...
Page 40 - Electric Clutch Adjustment
Maintenance Figure 31 1. Switch 3. Brake lever 2. 1/8 inch (3mm) gapneeded between switchand brake lever 9. If needed, loosen the screws holding the switch and adjust the switch. Electric Clutch Adjustment No adjustment necessary. However when the clutchbrake has worn to the point where the clutch n...
Page 41 - Troubleshooting
Maintenance G011733 1 Figure 34 1. Feeler gauge Figure 35 1. Feeler gauge • If the gap is less than 0.010 inch, thenreinstall the shim and reference the Troubleshooting section. • If the gap is sufficient, proceed to thesafety check in step F. F. Perform the following safety check: a. Sit on the sea...
Page 44 - After the cam is adjusted, the lever switch needs
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 checked. 9. Check the gap between the control lever and switch as shown in Figure 42. The gap needsto be an 1/8 inch (3mm) with the right m...
Page 45 - Cleaning; Service Interval: Every 80 hours; Clean Debris From Machine; Waste Disposal; Motor Oil Disposal
Maintenance Cleaning Clean Engine and ExhaustSystem Area Service Interval: Before each use or daily (May be required moreoften in dry or dirtyconditions.) CAUTION Excessive debris around engine cooling airintake and exhaust system area can cause engine,exhaust area, and hydraulic system to overheatw...
Page 46 - Battery Disposal
Maintenance Battery Disposal DANGER Battery electrolyte contains sulfuric acid, whichis poisonous and can cause severe burns.Swallowing electrolyte can be fatal or if it touchesskin can cause severe burns. • Wear safety glasses to shield eyes, and rubbergloves to protect skin and clothing whenhandli...
Page 47 - condition prior to mower use.
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 causedby an empty fuel tank. The followi...
Page 50 - Schematics; Electrical Diagram–All Units Except Kohler EFI
Schematics Schematics Electrical Diagram–All Units Except Kohler EFI 50
Page 51 - Electrical Diagram–Kohler EFI
Page 52 - Electrical Schematic–All Units Except Kohler EFI
Schematics Electrical Schematic–All Units Except Kohler EFI 52
Page 53 - Electrical Schematic–Kohler EFI
Page 54 - Hydraulic Diagram
Page 57 - Service Record
Service Record Date: Description of Work Done: Service Done By: 57
Page 60 - M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S; EXMARK ACCESSORIES AND OPTIONS*; WALK-BEHIND ACCESSORIES AND OPTIONS; *Some accessories and options not available for some models.
M I D - M O U N T R I D I N G AC C E S S O R I E S A N D O P T I O N S EXMARK ACCESSORIES AND OPTIONS* WALK-BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO-MULCH SYSTEM TURF STRIPER STANDON CUSTOM RIDE SEAT SUSPENSION SYSTEM FULL SUSPENSION SEAT DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V POWER...
