Vertex®

• Engine Specifications: See your Engine Owner’s Manual

• Engine Oil Type: Exmark 4-Cycle Premium Engine Oil

• RPM: Full Speed:

  • X-Series: 3600±50 RPM (No Load)

  • S-Series: 3700+75/-0 RPM (No Load)

• Capacity:

  • X-Series: 14.0 gal. (53 L)

  • S-Series: 8.0 gal. (30 L)

• Fuel Recommendations:

  • For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

  • Oxygenated fuel with up to 10% ethanol or 15% MTBE by volume is acceptable.

  • Do Not use ethanol blends of gasoline (such as E15 or E85) with more than 10% ethanol by volume. Performance problems and/or engine damage may result which may not be covered under warranty.

  • Do Not use gasoline containing methanol.

  • Do Not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.

  • Do Not add oil to gasoline.

• Fuel Filter: Replaceable In-line

• Charging System: Flywheel Alternator

• Charging Capacity:

  • Kawasaki:

    • X-Series EFI Models: 30 Amp

    • All S-Series Models and X-Series Non-EFI Models: 15 Amp

  • Kohler: 20 Amp

• Battery Type: BCI group U1

• Battery Voltage: 12 Volt

• Polarity: Negative Ground

• Fuses:

  • 20 amp charging system fuse

  • 15 amp accessory fuse

  • 20 amp power fuse

• Low Voltage Light/Error Message: Center of control panel (EFI Models Only)

• Clutch Saver (X-Series EFI Models Only): Allows the throttle to automatically reduce engine RPM when the PTO switch is engaged/disengaged or when stepping off the platform. Engine RPM will resume its setting when stepping back onto the platform and resetting the PTO.

• LCD indicators appear for the park brake, PTO, Neutral, and operator presence in the message display on the front control panel.

• PTO must be disengaged with motion control levers in the neutral position and park brake engaged to start the engine. (It is not necessary for the operator be on the platform in order to start the engine.)

  Note: The PTO Engagement Switch operates differently between the X- and S-Series models (refer to PTO Engagement Switch).

• Mower blades will stop if operator steps off the platform.

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.

• Two Hydro-Gear variable displacement high efficiency pumps independently coupled to two high efficiency wheel drive motors:

  • X-Series: Hydro-Gear

  • S-Series: Parker

• Hydraulic Oil: Use Exmark Premium Hydro Oil.

• Hydraulic Oil Capacity:

  • X-Series: 6.73 qt. (6.4 L)

  • S-Series: 2.25 qt. (2.1 L)

• Hydraulic Filter is replaceable spin-on type.

  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:

  • X-Series:

    • 0-12 mph (19 km/hr) forward.

    • 0-5.5 mph (8 km/hr) reverse.

  • S-Series:

    • 0-8.5 mph (14 km/hr) forward.

    • 0-5.5 mph (8 km/hr) reverse.

• Drive wheels release valves allow machine to be moved when engine is not running.

All S-Series Models

All X-Series Models

S-Series

X-Series

• Cutting Width:

  • 48 inches (121.9 cm)

  • 52 inches (132.1 cm)

  • 60 inches (152.4 cm)

  • 72 inches (182.9 cm)

• Discharge: Side

• Blade Size: (3 ea.):

  • 48 Inch Models: 16.25 inches (41.3 cm)

  • 52 Inch Models: 18.00 inches (45.7 cm)

  • 60 Inch Models: 20.50 inches (52.1 cm)

  • 72 Inch Models: 24.50 inches (62.2 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).

• Number of anti-scalp rollers:

  • 48 and 52 Inch Models: 3 anti-scalp rollers.

  • 60 Inch Models: 4 anti-scalp rollers.

  • 72 Inch Models: 6 anti-scalp rollers

• Deck: Full floating deck is attached to support frame, removable for service. Deck design allows for bagging, mulching or side discharge.

• Deck Depth: 5.5 inches (14 cm)

• Cutting Height Adjustment: All models adjusts from 1.5 inch (3.8 cm) to 5 inches (12.7 cm) in 1/4 inch (6.35 mm) increments.

• Mulching Kit: Optional

• Bagger: Optional

X-Series

S-Series

• X-Series: 48.9 inches (124 cm)

• S-Series: 49.2 inches (125 cm)

Note: Weights will vary slightly depending on deck size.

There are two sets of motion control levers, located in front and behind the reference bar on the top console, that control the forward and reverse motion of the machine.

Figure 4

1. LH Motion forward control lever
2. RH Motion forward control lever
3. Reference bar
4. LH Motion reverse control lever
5. RH Motion reverse control lever
6. Throttle
7. Height of cut lever
8. Ignition
9. Message display
10. PTO engagement switch
11. Choke (All Models Except EFI)
12. Park brake

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.

Note: When the motion control levers are in the neutral position, and park brake is engaged, a LCD indicator displays on the message display.

Figure 5

1. Neutral position

Located on the LH side of the control console (see Figure 4).

The choke is used to aid in starting a cold engine. Pulling up on the choke will put the choke in the “ON” position and pushing down on the choke will put the choke in the “OFF” position. Do Not run a warm engine with the choke in the “ON” position.

Located on the center of the control console (black lever).

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.

The machine has a clutch saver, which allows the throttle to automatically reduce engine RPM:

• when the PTO switch is engaged or disengaged.

• when stepping off the platform with the PTO engaged.

Engine RPM will resume its setting when the PTO is reset.

Located on the center of the control console (red lever).

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.

Located on the left side of the machine.

The brake lever engages a parking brake on the drive wheels and locks the motion controls in neutral.

Note: The LCD indicator appears in the message display on the front console when the park brake is engaged (see Figure 4 and Figure 7).

Pull the lever up and rearward to engage the brake.

Push the lever forward and down to disengage the brake.

When parking on a steep slope, the wheels must be chocked or blocked in addition to the brake being engaged. The machine must be tied down and brake engaged when transporting.

Park brake must be disengaged before motion control can move out of neutral.

Located on the RH side of the control console.

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.

Figure 6

1. Off
2. On
3. Start

Note: To start the engine, place the motion control levers in neutral and disengage the PTO switch (it is not necessary for the operator to be on the platform).

For X-Series EFI Models:

Note: The system will not allow the machine to start with the PTO switch in the pulled out (up) position.

For All S-Series Models and X-Series Non-EFI Models:

Note: The system will allow the machine to start with the PTO switch in the pulled out (up) position, but will not engage the blades. The PTO engagement switch must be reset to engage the PTO.

Located on the right side of the control console in the message display (see Figure 7).

The hour meter records the number of hours that the engine has run.

Figure 7

1. LCD Indicators
2. Low voltage indicator light
3. Hour/Voltage display

The hour meter is recording when the decimal point is flashing in Hour/Voltage display.

Hours are displayed when the key is off or when the machine is running.

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.

Note: The LCD indicators appear when each control meets the “safe to start” mode.

Located

• For X-Series: on the front of the hydrostatic pumps.

• For S-Series: on the rear of the hydrostatic pumps.

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. to 110-130 in-lb (12-15 N-m). Do Not overtighten. Do Not tow machine.

Located in the center of the console control below the hour meter (reference Figure 4).

Switch must be pulled out (up) to engage the blades. Switch is pushed in to disengage the blades.

The LCD indicator will disappear when the blades are engaged (see Figure 7).

For X-Series EFI Models:

Note: The machine has a clutch saver, which allows the throttle to automatically reduce engine RPM when the PTO switch is engaged/disengaged or when stepping off the platform. Engine RPM will resume its setting when stepping back onto the platform and resetting the PTO.

For All S-Series Models and X-Series Non-EFI Models:

The starter will crank with the PTO switch in the “ON” (pulled up) position; however, the system will disengage the PTO and a PTO reset error will occur. Engaging the PTO will require the operator to reset the PTO switch by turning it “OFF” (pushed down) and then turning it “ON”.

Located on the RH side of the front control panel.

To unlatch from transport, slightly pull the handle rearward and push the button down on top of the lever to disengage the transport lock. Allow the handle to move forward to lower the cutting deck to the cut height that has been set.

To raise to transport position, push the button down on top of the lever to disengage the deck lift latch. Pull the handle all the way rearward and release the button to latch the cutting deck into the raised transport position.

EFI Units Only:

The electronic control unit (ECU) continuously monitors operation of the EFI system. If a problem or Fault within the system is detected, the malfunction indicator light (MIL) is illuminated. The MIL is the light located in the left console panel to the left of the throttle control. Follow the Troubleshooting steps outlined in the engine operator’s manual if the MIL is illuminated.

The thigh pad can be removed for easy access to the hydro oil reservoir and pumps.

1. Lift the thigh pad roughly thirty degrees and lift to remove from machine.

   

   Figure 16

   1. Thigh pad

2. Perform any maintenance or adjustment on the machine.

1. Remove and retain the thigh pad.

2. Remove and retain the two knobs from the rear guard as shown in Figure 17.

   

   Figure 17

   1. Knob
   2. Rear guard

3. Pull the rear guard away from machine.

4. After the maintenance or adjustment is complete, reinstall the rear guard and hand tighten the knobs to secure the guard to the machine.

5. Reinstall the thigh pad.

Important: For Kawasaki and Kohler Engines, refer to the Engine Owner's Manual for additional maintenance procedures.

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 according to the engine manufacturer's recommendations. 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 fill to the “FULL” mark on the dipstick. Exmark 4-Cycle Premium Engine Oil is recommended; refer to the Engine Owner's manual for an appropriate API rating and viscosity. Do Not overfill.

Important: Do Not operate the engine with the oil level below the “LOW” (or “ADD”) mark on the dipstick, or over the “FULL” mark.

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 storage when the open circuit voltage drops to 12.4 volts.

Note: To prevent damage due to freezing, battery should be fully charged before putting away for winter storage.

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.

Check the voltage of the battery with a digital voltmeter or with the message display When the ignition is set to the accessory mode, the module will display the battery voltage. If the voltage is less than 12.4 volts, the battery may need to be charged.

Important: Make sure the negative battery cable is disconnected and the battery charger used for charging the battery should have an output of 16 volts and 7 amps or less to avoid damaging the battery (see chart for recommended charger settings). This is especially important on EFI (Electronic Fuel Injection) units. Failure to do so may damage the ECU (Electronic Control Unit).

Important: For EFI units: Unplug the harness from the ECU before performing any welding on the equipment.

1. Check the weak battery for terminal corrosion (white, green, or blue “snow”), it must be cleaned 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.

   Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine or EFI 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.

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

   Connecting the jumper cables incorrectly (wrong polarity) can immediately damage the electrical and/or EFI system.

   Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries.

   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).

   Warning

   Batteries contain acid and produce explosive gases.

   • Shield the eyes and face from the batteries at all times.

   • Do Not lean over the batteries.

   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.

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 18

   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 the positive terminal of the booster battery.

5. Connect the black negative (–) cable to the other terminal (negative) of the booster battery.

6. MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE (NOT TO THE NEGATIVE POST) AWAY FROM THE BATTERY. STAND BACK.

7. Start the vehicle and remove the cables in the reverse order of connection (the engine block (black) connection is the first to disconnect).

Note: A malfunctioning machine battery may cause the charging voltage to exceed 18.5 volts. The engine will turn off if there is a charge above 18.5 volts. Turn the ignition switch off, then on again to reset the engine before restarting the machine.

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:

   1. Install bushing through blade with bushing flange on bottom (grass) side of blade.

      

      Figure 19

      1. Install bushing in blade prior to installing bushing in spindle.

   2. Install bushing/blade assembly into spindle.

      

      Figure 20

      1. Use wrench here for blade installation. This nut has been torqued to 130-160 ft-lb (176–217 N-m)
      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.

   3. 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).

   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.

Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use.

Note: If machine does not pass any of these tests, Do Not operate. Contact an Authorized Service Dealer.

Note: To prevent PTO disengagement on rough terrain, the platform has a 1/2 second time delay before the PTO disengages after the operator leaves the platform.

Check the Normal Engine Starting Chart

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	Check the safety interlock system.

Note: It is not necessary for the operator to be on the platform to start the engine.

X- and S-Series

		System
		Parking Brake	PTO (Blades)	Motion Control Levers	Operator	Outcome
	State of System	Engaged	Disengaged	In neutral	On platform or off the platform	Starter should crank

All S-Series Models and X-Series Non-EFI Models Only

		System
		Parking Brake	PTO (Blades)	Motion Control Levers	Operator	Outcome
	State of System	Engaged	Up position, but blades disengaged*	In neutral	On platform or off the platform	Starter should crank

*Note: The starter will crank with the PTO switch in the “ON” (pulled up) position; however, the system will disengage the PTO and a reset PTO error will occur. Engaging the PTO will require the operator to reset the PTO switch by turning it “OFF” (pushed down) and then turning it “ON”.

Check Engine Starting Circuit Chart

Note: In the Check Engine Starting Circuit Chart, the state of system item that is bold is being checked in each scenario.

X- and S-Series

		System
		Parking Brake	PTO (Blades)	Motion Control Levers	Operator	Outcome
	State of System	Disengaged	Disengaged	In neutral	On platform or off the platform	Starter must not crank
	State of System	Engaged	Disengaged	* Levers not in neutral both levers moved forward or rearward, or either right or left lever moved forward or rearward	On platform or off the platform	Starter must not crank

*Note: First disengage the parking brake, move the motion controls out of neutral, re-engage the parking brake, then continue checking the scenario.

Check Engine Starting Circuit Chart—continued

X-Series Only

		System
		Parking Brake	PTO (Switch)	Motion Control Levers	Operator	Outcome
	State of System	Disengaged	Up position	In neutral	On platform or off the platform	Starter must not crank

Check Shutdown Circuit Chart

Note: The state of system item(s) that is bold is being checked in each scenario.

X- and S-Series

	System
State of System	Engine	Parking Brake	PTO (Blades)	Motion Control Levers	Operator	Outcome
	Running idle (1/3 throttle)	Engaged or Disengaged	Engaged	In neutral	Step off of platform	PTO must begin shutdown within 1 second; engine stays running.

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.

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.

Important: To prevent engine damage, always operate the engine with both air filters and cover installed.

1. When checking or replacing the air filter element, make sure the air filter assembly is installed in the brackets.

2. Position the air cleaner cover so that the breather valve does not interfere with the throttle mechanism.

   

   Figure 21

   Kawasaki Engine Only

   1. Air cleaner cover
   2. Throttle mechanism
   3. Breather valve

3. Secure the cover with latches.

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 hose is located on left hand side of engine at the rear. Place pan under machine to catch oil. Remove plug from end of drain hose. Allow oil to drain and replace oil drain plug. Torque plug to 20-24 ft-lb.

4. Replace the oil filter every other oil change. Clean around oil filter and unscrew filter to remove. Before reinstalling new filter, 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 1/2 to 3/4 turn.

5. Clean around oil fill cap and remove cap. Fill to specified capacity and replace cap.

6. Use oil recommended in the Check Engine Oil Level section. Do Not overfill. Start the engine and check for leaks.

7. Wipe up any spilled oil from engine deck mounting surfaces.

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.

   • X-Series:

     1. Wipe the dipstick clean and re-insert the cap back into the hydro. Lightly tighten the cap.

     2. Remove the cap again and check the level of the oil on the dipstick. See Figure 22 for oil levels.

        

        Figure 22

        1. Full
        2. Add

        Note: The oil level on the dipstick will be incorrect if the oil is checked when the machine is hot.

        Note: The dipstick has a cross-hatched area for hot oil (upper end) and cold oil (lower end). The oil level varies with the temperature of the oil.  The upper end of cross-hatching shows the level of oil when it is at 225°F (107°C). The lower end of cross-hatching 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 in the cross-hatched area. If the oil is at room temperature (about 75° F (24°C)), fill only to the lower end.

   • S-Series:

     Oil level should be to the top of the baffle inside the tank.

     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.

3. If the oil level is below the “ADD” or “COLD” level, add Exmark Premium Hydro Oil. Do Not overfill.

4. Replace hydraulic reservoir cap and tighten until snug. Do Not overtighten.

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.

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.

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 NLGI grade #2 multi-purpose gun grease.

   Refer to the following chart for fitting locations and lubrication schedule.

   Lubrication Chart

   Lubrication Chart
   Fitting Locations	Initial Pumps	Number of Places	Service Interval
   1. Deck Idler Pivot	1	2	Yearly
   2. Front Caster Pivots	*0	2	*Yearly

   

   Figure 23

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

   

   Figure 24

   1. Seal guard
   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 NLGI grade #1 multi-purpose grease.

7. Insert one bearing, one new seal into the wheel.

   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 NLGI 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.

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.

14. Reinstall the seal guards over the wheel hub and insert wheel into caster fork. Reinstall caster bolt and tighten nut fully.

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.

Remove spark plugs, check condition and reset gaps, or replace with new plugs. See Engine Owner's Manual.

A fuel filter is installed between the fuel tank and the engine. Replace when necessary.

Note: It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage.

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).

1. Stop engine, wait for all moving parts to stop, and remove key or spark plug wire(s). Engage parking brake.

2. Remove and retain the thigh pad and rear guard.

3. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely.

   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.

4. Remove and retain right and left drive tires and lug nuts.

5. Use a catch pan when draining the hydro oil.

6. There are three drains that need to be removed to do a complete fluid change. Place a pan under each drain from the following components: hydraulic filter and the left and right wheel motors.

   

   Figure 25

   Some components removed for clarity

   1. Hydraulic filter
   2. Left wheel motor plug
   3. Right wheel motor plug

7. Carefully clean area around filter. It is important that no dirt or contamination enter hydraulic system.

8. Unscrew the filter to remove and allow fluid to drain from the reservoir.

   Important: Before reinstalling new filter, fill it with 6 oz (.18 L) Exmark Premium Hydro oil and apply a thin coat of oil on the surface of the rubber seal.

   Install a new filter and turn the filter clockwise until the rubber seal contacts the filter adapter, then tighten the filter an additional 2/3 to 3/4 turn.

9. Remove the lowest plugs on the left and right wheel motors and allow the fluid to drain.

10. Reinstall both wheel motor plugs. The wheel motor drain plugs are magnetic; wipe clean before reinstalling.

11. Remove the fill port plug which is located near the “A” port on each wheel motor.

    

    Figure 26

    1. Fill port

    1. Fill the right-hand wheel motor up to the fill plug (approximately 29 oz (.95 L)).

    2. Fill the left-hand wheel motor up to the fill plug (approximately 42 oz (1.24 L)).

    3. Reinstall the plugs and torque to 46-50 ft-lb (62-68 N-m).

12. Exmark Premium Hydro Oil is recommended to fill the reservoir. Refer to the chart for an acceptable alternative:

    Hydro Oil	Service Interval
    Exmark Premium Hydro Oil (Preferred)	After first 250 hours*Every 500 hours/Yearly thereafter
    Mobil 1 15W50	After first 250 hours *Every 250 hours/Yearly thereafter

    *May need more often under severe conditions.

13. Fill reservoir as stated in Check Hydraulic Oil Level.

14. Remove the reservoir cap from the fluid tank.

15. Add 48 oz (1.41 L) of oil to the reservoir.

    Note: The machine may need to be started and ran in order to add all 48 oz (1.42 L) to the reservoir (reference Step 16 and Step 17). Total amount of oil added will be approximately 125 oz (3.9 qt (3.7L)). The reservoir will be overfull at this point, but the level will drop slightly once the machine is started and oil fills the rest of the system.

16. Reinstall the drive tires and torque the lug nuts as recommended (see Torque Requirements).

17. Start engine and move throttle control ahead to full throttle position. Disengage parking brake and move motion control levers forward with equal pressure, and run for one minute. Shut down the machine, allow the hydros to cool.

18. Check the level of the hydraulic oil; refer to Check Hydraulic Oil Level section.

    Add enough oil to put the level in the cross-hatched area on the dipstick. Reinstall the cap.

19. If either drive wheel does not rotate, one or both of the charge pumps may have lost their “prime.” Refer to Hydraulic System Air Purge section.

20. Reinstall the rear guard and thigh pad.

21. Remove the jack stands.

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: 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).

1. Stop engine, wait for all moving parts to stop, and remove key or spark plug wire(s). Engage parking brake.

2. Remove and retain the thigh pad and rear guard.

3. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely.

4. Use a catch pan when draining the hydro oil.

5. Place a catch pan under the hydro filter.

6. Carefully clean area around filter. It is important that no dirt or contamination enter hydraulic system.

7. Unscrew filter to remove and allow oil to drain from reservoir. Remove clamp and one hose from the reservoir to fully drain the machine.

   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.

   Turn filter clockwise until rubber seal contacts the filter adapter, then tighten the filter an additional 2/3 to 3/4 turn.

8. Reinstall the hose and clamp onto reservoir fitting.

9. Exmark Premium Hydro Oil is recommended to fill the reservoir. Refer to the chart for an acceptable alternative:

   Hydro Oil	Service Interval
   Exmark Premium Hydro Oil (Preferred)	After first 250 hours*Every 500 hours/Yearly thereafter
   Mobil 1 15W50	After first 250 hours *Every 250 hours/Yearly thereafter

   *May need more often under severe conditions.

10. Fill reservoir as stated in Check Hydraulic Oil Level.

11. 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.

12. Start engine and move throttle control ahead to full throttle position. Disengage parking brake and move motion control levers forward with equal pressure, and run for one minute. Shut down the machine, allow the hydros to cool.

13. Check the level of the hydraulic oil; refer to Check Hydraulic Oil Level section.

14. If either drive wheel does not rotate, one or both of the charge pumps may have lost their “prime.” Refer to Hydraulic System Air Purge section.

15. Reinstall the rear guard and thigh pad.

16. Remove the jack stands.

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.

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 27). Air in other parts of the hydraulic system will be purged through normal operation once the charge pump is “primed”.

Figure 27

1. Pump fan and guard
2. Bypass valve

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. Disengage parking brake and move motion control levers forward with equal pressure.

   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.

   Note: It is necessary to lightly touch the pump to check the pump temperature. If the pump 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.

4. Open the bypass valve (shown in Figure 27).

5. With the bypass valve open and the engine running, slowly move the motion control levers in both forward and reverse directions five to six times. As air is purged from the unit, the oil level in the reservoir will drop.

6. Close the bypass valve. With the bypass valve closed and the engine running, slowly move the motion control levers in both forward and reverse directions five to six times.

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.

Torque the nut on the wheel motor tapered shaft to 211-260 ft-lb (286-352 N-m).

Note: Do Not use anti-seize compound on the wheel hub.

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 such as “Loctite 242” or “Fel-Pro, Pro-Lock Nut Type” are used on the following fasteners:

• Pump sheave screws.

• Sheave retaining bolt in end of engine crankshaft.

General purpose 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 is used in the following locations:

• On threads of Blade Bolts. See Check Mower Blades section.

• Between engine crankshaft, PTO shaft, and PTO pulley.

• Between pump shafts and sheaves.

Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact. Dielectric grease should not be applied to sealed connectors.

Note: Small adjustments can be accomplished by increasing the tire pressure in the tire on the low side.

1. Adjust the height — to increase, turn the adjuster screw clockwise; to decrease, turn counterclockwise.

2. Loosen the jam nuts on the top of each deck adjuster. Fine tune the adjuster on the front deck lift assembly by turning it to get the correct height for the center deck left and right front blade tips

3. Measure the back tip height. Fine tune rear adjusters as required

4. Re-measure until all four sides are the correct height. Tighten all the jam nuts on the deck lift arm assemblies

   

   Figure 28

   1. Adjuster link
   2. Adjuster
   3. Jam nut

5. Position the mower on a flat surface.

6. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

7. Check the tire pressure in drive tires and pneumatic front caster tires (if equipped). Proper inflation pressure for tires is 13 psi (90 kPa). Adjust if necessary

8. Push the button down on top of the lever to disengage the deck lift latch. Pull the handle all the way rearward and release the button to latch the cutting deck into the raised transport position.

9. Insert the height adjustment pin into the 3 inch (7.6 cm) cutting height location.

10. Slightly pull the handle rearward and push the button down on top of the lever to disengage the transport lock. Allow the handle to move forward to lower the cutting deck to the cutting height.

11. Raise the discharge deflector.

12. Carefully rotate the blades front to rear. Measure from the level surface to the front tip of the center blade. The measurement should read 3 inches (7.6 cm).

    Note: In most conditions, the back tips on the side blades should be adjusted 1/8-1/4 inch (3.2-6.4 mm) higher than the front.

    

    Figure 29

    1. 3 1/8-3 1/4 inches (7.9-8.3 cm)
    2. Back blade tip
    3. Front blade tip
    4. 3 inches (7.6 cm)
    5. Level surface

13. Raise the deck to transport position.

Self-tensioning - No adjustment necessary.

Self-tensioning - No adjustment necessary.

If the parking brake does not hold securely, an adjustment is required.

1. Park the machine on a level surface.

2. Shut off engine and wait for all moving parts to stop.

3. When the park brake is released, the brake bars should lift off the tires and the hand lever should travel forward. When the brake is disengaged, the gap between the brake snubber teeth and drive tire on the right side of the machine should measure 1/4–3/8 inch (6–10 mm) (see Figure 30).

   • 48 and 52 Inch Models: Measure from center teeth

   • 60 Inch Model: Measure from outer tooth

   

   Figure 30

   1. Tire
   2. Brake snubber teeth
   3. 1/4–3/8 inch (6–10 mm)—60 Inch Model
   4. 1/4–3/8 inch (6–10 mm)—48 and 52 Inch Models

4. If the parking brake still does not hold securely, an adjustment is required. To adjust the brake, loosen whizlock nuts and slide the lower link up or down until the measurement is achieved.

   

   Figure 31

   1. Lower link
   2. Whizlock nut

5. Tighten the whizlock nuts to 27-33 ft lb (37-45 N-m).

If the machine travels or pulls to one side when the motion control levers are in the full forward position, adjust the rear control links.

1. Remove the thigh pad.

2. Adjust the rear control link (see Figure 32).

   1. Shorten link to increase speed.

   2. Lengthen link to decrease speed.

   

   Figure 32

   1. Link

3. Replace thigh pad.

4. Drive the machine and check the full forward tracking.

5. Repeat steps 1 through 4 until desired tracking is obtained.

   Note: The motion control lever needs to be in neutral while making any necessary adjustments.

There is a plate under the control panel that engages notches in the motion controls when the brake is applied in neutral. If the parking brake plate tabs do not engage these notches, adjust the front control links.

1. Slowly apply the brake while observing the tabs of the brake plate engaging the notches in the motion controls. The lock plate should drop easily and freely into the notches on each side.

2. Check that controls are in neutral. Adjust each side via the front control link (see Figure 33).

   

   Figure 33

   1. Link
   2. Jam nut

3. Remove the thigh pad.

4. Loosen upper and lower jam nuts at the top of the front control link.

   1. Lengthen link to move control rearward.

   2. Shorten link to move control forward.

5. Partially cycle brake on and off to observe plate movement in and out of notch.

6. Tighten jam nuts.

7. Replace thigh pad.

8. Check full forward tracking.

1. Remove the thigh pad.

2. The motion control link can be adjusted into the following positions to decrease the amount of force on the motion control levers.

   • Maximum force (factory setting) / Maximum speed forward and reverse:

     

     Figure 34

     Right side shown

     1. Motion control link
     2. Pump control bracket
     3. Nut

   • Medium force / Reduced speed forward and reverse:

     Remove the pump control bracket and position the link directly to the inside of the pump control arm.

     

     Figure 35

     Right side shown

     1. Motion control link
     2. Pump control arm
     3. Nut

   • Minimum force / Slowest speed forward and reverse:

     Place the linkage on the outside of the pump control bracket.

     

     Figure 36

     Right side shown

     1. Motion control link
     2. Pump control bracket
     3. Nut

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 belt shields, around the fuel tank, around engine and exhaust area.

   Important: You can wash the machine with mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, around the engine, hydraulic pumps, and motors.

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.

4. Clean oil coolers (if equipped) of all debris, dirt, and oil.

1. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

2. Remove cooling shroud access panels 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 shroud access panels are properly reinstalled. Operating the engine without cooling shroud access panels will cause engine damage due to overheating.

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 machine using jack stands or equivalent support.

3. Clean out any grass build-up from underside of deck and in discharge deflector.