quest® front steer - Hickory International

QUEST FRONT
STEER
®
For Serial Nos.
315,000,000 & Higher
Part No. 4502-541 Rev. A
no responsibility for variations which may be
evident in the actual specifications of its products
and the statements and descriptions contained
in this publication.
WARNING
CALIFORNIA
Proposition 65 Warning
This product contains a chemical
or chemicals known to the State of
California to cause cancer, birth defects,
or reproductive harm.
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 a
violation of California Public Resource Code
(CPRC) Section 4442 to use or operate this
engine on any forest-covered, brush-covered,
or grass-covered land as defined in CPRC 4126.
Other states or federal areas may have similar
laws.
To acquire a spark arrester for your unit, see your
Engine Service Dealer.
This spark ignition system complies with the
Canadian standard ICES-002. Ce système d’allumage
par ètincelle de vèhicule est conforme à la norme
NMB-002 du Canada.
The enclosed Engine Owner’s Manual is
supplied for information regarding The U.S.
Environmental Protection Agency (EPA) and
the California Emission Control Regulation of
emission systems, maintenance and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become
damaged or illegible, replace immediately.
Replacements may be ordered through the
engine manufacturer.
Labeled power ratings are supplied by the engine
manufacturer in accordance with SAE testing
and gross/net power rating standards (J1940,
J1995, J1349).
Exmark reserves the right to make changes or
add improvements to its products at any time
without incurring any obligation to make such
changes to products manufactured previously.
Exmark, or its distributors and dealers, accept
©2015 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
2
Contact us at www.Exmark.com.
Printed in the USA
All Rights Reserved
Introduction
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.
CONGRATULATIONS on the purchase of your
Exmark Mower. This product has been carefully
designed and manufactured to give you a maximum
amount of dependability and years of trouble-free
operation.
1
This manual contains operating, maintenance,
adjustment, and safety instructions for your Exmark
mower.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
G014523
Figure 1
By following the operating, maintenance, and safety
instructions, you will prolong the life of your mower,
maintain its maximum efficiency, and promote safe
operation.
1. Model and serial number location
Important: To maximize safety, performance,
and proper operation of this machine, it is
essential that all operators carefully read and
fully understand the contents of the Operator’s
manual provided with the product. Safe
operation of Exmark equipment is essential.
Failure to comply with the operating instructions
or receive proper training may result in injury.
Go to http://www.Exmark.com for additional
safe operation information, such as safety tips,
training materials, and Operator’s manuals.
Model No.
Serial No.
If additional information is needed, or should
you require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
All Exmark equipment dealers and distributors are
kept informed of the latest methods of servicing
and are equipped to provide prompt and efficient
service in the field or at their service stations. They
carry ample stock of service parts or can secure them
promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
3
Contents
Cleaning the Blower Housing..........................48
Fuel System Maintenance ...............................48
Servicing the Emissions Filter .........................48
Electrical System Maintenance........................49
Charging the Battery.......................................49
Drive System Maintenance .............................52
Checking the Tire Pressure .............................52
Checking the Hydraulic Oil Level–50 Inch
Only...........................................................52
Changing the Hydraulic System Filter and
Oil––50 Inch Only .....................................53
Mower Maintenance .......................................55
Servicing the Cutting Blades ...........................55
Leveling the Mower Deck ...............................57
Mower Belt Maintenance ................................60
Replacing the Discharge Deflector ..................62
Cleaning ............................................................63
Clean Grass Build-Up Under Deck .................63
Clean Engine and Exhaust System
Area ...........................................................63
Clean Debris From Machine ...........................64
Storage ..................................................................65
Cleaning and Storage ......................................65
Troubleshooting ....................................................66
Schematics ............................................................68
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ....................... 9
Specifications ........................................................17
Model Numbers .............................................17
Systems ..........................................................17
Dimensions....................................................18
Torque Requirements .....................................19
Product Overview .................................................19
Operation ..............................................................20
Controls .........................................................20
Operating Instructions ...................................22
Think Safety First ...........................................22
Recommended Gasoline.................................22
Checking the Engine Oil Level........................24
Starting the Engine.........................................24
Operating the Parking Brake
(SmartPark™) .............................................25
Operating the Blades ......................................25
Stopping the Engine .......................................25
The Safety Interlock System............................26
Driving Forward or Backward.........................27
Stopping the Machine.....................................27
Mowing in Reverse .........................................28
Adjusting the Height-of-Cut ...........................28
Adjusting the Anti-Scalp Rollers......................29
Positioning the Seat ........................................29
Changing the Seat Ride Suspension .................29
Positioning the Steering Wheel........................30
Pushing the Machine by Hand.........................30
Side Discharge................................................31
Transporting the Machine...............................31
Loading the Machine ......................................32
Operating Tips ..............................................33
Maintenance ..........................................................35
Recommended Maintenance Schedule(s) ............36
Premaintenance Procedures ...............................37
Raising the Seat ..............................................37
Raising the Front of the Machine.....................37
Periodic Maintenance ........................................37
Lubrication.....................................................37
Engine Maintenance.......................................38
Servicing the Engine Oil .................................40
Servicing the Spark Plug-Exmark 708cc
Engine .......................................................45
Servicing the Spark Plug-Kohler
Engine .......................................................46
4
Safety
Safety
• Allow only responsible adults who are familiar
with the instructions to operate the machine.
Safety Alert Symbol
• Clear the area of objects such as rocks, toys, wire,
etc., which could be picked up and thrown by the
blade.
This manual identifies potential hazards and has
safety messages identified by the safety alert symbol
(Figure 2), which signals a hazard that may cause
serious injury or death if you do not follow the
recommended precautions.
• Be sure the area is clear of other people before
mowing. Stop the machine if anyone enters the
area.
• Never carry passengers.
• Do Not mow in reverse unless absolutely
necessary. Always look down and behind before
and while backing up.
Figure 2
Safety Alert Symbol
• Be aware of the mower discharge direction and
Do Not point it at anyone. Avoid discharging
material against a wall or obstruction. Material
may ricochet back toward the operator. Stop the
blades when crossing gravel surfaces.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
• Do Not operate the mower without either the
entire grass collection system or the discharge
deflector in place.
This machine meets or exceeds the safety
specifications of the American National
Standards Institute B71.1 in effect at the time
of production. However, improper use or
maintenance by the operator or owner can
result in injury. To reduce the potential for
injury, comply with these safety instructions
and always pay attention to the safety alert
symbol, which means CAUTION, WARNING,
or DANGER-"personal safety instruction."
Failure to comply with the instruction may result
in personal injury or death.
• Be alert, slow down and use caution when
making turns. Look behind and to the side before
changing directions.
• Never leave a running machine unattended.
Always turn off blades, engage parking brake,
stop engine, and remove key before dismounting.
• Turn off blades when not mowing. Stop the
engine, wait for all parts to come to a complete
stop, engage parking brake, and remove key
before cleaning the machine, removing the grass
or unclogging the deflector.
Safe Operating Practices
• Operate the machine only in daylight or good
artificial light.
The following instructions are from ANSI standard
B71.1.
• Do Not operate the machine while under the
influence of alcohol or drugs.
This product is capable of amputating hands and
feet and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
• Watch for traffic when operating near or crossing
roadways.
General Operation
• Use extra care when loading or unloading the
machine into a trailer or truck
• Always wear eye protection when operating the
mower.
• Read, understand, and follow all instructions in
the operator’s manual and on the machine before
starting.
• Data indicates that operators, age 60 years and
above, are involved in a large percentage of riding
mower-related injuries. These operators should
evaluate their ability to operate the riding mower
• Do Not place hands or feet near rotating parts or
under the machine. Keep clear of the discharge
opening at all times.
5
Safety
safely enough to protect themselves and others
from serious injury.
rollovers, which may result in serious injury, death
or drowning.
• Use a walk behind mower and/or a hand trimmer
on slopes greater than 15 degrees, near drop-offs,
ditches, steep banks or water.
• Always follow the recommendations for wheel
weights or counterweights.
• Lightning can cause severe injury or death. If
lightning is seen or thunder is heard in the area,
Do Not operate the machine; seek shelter.
Children
Tragic accidents can occur if the operator is not
alert to the presence of children. Children are often
attracted to the machine and the mowing activity.
Never assume that children will remain where you
last saw them.
• Keep children out of the mowing area and under
the watchful care of another responsible adult,
not the operator.
• Be alert and turn the machine off if children enter
the area.
• Before and while backing or changing direction,
look behind, down, and side-to-side for small
children.
• Never carry children, even with the blades off.
They may fall off and be seriously injured or
interfere with safe machine operation.
• Children who have been given rides in the past
may suddenly appear in the mowing area for
another ride and be run over or backed over by
the mower.
• Never allow children to operate the machine.
• Use extra care when approaching blind corners,
shrubs, trees, the end of a fence or other objects
that may obscure vision.
Slope Operation
Slopes are a major factor related to loss of control
and tip-over accidents, which can result in severe
injury or death. Operation on all slopes requires extra
caution. If you cannot back up the slope or if you feel
uneasy on it, Do Not mow it.
• Do Not mow slopes greater than 15 degrees.
• Watch for ditches, holes, rocks, dips, and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Choose a low ground speed so you will not have
to stop while operating on a slope.
• Do Not mow slopes when grass is wet. Slippery
conditions reduce traction and could cause sliding
and loss of control.
• Reduce speed and use extreme caution on slopes.
• Do Not make sudden turns or rapid speed
changes.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
Towing Safety
• Be aware that operating on wet grass, across steep
slopes or downhill may cause the mower to lose
traction. Loss of traction to the drive wheels may
result in sliding and a loss of braking and steering.
• Do not attach towed equipment except at the
hitch point.
• Follow the attachment manufacturer's
recommendation for weight limits for towed
equipment and towing on slopes. Towed weight
must not exceed the weight of the machine,
operator, and ballast. Use counterweights or
wheel weights as described in the attachment, or
in the pulling machine Operator’s Manual.
• Never allow children or others in or on towed
equipment.
• On slopes, the weight of the towed equipment
may cause loss of traction, increased risk of
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• Use extreme care with grass collection systems or
other attachments. These can change the stability
of the machine and cause loss of control.
• Do Not try to stabilize the machine by putting
your foot on the ground.
• Do Not mow near drop-offs, ditches, steep banks
or water. Wheels dropping over edges can cause
6
Safety
rollover, and loss of control. Reduce the towed
weight and slow down.
• Stopping distance increases with the weight of the
towed load. Travel slowly and allow extra distance
to stop.
• Make wide turns to keep the attachment clear of
the machine.
• Never interfere with the intended function of a
safety device or reduce the protection provided
by a safety device. Check their proper operation
regularly.
• Keep the machine free of grass, leaves, or other
debris build-up. Clean up oil or fuel spillage and
fuel soaked debris. Allow the machine to cool
before storing.
Service
• Stop and inspect the equipment if you strike an
object. Repair, if necessary, before restarting.
Safe Handling of Gasoline
• Never make any adjustments or repairs with the
engine running.
To avoid personal injury or property damage, use
extra care when handling gasoline and other fuels.
They are flammable and the vapors are explosive.
• Extinguish all cigarettes, cigars, pipes and other
sources of ignition.
• Use only an approved container.
• Never remove the gas cap or add fuel when the
engine is running. Allow the engine to cool before
refueling.
• Never refuel the machine indoors.
• Never store the machine or fuel container inside
where there is an open flame, such as near a water
heater or furnace.
• Never fill containers inside a vehicle or on a
truck or trailer with a plastic liner. Always place
containers on the ground away from your vehicle
before filling.
• Remove gas-powered equipment from the truck
or trailer and refuel it on the ground. If this is
not possible, then refuel such equipment with a
portable container, rather than from a gasoline
dispenser nozzle.
• Keep the nozzle in contact with the rim of the
fuel tank or container opening at all times until
the fueling is complete. Do Not use a nozzle
lock-open device.
• If fuel is spilled on clothing, change clothing
immediately.
• Never overfill the fuel tank. Replace gas cap and
tighten securely.
• Grass collection system components are subject
to wear, damage and deterioration, which could
expose moving parts or allow objects to be
thrown. Frequently check components and
replace with manufacturers’ recommended parts,
when necessary.
• Mower blades are sharp and can cut. Wrap the
blades or wear gloves, and use extra caution when
servicing them.
• Check for proper brake operation frequently.
Adjust and service as required.
• Maintain or replace safety and instruction decals
as necessary.
• Use only genuine Exmark replacement parts to
ensure that original standards are maintained.
Exmark Riding Mower Safety
The following list contains safety information specific
to Exmark products or other safety information that
you must know that is not included in the ANSI
standards.
• Only adults and mature teenagers should operate
a mower, and even mature teenagers should have
adult supervision. Be sure a teenager:
1. has read and understands the Operator's
Manual and recognizes the risks involved;
2. is sufficiently mature to use caution; and
3. is of sufficient size and weight to operate
the controls comfortably and to manage the
mower without taking risks.
General Service:
• Never run a machine inside a closed area.
• Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good
condition.
• Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you. Do
Not run engine indoors or in an enclosed area.
7
Safety
• Park machine on level ground. Stop the engine,
wait for all moving parts to stop, engage parking
brake, disconnect spark plug wire(s) and remove
key before performing any service, repairs,
maintenance or adjustments.
• Keep hands, feet, hair, and loose clothing away
from attachment discharge area, underside of
mower and any moving parts while engine is
running.
• Do Not touch equipment or attachment parts
which may be hot from operation. Allow to cool
before attempting to maintain, adjust or service.
• Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes, and clothing.
Protect your face, eyes, and clothing when
working with a battery.
• Battery gases can explode. Keep cigarettes, sparks
and flames away from battery.
• Use only Exmark approved attachments.
Warranty may be voided if used with unapproved
attachments.
• If loading the machine onto a trailer or truck, use
a single, full-width ramp only. The ramp angle
should not exceed 15 degrees.
Note: The left and right sides of the machine are
determined while sitting in the seat in the normal
operating position
8
Safety
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
93-7009
1. Warning—don't operate the mower with the deflector up
or removed; keep the deflector in place.
2. Cutting/dismemberment hazard of hand or foot, mower
blade—stay away from moving parts.
105-7015
For Models with 42 Inch Decks
1. Belt routing
99-3943
For Models with 50 Inch Decks
106-8717
1. Engine
1. Read the instructions before servicing or performing
maintenance.
2. Check tire pressure every 25 operating hours.
3. Grease every 25 operating hours.
4. Engine
9
Safety
110-6691
1. Thrown object hazard—keep bystanders a safe distance
from the machine.
2. Thrown object hazard, mower—do not operate without
the deflector, discharge cover, or grass collection
system in place.
3. Cutting/dismemberment of hand or foot—stay away
from moving parts.
119-8870
50-inch Model
1. Height-of-cut
112-9840
1. Read the Operator's
Manual.
3. Remove the ignition key
and read the instructions
before servicing or
performing maintenance.
2. Height of cut
114-1606
1. Entanglement hazard, belt—keep all guards in place.
119-8871
42 Inch Model
1. Height-of-cut
10
Safety
131-3620
121-2989
1. Bypass lever position for
pushing the machine
1. Pedal position—forward
2. Bypass lever position for
operating the machine
3. Pedal position—reverse
2. Pedal position—neutral
127–0051
2. Warning—do not sit or
1. Maximum carrier frame
ride on the carrier frame;
load is less than or equal
read the Operator’s
to 100 lbs (45 kg).
Manual.
131-3621
1. Crushing/dismemberment hazard—keep bystanders
away from the machine; do not activate KeyChoice®
switch (allows mowing in reverse) with bystanders
nearby.
131-1097
42 and 50 Inch Models with Exmark Engine
1. Oil drain
11
Safety
131-3955
42 inch Model
131-3664
50 inch Model
1. Spinning blade
3.
1. On
2. Off
Operator's Manual
2. Reverse
131-4036
1. Tow or pull weights less
than or equal to 36 kg
(80 lbs).
2. Read the Operator's
Manual.
131-3665
42 inch Model
1. Spinning Blade
3. Read the Operator's
Manual.
PTO Switch Symbols
2. Reverse
1. PTO–disengage
2. PTO–engage
Exmark Engines Only
1. Shut down engine at full throttle
131-3954
50 inch Model
1. On
2. Off
12
Safety
121-0772
42 Inch Models with Exmark Engine
1. Fast
2. Continuous variable setting
4. Choke
5. Power take-off (PTO), Blade control switch
3. Slow
121-0773
50 Inch Models with Exmark Engine
1. Fast
2. Continuous variable setting
4. Choke
5. Power take-off (PTO), Blade control switch
3. Slow
13
Safety
131-4161
42 Inch Models with Kohler Engine
1. Fast
2. Continuous variable setting
3. Slow
4. Power take-off
131-4162
50 Inch Models with Kohler Engine
1. Fast
2. Continuous variable setting
3. Slow
4. Power take-off
14
Safety
132-0870
1. Warning—read the Operator's Manual.
4. Thrown object hazard—keep bystanders a safe distance
from the machine, pick up debris before operating, keep
deflector in place.
2. Cutting/dismemberment hazard, mower blade;
entanglement hazard, belt—stay away from moving parts,
keep all guards and shields in place.
5. Ramp hazard—When loading onto a trailer, do not use
split ramps. Only use a full width ramp wide enough for
the machine. Ramp angle with the ground should be less
than 15 degrees. Back up the ramp and drive forward off
the ramp.
3. Crushing/dismemberment hazard of bystanders, in
reverse and forward—do not carry passengers, look
behind and down when reversing.
6. Tipping hazard—do not turn at high speeds; do not use
with slopes greater than 15 degrees; only use on slopes
less than 15 degrees.
15
Safety
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
5. Read the Operator's Manual.
2. No fire, open flames, or smoking
6. Keep bystanders a safe distance
from the battery.
3. Caustic liquid/chemical burn hazard
7. Wear eye protection; explosive
gases can cause blindness and
other injuries.
4. Wear eye protection
8. Battery acid can cause blindness or
severe burns.
16
9. Flush eyes immediately with water
and get medical help fast.
10. Contains lead; do not discard.
Specifications
Specifications
Model Numbers
Serial Nos: 315,000,000 and Higher
QSS708GEM42200; QSS708GEM50200; QSS725GKC42200; QSS725GKC50200
Systems
• Polarity: Negative Ground
• Fuses: One 30 amp, one 25 amp; blade type
Engine
Safety Interlock System
• Engine Specifications: See your Engine Owner’s
Manual
• Engine Oil Type: Exmark 4-Cycle Premium
Engine Oil
• RPM:
Full Speed: 3300 ±100 (max) RPM (No Load)
Idle: 1650 (min) RPM
• PTO must be disengaged, traction pedal in
neutral, and parking brake engaged to start engine.
(It is not necessary for the operator to be in the
seat to start the engine.)
• Operator must be in seat when PTO is engaged
or traction pedal is moved forward/reverse or
engine will stop.
Fuel System
Operator Controls
• Capacity: 2.9 gal. (11 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: In-line
• Steering Wheel: Controls the direction and
turning radius. Rear tires operate independently
allowing zero-turns.
Note: Steering wheel is adjustable to three
operating positions and one, full-up position.
• Traction-control foot pedal: Controls the forward
and reverse motion along with speed.
• PTO Engagement Switch: Engages electric clutch
(to drive belt) which engages mower blades.
• Deck Height Adjustment Lever: Sets cutting
height to desired position.
Seat
• Type: Two tone upholstered high back, foam
padded seat with spring suspension and armrests.
• Mounting: Hinged to tilt up for access to battery
and other components. Adjustable fore and aft.
• Armrests: Standard–padded flip-up armrests.
• Seat Safety Switch: Incorporated into the Safety
Interlock System.
Electrical System
• Charging System: Flywheel Alternator
• Charging Capacity:
– Exmark: 15 amps
– Kohler: 12 amps
• Battery Type: 195 CCA
• Battery Voltage: 12 Volt
Hydrostatic Ground Drive System
• Hydrostatic Pumps:
– 42 inch unit: Two Hydro Gear ZT2200
Integrated drive systems.
17
Specifications
•
•
•
•
– 50 inch unit: Two Hydro Gear ZT2800
Integrated drive systems.
Hydraulic Oil Type: Exmark Premium Hydro Oil.
Hydraulic Filter—50 inch: P/N 109-3321
Speeds:
– 0-7.0 mph (11.3 km/hr) forward.
– 0-5.0 mph (8.0 km/hr) reverse.
Drive wheel releases, located on left and right
sides of engine deck, allow machine to be moved
when the engine is not running and brake is off.
• Deck Drive: Electric clutch mounted on vertical
engine shaft. Blades are driven by one belt
(w/self-tensioning idler) direct from the engine.
• Deck: Full floating deck is attached to out-front
support frame. Maximum turf protection is
provided with anti-scalp rollers.
Deck design allows for bagging, mulching or side
discharge.
• Deck Depth:
– 42 inch Deck: 4.0 inches (10.2 cm)
– 50 inch Deck: 4.0 inches (10.2 cm)
• Cutting Height Adjustment: A hand deck lift lever
is used to adjust the cutting height from 1 1/2
inch (3.8 cm) to 4 1/2 inches (11.4 cm) in 1/2
inch (1.3 cm) increments.
• Mulching Kit: Optional.
Tires and Wheels
Drive
Pneumatic (Air-Filled)
Deck Size
42
50
Quantity
2
2
Tread
Turf Tech TL
Kenda Super
Turf
Dimensions
Size
18 x 7.50-8
20 x 8-10
Overall Width:
Ply Rating
4
4
Pressure
13 psi
(90 kPa)
13 psi
(90 kPa)
Front Caster
Pneumatic (Air-Filled)
42 inch Deck
50 inch Deck
Without Deck
39.0 inches
(99 cm)
46.3 inches
(118 cm)
Deflector Up
43.2 inches
(110 cm)
50.6 inches
(129 cm)
Deflector Down
54.1 inches
(137 cm)
61.7 inches
(157 cm)
Deck Size
42
50
Quantity
2
2
Tread
Ribbed
Ribbed
Size
11 x 4-5
13 x 5-6
42 inch Deck
50 inch Deck
Ply Rating
2
2
81.7 inches (208 cm)
81.7 inches (208 cm)
Pressure
13 psi
(90 kPa)
13 psi
(90 kPa)
Overall Length:
Overall Height:
Cutting Deck
All Units
• Cutting Width:
– 42 inch Deck: 42 inches (107 cm)
– 50 inch Deck: 50 inches (127 cm)
• Discharge: Side
• Blade Size:
– 42 inch Deck: 21.60 inches (54.9 cm)–Qty: 2
– 50 inch Deck: 17.50 inches (44.5 cm)–Qty: 3
• Blade Spindles: Solid steel spindles with no
maintenance bearings.
42.8 inches (109 cm)
Tread Width: (Center to Center of
Tires, Widthwise)
18
42 inch Deck
50 inch Deck
Drive Wheels
31.5 inches
(80 cm)
37.4 inches
(95 cm)
Caster Wheels
30.8 inches
(78 cm)
34.0 inches
(86 cm)
Product Overview
Wheel Base: (Center of Caster Tire to
Center of Drive Tire)
42 Inch Deck
50 Inch Deck
52.5 inches (133 cm)
50.5 inches (128 cm)
Product Overview
Curb Weight:
42 inch Deck
50 inch Deck
645 lb (293 kg)
713 lb (323 kg)
Torque Requirements
Bolt Location
Torque
Spindle Pulley Nut
35-65 ft-lb (47-88 N-m)
Blade Mounting Bolt
35-65 ft-lb (47-88 N-m)
Engine Mounting Bolts
330-400 in-lb (37-45 N-m)
Wheel Lug Nuts
70-90 ft-lb (95-122 N-m)
2. Anti-scalp roller
50-60 ft-lb (68-81 N-m)
3. Traction-control pedal
10. Seat
4. Discharge deflector
11. Fuel tank
Clutch Mounting
Bolt (secured with
threadlocker)
Figure 3
1. Front caster wheel
8. Control panel
9. Engine
5. Deck height adjustment 12. Steering wheel
lever
6. SmartPark™ switch
13. KeyChoice® control
7. Rear drive wheel
19
14. Mower deck
Operation
Operation
Blade Control Switch (Power
Take-Off)
Controls
Located on the control panel.
Note: Become familiar with all of the controls
before you start the engine and operate the machine.
The blade control switch, represented by a power
take-off (PTO) symbol, engages and disengages
power to the mower blades (see Figure 4).
Ignition Switch
Pull up on the blade control switch to “ON” to
engage the blades.
Located on control panel.
Push down on the blade control switch to “OFF”
to disengage the blades.
The ignition switch is used to start and stop the
engine. The switch has three positions “OFF”,
“RUN” 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).
Throttle Lever
Located on control panel.
The throttle is used to control engine speed. Moving
throttle lever forward will increase engine speed and
moving throttle lever to the rear will decrease engine
speed (see Figure 4).
Choke Control
The choke is used to aid in starting a cold engine. Do
Not run a warm engine with the choke in the “ON”
position.
• Units with Exmark Engines: Pulling up on the
choke control will put the choke in the “ON”
position and pushing down the control will put
the choke in the “OFF” position.
Figure 4
Exmark Engine with 50 Inch Deck Shown
1. SmartPark™ (Parking brake) switch
2. Choke control
3. Throttle lever
4. Ignition switch
• Units with Kohler Engines: The engine is
integrated with an auto-choke. There is no need
to manually prime or choke these engines.
5. Blade control switch (power take-off)
6. Parking brake-On
Steering Wheel
7. Parking brake-indicator light
8. Parking brake-Off
The steering wheel is located in front of the seat.
The steering wheel controls the direction and turning
radius. The rear tires operate independently of each
other, like a zero-turn, which allows for sharp turns
and to turn in different directions quickly.
Note: Brake must be engaged, traction-control pedal
in neutral, and PTO switch “OFF” to start engine.
(It is not necessary for the operator to be in the seat
to start the engine.)
The steering wheel has three positions for operation
and one, full-up position. Use the full-up position for
stepping on and off the machine and getting out of
the seat. When operating the machine, position the
steering wheel where you have the best control of the
machine and are most comfortable.
Turning the key to the “OFF” position will stop the
engine; however, always remove the key when leaving
the machine to prevent someone from accidentally
starting the engine.
20
Operation
Traction-Control Pedal
cutting deck. Move the deck height adjustment lever
outward at the desired height-of-cut. Only adjust the
height of cut while the machine is not moving.
Located to the right of the steering wheel column
base.
Pressing the top of the traction-control pedal moves
the unit forward. Pressing the bottom of the pedal
moves the machine rearward. Releasing pressure off
of the pedal slows the machine.
KeyChoice® Switch
This switch allows you to mow in reverse when it is
activated. To activate it, turn the switch to “ON” and
release it after the power take-off (PTO) is engaged.
To deactivate it, disengage the PTO.
Note: The farther the pedal is pressed in either
direction, the faster the machine will move in that
direction.
Removing your foot and releasing all pressure from
the pedal places the traction-control pedal in neutral.
SmartPark™ Switch
Located on the lower right control panel.
The parking brake is activated electronically.
Figure 5
Engage the parking brake by one of the following
actions:
SmartPark™
• Pressing the
position (see Figure 4).
1. Operating–in–Reverse
warning light
switch to the “ON”
3. Fuel window
2. KeyChoice® switch (blue
in color)
• The parking brake engages automatically when the
operator leaves the seat and the traction-control
pedal is in neutral position.
Operating–in–Reverse Warning Light
• The parking brake automatically engages 5 to 6
seconds after the ignition switch is turned to the
“OFF” position (if not already engaged).
Located next to the KeyChoice® switch
The Operating–in–Reverse warning light will
illuminate whenever the KeyChoice® switch is used
to deactivate the operating–in–reverse interlock. It is
a reminder that the interlock system is deactivated.
The light goes out whenever the PTO is disengaged
or the engine is shut off. When the light is on, look
behind and use extra caution when backing.
Note: The light on the SmartPark™ switch will
illuminate when the parking brake is engaged.
Disengage the parking brake by one of the following
actions:
• Press the SmartPark™ switch to the “OFF”
position with the key in the run position.
• Tap the traction-control pedal forward or reverse.
Fuel Window
Make sure the parking brake engages when you stop
the machine or leave it unattended. The unit must be
tied down and brake engaged when transporting.
Located on the left side of the machine.
The fuel window can be used to determine the
amount of fuel in the tank.
Deck Height Adjustment Lever
Hour Meter
Located on right side in front of the SmartPark™
switch (see Figure 4).
The hour meter records the number of hours when
the operator is in the seat and the ignition switch is in
the “ON” position (Figure 6).
Pull the lever inward and rearward to raise the cutting
deck. Allow the handle to move forward to lower the
21
Operation
Figure 6
1. Hour meter location behind the seat
g027830
Operating Instructions
Figure 7
1. Safe Zone–use the Quest here.
2. Danger Zone–Use walk behind mower and/or hand
trimmer on slopes greater than 15 degrees, near
drop-offs and water.
Think Safety First
Note: Determine the left and right sides of the
machine from the normal operating position.
3. Water
Please carefully read all of the safety instructions and
decals in the safety section. Knowing this information
could help you, your family, pets or bystanders avoid
injury.
See inside back cover to determine the approximate
slope angle to be mowed.
CAUTION
DANGER
This machine produces sound levels in excess of
85 dBA at the operators ear and can cause hearing
loss through extended periods of exposure.
Mowing on wet grass or steep slopes can cause
sliding and loss of control. Wheels dropping
over edges can cause rollovers, which may result
in serious injury, death or drowning. A loss of
traction is a loss of steering control.
Wear hearing protection when operating this
machine.
To avoid loss of control and possibility of rollover:
• Do Not mow near drop-offs or near water.
• Do Not mow slopes greater than 15 degrees.
• Reduce speed and use extreme caution on
slopes.
• When mowing slopes, gradually work from
lower to higher areas on the incline.
• Avoid sudden turns or rapid speed changes.
• Turn up, into an incline when changing
directions on slopes. Turning down the slope
reduces traction.
• Attachments change the handling
characteristics of the machine. Use extra
caution when using attachments with the
machine.
1
2
G009027
Figure 8
1. Wear safety glasses
2. Wear hearing protection
Recommended Gasoline
Fill fuel tank on level ground. See Fuel
Recommendations in the Specifications section for
additional gasoline information.
Do Not add oil to gasoline.
22
Operation
Do Not overfill fuel tank. Fill the fuel tank to the
bottom of the filler neck. The empty space in the
tank allows gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine or emission
system.
DANGER
In certain conditions during fueling, static
electricity can be released causing a spark which
can ignite gasoline vapors. A fire or explosion
from gasoline can burn you and others and cause
property damage.
• Always place gasoline containers on the
ground away from your vehicle before filling.
• Do Not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the loss
of any static charge.
• When practical, remove gas-powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• If a gasoline dispenser nozzle must be used,
keep the nozzle in contact with the rim of the
fuel tank or container opening at all times
until fueling is complete. Do Not use a nozzle
lock open device.
DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.
A fire or explosion from gasoline can burn you,
others, and cause property damage.
• Fill the fuel tank outdoors on level ground, in
an open area, when the engine is cold. Wipe
up any gasoline that spills.
• Never refill the fuel tank or drain the machine
indoors or inside an enclosed trailer.
• Do Not fill the fuel tank completely full. Add
gasoline to the fuel tank until the body of the
tank is full but fuel does not fill the neck of
the tank. This empty space in the tank allows
gasoline to expand.
• Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never
buy more than a 30-day supply of gasoline.
WARNING
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors has caused cancer
in laboratory animals. Failure to use caution may
cause serious injury or illness.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Keep away from eyes and skin.
• Never siphon by mouth.
• Do Not operate without entire exhaust system
in place and in proper working condition.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to
provide the following benefits:
• Keeps gasoline fresh during storage of 30 days or
less. For longer storage it is recommended that
the fuel tank be drained.
• Cleans the engine while it runs.
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting Add the
23
Operation
correct amount of gas stabilizer/conditioner to
the gas.
result in fuel leakage or damage to the engine or
emissions system.
4. Install the fuel tank cap securely and tighten until
it “clicks”. Wipe up any gasoline that may have
spilled.
Note: A fuel stabilizer/conditioner is most effective
when mixed with fresh gasoline. To minimize the
chance of varnish deposits in the fuel system, use fuel
stabilizer at all times.
Checking the Engine Oil
Level
Filling the Fuel Tank
Make sure the engine is shut off and the parking brake
is engaged. Tank maximum capacity is 2.9 gallons.
Before you start the engine and use the machine,
check the oil level in the engine crankcase; refer to
Checking the Oil Level in Engine Maintenance
section.
Note: Use the fuel window to verify the presence of
gasoline before filling the tank.
Important: Do Not overfill fuel tank. Fill the
fuel tank to the bottom of the filler neck. The
empty space in the tank allows the fuel to expand.
Overfilling may result in fuel leakage or damage
to the engine or emission system.
1. Shut the engine off and engage parking brake.
2. Clean around the fuel tank cap and remove the
cap (see Figure 9).
A
B
Starting the Engine
1. Sit down on the seat, make sure the
traction-control pedal is in neutral and the parking
brake is engaged.
2. Disengage the blades by moving the blade control
switch to “OFF”.
C
D
Figure 10
Exmark Engine with 50 Inch Deck Shown
E
1. Ignition
5. Throttle lever
2. Off
3. Run
6. Choke control
7. Blade control switch–Off
position
4. Start
g027243
Figure 9
3. Engage the choke before starting a cold engine
(if applicable).
3. Add unleaded regular gasoline until the fuel
reaches the base of the filler neck and does not fill
the neck of the tank. This space at the base of
the filler neck allows gasoline to expand. Do Not
fill the fuel tank completely full. Overfilling may
Note: A warm or hot engine may not require
choking.
4. Turn the ignition key to “START” to energize the
starter. When the engine starts, release the key.
24
Operation
Important: Do Not engage the starter for
more than 5 seconds at a time. If the engine
fails to start, allow a 60 second cool-down
period between attempts. Failure to follow
these instructions can burn out the starter
motor.
5. Once the engine starts, gradually push down the
choke control (if applicable) as the engine warms.
If the engine stalls or hesitates, slightly pull the
control up for a few seconds.
3. Pull out on the blade control switch, to the “ON”
position, to engage the blades.
Operating the Parking Brake
(SmartPark™)
The parking brake is activated electronically.
Figure 11
Exmark Engine with 50 Inch Deck Shown
Engage the parking brake by one of the following
actions:
• Pressing the SmartPark™ switch to the “ON”
position (Figure 4).
• The parking brake engages automatically when
the operator leaves the seat and the traction
control pedal is in the neutral position.
• The parking brake automatically engages 5 to 6
seconds after the ignition switch is turned to the
“OFF” position (if not already engaged).
1. Throttle–Midway position 2. Blade control
switch—On position
4. Move throttle to full forward position before
mowing.
Disengaging the Blades
Set the throttle to the midway position. Push the
blade control switch to “OFF” to disengage the
blades (Figure 10).
Disengage the parking brake by one of the following
actions:
• Tap the traction-control pedal forward or reverse.
• Pressing the brake switch to the “OFF” position
(Figure 4).
Stopping the Engine
1. Bring the unit to a full stop.
2. Disengage the blades.
Operating the Blades
3. Release the traction-control pedal to place the
machine in neutral and engage the parking brake.
The blade control switch, represented by a power
take-off (PTO) symbol, engages and disengages
power to the mower blades. This switch controls
power to any attachments that draw power from the
engine, including the mower deck and cutting blades.
4. Adjust the throttle.
• For All Engines except Exmark: Place the
throttle midway between the “SLOW” and
“FAST” positions.
• For Exmark Engines: Place the throttle in the
“FAST” position.
Engaging the Blades
1. Release the traction-control pedal to place the
machine in neutral.
2. Move the throttle midway between the “SLOW”
and “FAST” positions.
5. Allow the engine to run for a minimum of 15
seconds, then turn the ignition switch to the
“OFF” position to stop the engine.
6. Remove the key to prevent children or other
unauthorized persons from starting engine.
Note: Always engage the blades with the throttle
in the midway position.
25
Operation
The Safety Interlock System
6. With brake disengaged and traction pedal in
neutral, turn the ignition switch to the “START”
position.
WARNING
Note: The brake should automatically engage,
the engine should crank, and the brake light will
turn on.
7. Engage the PTO by pulling up on the
blade-control switch.
8. Ensure the traction-control pedal is in neutral and
turn ignition switch to the “START” position.
If safety-interlock switches are disconnected
or damaged, the machine could operate
unexpectedly causing personal injury.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily, and replace any damaged switches
before operating the machine.
Note: The PTO should disengage and the engine
should crank.
9. Ensure the traction-control pedal is in the neutral
position and start the engine.
10. Raise from the seat.
Understanding the Safety-interlock
System
The safety-interlock system is designed for the
following:
• To prevent the engine from starting unless the
traction-control pedal is in the neutral position.
• To automatically ensure that the parking brake is
engaged and the PTO is off when starting.
• To stop the engine whenever the traction-control
pedal is not in the neutral position and you rise
from the seat.
• To automatically engage the parking brake and
disengage the PTO, when you rise out of the
seat with the traction-control pedal in the neutral
position.
• To stop the engine whenever the parking brake is
not engaged and you rise from the seat.
Note: The engine should remain running.
11. Return to the seat, disengage the parking brake
by pushing the SmartPark switch to the “OFF”
position.
Note: The engine should remain running.
12. Raise from the seat.
Note: The brake should automatically engage
and the engine should remain running.
13. Return to the seat, engage the blades by pulling
up on the blade-control switch.
14. Raise from the seat.
Note: The blades should disengage and the
engine should remain running.
15. Return to the seat, and pull the blade control
switch up.
Testing the Safety Interlock System
Test the safety interlock system before you use the
machine each time
1. While sitting on the seat, with the parking brake
disengaged, move the traction-control pedal
forward to “ON”.
2. Try starting the engine.
Note: The blades should engage.
16. Push down on the blade-control switch.
Note: The blades should disengage.
17. Engage the blades by pulling up on the
blade-control switch.
18. Move traction-control pedal to reverse.
Note: The engine should not crank.
3. While sitting on the seat, move the blade-control
switch to “OFF”.
4. Turn the ignition key to the “START” position.
Note: The blades should disengage.
19. Engage the blades by pulling up on the
blade-control switch.
20. Turn the KeyChoice® switch to “ON” and release.
Note: The starter should crank.
5. Push the SmartPark switch to the “OFF” position.
Note: The operating in reverse light should
illuminate.
21. Move the traction-control pedal to reverse.
Note: The brake should disengage, and the brake
light should turn off.
26
Operation
Note: The blades should remain engaged.
WARNING
22. Push the PTO switch to the “OFF” position.
The machine can spin very rapidly. The operator
may lose control of the machine and cause
personal injury or damage to the machine.
Note: The blades should turn off and the reverse
warning light should turn off.
• Use caution when making turns.
23. Engage the parking brake by pushing SmartPark
switch to the “ON” position.
• Slow the machine down before making sharp
turns.
Note: The brake should engage and the brake
light should be on.
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Placing
the throttle control in the “FAST” position can
be best for performance. For most applications,
operating in the full-throttle position is desirable.
24. Push and release the traction-control pedal in
either the forward or reverse direction.
Note: The brake should disengage and the brake
light should turn off.
Forward
25. Raise from the seat, and push the traction-control
pedal to either the forward or reverse direction.
1. Move the throttle to the “FAST” position.
Note: The engine should must initiate shutdown.
2. Place your foot onto the traction-control pedal
and slowly press the top of the pedal to go
forward, or press on the bottom of the pedal to
move backward (Figure 12).
Note: If machine does not pass any of these tests,
Do Not operate. Contact your authorized EXMARK
SERVICE DEALER.
Note: The farther you move the pedal in either
direction, the faster the machine will move in that
direction.
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
Driving Forward or Backward
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place
the throttle control in the Fast position for best
performance. Always operate in the Fast (full throttle)
position.
This machine has the characteristics of both a garden
tractor and a zero-turn machine. Like a garden
tractor, the machine has a foot pedal that controls the
forward and reverse motion along with the speed,
and it has a steering wheel that controls the direction
and the turning radius. Like a zero-turn machine,
the rear drive wheels operate independently of each
other, enabling you to make sharp turns and to turn
in different directions quickly. These characteristics
vastly improve the maneuverability of the machine,
but they may also require you to practice driving if
you are unfamiliar with this type of machine.
Figure 12
1. Forward
2. Traction-control pedal
3. Backward
3. To slow down, release the pressure on the
traction-control pedal.
Note: Always use caution when backing up and
turning.
Stopping the Machine
To stop the machine:
27
Operation
1. Release the traction-control pedal to place
the machine in neutral and disengage the
blade-control switch.
2. Adjust the throttle:
• For All Engines except Exmark: Place the
throttle midway between the “SLOW” and
“FAST” positions.
• For Exmark Engines: Place the throttle in the
“FAST” position.
3. Set the parking brake.
4. Allow the engine to run for a minimum of 15
seconds, then turn the ignition switch to the
“OFF” position. Remember to remove the key
from the ignition switch.
2. Engage the PTO.
3. Turn the KeyChoice® key clockwise until it stops
and release it.
Note: A red light illuminates on the console to
serve as a reminder that the interlock has been
deactivated.
4. Perform the mowing.
5. When finished mowing, remove the KeyChoice®
key (Figure 5).
Note: Once you deactivate the interlock, it stays
in this mode—with your mower blade or PTO
powered attachment operating whenever you
back up—and the console light stays on until you
either disengage the PTO or turn off the engine.
Mowing in Reverse
Adjusting the Height-of-Cut
The machine has an interlock feature that prevents
the mower deck from mowing while the machine
is traveling in reverse. If you shift into reverse with
the PTO engaged, the PTO will stop. If you need
to mow while in reverse gear, you can temporarily
deactivate this interlock.
Note: The transport position is the highest
height-of-cut position or cutting height 4.5 inches (
115 mm) as shown in Figure 13.
Note: Do not mow while backing up unless it is
absolutely necessary.
DANGER
A child or bystander could be backed over by a
riding mower with blades engaged and cause
serious personal injury or death.
• Do not mow in reverse unless absolutely
necessary.
• Always look backward and down before
backing up.
• Use the KeyChoice® switch only if you are
certain no children or other bystanders will
appear in the mowing area.
• Always remove both the ignition and
KeyChoice® keys and put them in a safe place
out of the reach of children or unauthorized
users when leaving the unit unattended.
If you are certain that you can safely mow or operate
an attachment in reverse, complete the following
procedure:
1. Insert the KeyChoice® key into the KeyChoice®
switch (Figure 5).
Figure 13
28
Operation
Adjusting the Anti-Scalp
Rollers
It is recommended to change the anti-scalp roller
position when the height of cut has changed.
1. Stop the machine and release the traction-control
pedal to place the machine in the neutral position.
2. Disengage the PTO.
3. Engage the park brake.
Figure 15
50 Inch Deck
For cutting heights above 3 1/2 inches (90 mm)
use the bottom hole. The rollers will still be effective
against scalping.
4. Stop the engine, remove the key and wait for all
moving parts to stop.
5. After adjusting the height of cut, adjust the
anti-scalp rollers by removing the nyloc nut.
1. Anti-scalp roller
mounting bracket
6. Adjust the anti-scalp rollers for the normal
operating conditions. Place rollers in one of the
positions shown in Figure 14 or Figure 15. Rollers
will maintain 3/4 inches (19 mm) clearance to
the ground to minimize gouging and roller wear
or damage.
2. Cutting height
7. Torque hardware to 27-33 ft-lb (37-45 N-m) or
loss of roller may result.
Positioning the Seat
Note: For Maximum Deck Flotation, place
the rollers one hole position lower. Rollers should
maintain 1/4 inch (6.35 mm) clearance to the
ground. Do Not adjust rollers to support the
deck.
The seat can move forward and backward. Position
the seat where you have the best control of the
machine and are most comfortable.
Figure 14
42 Inch Deck
1. Anti-scalp roller mounting bracket
2. Below 2 1/2 inches (64mm) cutting height
3. 2 1/2 inches (64mm) and above cutting height
Figure 16
Changing the Seat Ride
Suspension
The number of seat springs can be changed to
maximize rider comfort. More springs should be used
with heavier operators and on rough terrain. Fewer
29
Operation
springs should be used with lighter operators and
when mowing smooth, well established lawns. Always
keep the number of springs on the left and right side
the same when adding and removing springs.
Figure 17
1. Bolt
2. Spring
3. Nut
4. Additional mounting
holes
Figure 18
Up to five springs can be secured to the seat box with
a nut and bolt, see Figure 17.
Pushing the Machine by
Hand
Refer to your Parts Manual for spring and hardware
part numbers.
Important: Always push the machine by hand.
Do not tow the machine, because damage may
occur.
Positioning the Steering
Wheel
This machine has an electric-brake mechanism, and to
push the machine, the ignition key needs to be in the
Run position. The battery needs to be charged and
functioning for the electric brake to be disengaged.
The steering wheel has three positions for operation
and one, full-up position. Use the full-up position for
stepping on and off the machine and getting out of
the seat. When operating the machine, position the
steering wheel where you have the best control of the
machine and are most comfortable.
Note: If the battery does not have a charge,
the electric brake can be released manually; refer
to Releasing the Electric Brake section in
Maintenance.
1. Press your foot onto the steering-column release
lever.
Pushing the Machine
2. Position the steering wheel to the desired position
(Figure 18).
1. Park the machine on a level surface, and disengage
the blade-control switch.
2. Set the parking brake, stop the engine, and wait
for all moving parts to stop before leaving the
operating position.
3. Locate the bypass levers on the frame on both
sides of the engine.
30
Operation
4. Move the bypass levers forward through the key
hole and down to lock them in place (Figure 19).
DANGER
Without the discharge deflector, mulch kit, or
entire grass collection system mounted in place,
you and others are exposed to blade contact and
thrown debris. Contact with rotating mower
blade(s) and thrown debris will cause injury or
death.
Note: Ensure this is done for each lever.
5. Turn the ignition key on and disengage the
parking brake.
Note: Do not start the machine.
• Never remove the discharge deflector from
the mower because the discharge deflector
routes material down toward the turf. If the
discharge deflector is ever damaged, replace
it immediately.
Note: The machine is now able to be pushed
by hand.
3
• Never put your hands or feet under the
mower.
• Never try to clear discharge area or mower
blades unless you move the blade control
switch to Off and rotate the ignition key to
Off. Also remove the key and pull the wire
off the spark plug(s).
Transporting the Machine
1 2
Use a heavy-duty trailer or truck to transport the
machine. Ensure that the trailer or truck has all
necessary brakes, lighting, and marking as required by
law. Please carefully read all the safety instructions.
Knowing this information could help you, your
family, pets, or bystanders avoid injury.
g017303
Figure 19
1. Bypass-lever locations
3. Lever position for
pushing the machine
2. Lever position for
operating the machine
WARNING
6. When finished, ensure that the key has been
returned to the Stop position to avoid draining
the battery charge.
Driving on the street or roadway without turn
signals, lights, reflective markings, or a slow
moving vehicle emblem is dangerous and can
lead to accidents causing personal injury.
Note: If the machine fails to move, the electric brake
may still be engaged. If necessary, the electric brake
can be released manually; refer to Releasing the
Electric Brake section in Maintenance.
Do not drive machine on a public street or
roadway.
To transport the machine:
Side Discharge
1. If using a trailer, connect it to the towing vehicle
and connect the safety chains.
The mower has a hinged discharge deflector that
disperses clippings to the side and down toward the
turf.
2. If applicable, connect the trailer brakes.
3. Load the machine onto the trailer or truck.
4. Stop the engine, remove the key, set the brake,
and close the fuel valve.
5. Tie down the machine near the front caster wheels
and the rear bumper (Figure 20).
31
Operation
WARNING
Loading a machine onto a trailer or truck
increases the possibility of tip-over and could
cause serious injury or death.
• Use extreme caution when operating a
machine on a ramp.
• Use only a full-width ramp; do not use
individual ramps for each side of the machine.
Figure 20
• Do not exceed a 15-degree angle between the
ramp and the ground or between the ramp
and the trailer or truck.
Loading the Machine
• Ensure the length of ramp is at least four
times (4X) as long as the height of the trailer
or truck bed to the ground. This will ensure
that ramp angle does not exceed 15 degrees
on flat ground.
Use extreme caution when loading or unloading
machines onto a trailer or a truck. Use a full-width
ramp that is wider than the machine for this
procedure. Back up ramps and drive forward down
ramps (Figure 21).
• Back up ramps and drive forward down
ramps.
• Avoid sudden acceleration or deceleration
while driving the machine on a ramp as this
could cause a loss of control or a tip-over
situation.
Figure 21
1. Back up ramps
2. Drive forward down
ramps
Important: Do not use narrow individual ramps
for each side of the machine.
Ensure the ramp is long enough so that the angle with
the ground does not exceed 15 degrees (Figure 22).
On flat ground, this requires a ramp to be at least four
times (4X) as long as the height of the trailer or truck
bed to the ground. A steeper angle may cause mower
components to get caught as the unit moves from the
ramp to the trailer or truck. Steeper angles may also
cause the machine to tip or lose control. If loading on
or near a slope, position the trailer or truck so that it
is on the down side of the slope and the ramp extends
up the slope. This will minimize the ramp angle.
32
Operation
Cutting a Lawn for the First Time
1
Cut grass slightly longer than normal to ensure that
the cutting height of the mower does not scalp any
uneven ground. However, the cutting height used in
the past is generally the best one to use. When cutting
grass longer than six inches tall, you may want to cut
the lawn twice to ensure an acceptable quality of cut.
Cut 1/3 of the Grass Blade
It is best to cut only about 1/3 of the grass blade.
Cutting more than that is not recommended unless
grass is sparse, or it is late fall when grass grows more
slowly.
2
Mowing Direction
Alternate mowing direction to keep the grass standing
straight. This also helps disperse clippings which
enhances decomposition and fertilization.
6
Mow at Correct Intervals
Normally, mow every four days. But remember,
grass grows at different rates at different times.
So to maintain the same cutting height, which is a
good practice, mow more often in early spring. As
the grass growth rate slows in mid summer, mow
less frequently. If you cannot mow for an extended
period, first mow at a high cutting height; then mow
again two days later at a lower height setting.
g027996
5
Figure 22
1. Full-width ramp in
stowed position
4. Ramp is at least four
times (4X) as long as the
height of the trailer or
truck bed to the ground
2. Side view of full-width
ramp in loading position
5. H= height of the trailer or
truck bed to the ground
3. Not greater than
15 degrees
6. Trailer
Cutting Speed
To improve cut quality, use a slower ground speed.
Avoid Cutting Too Low
Operating Tips
If the cutting width of the mower is wider than the
mower you previously used, raise the cutting height
to ensure that uneven turf is not cut too short.
Fast Throttle Setting
Long Grass
For best mowing and maximum air circulation,
operate the engine at the Fast position. Air is required
to thoroughly cut grass clippings, so Do Not set the
height-of-cut so low as to totally surround the mower
by uncut grass. Always try to have one side of the
mower free from uncut grass, which allows air to be
drawn into the mower.
If the grass is ever allowed to grow slightly longer
than normal, or if it contains a high degree of
moisture, raise the cutting height higher than usual
and cut the grass at this setting. Then cut the grass
again using the lower, normal setting.
When Stopping
If the machine’s forward motion must be stopped
while mowing, a clump of grass clippings may drop
33
Operation
onto your lawn. To avoid this, move onto a previously
cut area with the blades engaged.
Keep the Underside of the Mower
Clean
Clean clippings and dirt from the underside of the
mower after each use. If grass and dirt build up inside
the mower, cutting quality will eventually become
unsatisfactory.
Blade Maintenance
Maintain a sharp blade throughout the cutting season
because a sharp blade cuts cleanly without tearing or
shredding the grass blades. Tearing and shredding
turns grass brown at the edges, which slows growth
and increases the chance of disease. Check the
cutter blades daily for sharpness, and for any wear or
damage. File down any nicks and sharpen the blades
as necessary. If a blade is damaged or worn, replace
it immediately with a genuine Exmark replacement
blade. Only Exmark blades are to be used with this
unit. No other blades are approved.
34
Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could seriously
injure you or other bystanders.
Remove the key from the ignition switch, engage
parking brake, and pull the wire(s) off the spark
plug(s) before you do any maintenance. Also
push the wire(s) aside so it does not accidentally
contact the spark plug(s).
WARNING
The engine can become very hot. Touching a hot
engine can cause severe burns.
Allow the engine to cool completely before
service or making repairs around the engine area.
WARNING
Removal or modification of original equipment,
parts and/or accessories may alter the warranty,
controllability, and safety of the machine.
Unauthorized modifications to the original
equipment or failure to use original Exmark
parts could lead to serious injury or death.
Unauthorized changes to the machine, engine,
fuel or venting system, may violate applicable
safety standards such as: ANSI, OSHA and
NFPA and/or government regulations such as
EPA and CARB.
CAUTION
Raising the mower deck 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.
35
Maintenance
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 5 hours
• Change the engine oil (Exmark 708cc Engine).
• Change the engine oil (Kohler Engine).
After the first 50 hours
• Change the hydraulic system filter and oil (50 inch only).
Before each use or daily
•
•
•
•
•
•
•
•
Check the safety interlock system.
Check the air cleaner for dirty, loose or damaged parts.
Check the engine oil (Exmark 708cc Engine).
Check the engine oil (Kohler Engine).
Check the cutting blades.
Clean the grass build-up from under the cutting deck.
Clean the engine and exhaust system area.
Clean the grass and debris build-up from the machine and cutting deck.
Every 25 hours
• Grease all lubrication points.
• Clean the air cleaner foam element (more often in dusty, dirty conditions)(Exmark 708cc
engine).
• Service or replace the air cleaner pre-cleaner (more often under extremely dusty, dirty
conditions)(Kohler engine).
• Check the tire pressure.
• Check the hydraulic oil level in the expansion tank (50 inch only).
• Check the belts.
Every 50 hours
• Service the air cleaner paper element (more often under extremely dusty, dirty
conditions)(Kohler engine).
Every 100 hours
• Service the air cleaner paper element (more often in dusty, dirty conditions)(Exmark
708cc engine).
• Replace the air cleaner foam element (more often in dusty, dirty conditions)(Exmark
708cc engine).
• Replace the air cleaner paper element (more often under extremely dusty, dirty
conditions)(Kohler engine).
• Change the engine oil (change it more often under a heavy load or in high
temperatures)(Exmark 708cc Engine).
• Change the engine oil (change it more often under a heavy load or in high temperatures)
(Kohler Engine).
• Check the spark plug (Exmark 708cc engine).
• Clean the blower housing. More often under dirty conditions.
• Replace the fuel filter.
Every 200 hours
• Replace the air cleaner paper element (more often in dusty, dirty conditions)(Exmark
708cc engine).
• Replace the spark plug (Exmark 708cc engine).
• Check the spark plug (Kohler engine).
Every 400 hours
• Change the hydraulic system filter and oil (50 inch only).
Every 500 hours
• Replace the spark plug (Kohler engine).
Before storage
Monthly
Yearly
• Charge the battery and disconnect the battery cables.
• Perform all maintenance procedures listed above before storage.
• Paint any chipped surfaces.
• Check the battery charge.
• Inspect the emissions filter.
Important: For Kohler engines, refer to your Engine Operator's Manual for additional maintenance
procedures.
36
Maintenance
Premaintenance
Procedures
Periodic Maintenance
Raising the Seat
Greasing the Bearings
Make sure that the parking brake is engaged, and lift
the seat forward.
Service Interval: Every 25 hours/Monthly
(whichever comes first)
The following components can be accessed by raising
the seat:
Grease Type: NGLI grade #2 multi-purpose gun
grease.
• Serial plate
Grease the front caster wheels (Figure 24).
Lubrication
• Service decal
• Seat-adjustment bolts
• Fuel filter
• Battery and battery cables
Raising the Front of the
Machine
Figure 24
1. Front caster tire
If the front of the machine needs to be raised, use the
very front edge as show in .
1. Park the machine on a level surface and disengage
the blade control switch.
2. Stop the machine and release the traction-control
pedal to place the machine in the neutral position,
engage parking brake, stop the engine, remove the
key, and wait for all moving parts to stop before
leaving the operating position.
3. Clean the grease fittings shown in Figure 25 with
a rag. Make sure to scrape any paint off of the
front of the fitting(s).
Important: To prevent damage to the steering
mechanism, ensure the very front edge of the
machine is used for jacking points.
Figure 25
Located on the seat pan
1. Read the instructions before servicing or performing
maintenance.
2. Check tire pressure every 25 operating hours.
Figure 23
3. Grease every 25 operating hours.
4. Engine
4. Wipe up any excess grease.
37
Maintenance
Engine Maintenance
engage parking brake, stop the engine, remove the
key, and wait for all moving parts to stop before
leaving the operating position.
Servicing the Air Cleaner–Exmark
708cc Engine
3. Clean around the air cleaner cover to prevent dirt
from getting into the engine and causing damage.
Service Interval: Every 100 hours/Yearly
(whichever comes
first)—Service the air
cleaner paper element
(more often in dusty, dirty
conditions)(Exmark 708cc
engine).
Every 200 hours/Every 2
years (whichever comes
first)—Replace the air
cleaner paper element
(more often in dusty, dirty
conditions)(Exmark 708cc
engine).
Every 25 hours/Monthly
(whichever comes
first)—Clean the air
cleaner foam element
(more often in dusty, dirty
conditions)(Exmark 708cc
engine).
Every 100 hours/Yearly
(whichever comes
first)—Replace the air
cleaner foam element
(more often in dusty, dirty
conditions)(Exmark 708cc
engine).
4. Lift the cover and rotate the air-cleaner assembly
out of the engine (see Figure 26 and Figure 27).
g027800
Figure 26
Check the air cleaner daily or before starting the
engine. Check for a buildup of dirt and debris around
the air cleaner system. Keep this area clean. Also
check for loose or damaged components. Replace all
bent or damaged air cleaner components.
g027801
Figure 27
5. Separate the foam and paper elements.
Note: Operating the engine with loose or damaged
air cleaner components could allow unfiltered air into
the engine causing premature wear and failure.
Note: Service the air cleaner more often under
extremely dusty, dirty conditions.
Removing the Elements:
1. Park the machine on a level surface and disengage
the blade control switch.
2. Stop the machine and release the traction-control
pedal to place the machine in the neutral position,
g027802
Figure 28
38
Maintenance
Every 100 hours—Replace
the air cleaner paper
element (more often
under extremely dusty,
dirty conditions)(Kohler
engine).
Cleaning the Foam and Paper Elements:
Foam Element:
Wash the foam element with water.
Important: Replace the foam element if it is
torn or worn.
This engine is equipped with a replaceable, high
density paper air-cleaner element. Check the air
cleaner daily or before starting the engine. Check for
a buildup of dirt and debris around the air-cleaner
system. Keep this area clean. Also, check for loose or
damaged components. Replace all bent or damaged
air-cleaner components.
Paper Element:
1. Lightly tap the element on a flat surface to remove
dust and dirt.
2. Inspect the element for tears, an oily film, and
damage to the seal.
Important: Do not clean the paper element
with pressurized air or liquids, such as
solvent, gas, or kerosene. Replace the paper
element if it is damaged or cannot be cleaned
thoroughly.
Note: Operating the engine with loose or damaged
air-cleaner components could allow unfiltered air into
the engine, causing premature wear and failure.
Note: Service the air cleaner more often under
extremely dusty, dirty conditions.
1. Park the machine on a level surface and disengage
the blade control switch.
2. Stop the machine and release the traction-control
pedal to place the machine in the neutral position,
engage parking brake, stop the engine, remove the
key, and wait for all moving parts to stop before
leaving the operating position.
3. Rotate the latches outward.
4. Remove the cover to access the air-cleaner
element (see Figure 30).
To learn more about the Exmark twin-cylinder engine
go to http://exmark.com/engines or scan the QR
code.
Figure 29
708cc Engine
Servicing the Air Cleaner–Kohler
Engine
1
2
3
Service Interval: Before each use or
daily—Check the air
cleaner for dirty, loose or
damaged parts.
Every 25 hours—Service
or replace the air cleaner
pre-cleaner (more often
under extremely dusty,
dirty conditions)(Kohler
engine).
4
g023919
Figure 30
Every 50 hours—Service
the air cleaner paper
element (more often
under extremely dusty,
dirty conditions)(Kohler
engine).
1. Air-cleaner latch
3. Paper element
2. Engine
4. Air-cleaner base
5. Remove the pre-cleaner and paper element.
6. Remove the element, and gently tap the element
to dislodge dirt.
39
Maintenance
Note: Do Not wash the paper element or use
pressurized air, as this will damage the element.
A
B
C
D
Note: Replace a dirty, bent, or damaged element.
Handle the new element carefully; do not use if
the sealing surfaces are bent or damaged.
7. Wash the pre-cleaner in warm water with
detergent, rinse, and air dry.
8. Lightly oil the pre-cleaner with new engine oil and
squeeze out excess oil.
E
9. Clean the air-cleaner base as required, and check
the condition.
10. Install the pre-cleaner over the paper element.
11. Install the pre-cleaner and paper element onto the
air-cleaner base.
F
12. Install the cover, and secure it with the latches.
G
H
Servicing the Engine Oil
Checking the Engine Oil
Level–Exmark 708cc Engine
I
Service Interval: Before each use or daily
J
K
Important: Do not overfill the crankcase with oil
and run the engine; engine damage may result.
1. Park the machine on a level surface, disengage
the blade control switch, stop the engine, engage
parking brake, and remove the key.
G029368
2. Make sure the engine is stopped, level, and is cool
so the oil has had time to drain into the sump.
Figure 31
3. To keep dirt, grass clippings, etc., out of
the engine, clean the area around the oil fill
cap/dipstick before removing it.
5. If the level is low, wipe off the area around the oil
fill cap, remove cap/dipstick and add oil to the
“FULL” mark on the dipstick. Exmark 4-Cycle
Premium Engine Oil is recommended. Always
check the level with the dipstick before adding
more oil. Do Not overfill.
4. Check the engine oil level.
• Crankcase Capacity: 2.0 L (67.6 oz)
• Recommended Oil Type: Exmark 4-Cycle
Premium Engine Oil
– API service SF, SG, SH, SJ, or SL
40
Maintenance
A
SAE 30
B
SAE 5W -30, 10W -30
SYNTHETIC 5W -20, 5W -30, 10W -30
C
g029683
D
E
Figure 32
Viscosity table
Note: To prevent extensive engine wear or
damage, always maintain the proper oil level in the
crankcase. Never operate the engine with the oil
level below the “ADD” mark or over the “FULL”
mark on the dipstick.
F
G
H
Checking the Engine Oil–Kohler
Engine
Service Interval: Before each use or daily
g027515
Figure 33
Important: Do not overfill the crankcase with oil
and run the engine; engine damage may result.
5. If the level is low, wipe off the area around the
oil fill cap, remove cap/dipstick and add oil to
the “F” (FULL) mark on the dipstick. Exmark
4-Cycle Premium Engine Oil is recommended.
Always check the level with the dipstick before
adding more oil. Do Not overfill.
1. Park the machine on a level surface, disengage
the blade control switch, stop the engine, engage
parking brake, and remove the key.
2. Make sure the engine is stopped, level, and is cool
so the oil has had time to drain into the sump.
3. To keep dirt, grass clippings, etc., out of
the engine, clean the area around the oil fill
cap/dipstick before removing it.
• Crankcase Capacity: 1.9L (64 oz) when the
filter is changed.
• Recommended Oil Type: Exmark 4-Cycle
Premium Engine Oil
4. Check the engine oil level.
– API service SJ or higher
41
Maintenance
g027799
Figure 35
Figure 34
Viscosity table
Note: To prevent extensive engine wear or
damage, always maintain the proper oil level in
the crankcase. Never operate the engine with the
oil level below the “L”(LOW) mark or over the
“F” (FULL) mark on the dipstick.
Changing the Engine Oil-Exmark
708cc Engine
Service Interval: After the first 5 hours
Every 100 hours (change
it more often under a
heavy load or in high
temperatures)(Exmark
708cc Engine).
1. Park the machine so that the drain side is slightly
lower than the opposite side to ensure the oil
drains completely.
2. Start the engine and let it run until warm. This
warms the oil so it drains better.
3. Disengage the blade control switch and ensure
the parking brake is engaged.
4. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
42
Maintenance
A
B
C
D
E
A
B
C
D
E
F
3/4
F
g027477
G
Figure 37
Note: Ensure the oil filter gasket touches the
engine, then an extra 3/4 turn is completed.
Note: Dispose of the used oil at a recycling
center.
H
6. Slowly pour approximately 80% of the specified
oil into the filler tube—use oil recommended in
the Checking the Engine Oil Level–Exmark
708cc Engine section.
g029570
Figure 36
5. Change the engine oil filter. Apply a thin film of
clean Exmark 4-Cycle Premium Engine Oil to the
rubber gasket on the new filter.
43
Maintenance
A
B
C
D
E
F
g027484
Figure 38
7. Check the oil level; refer to Checking the
Engine Oil Level–Exmark 708cc Engine
section.
8. Start the engine and check for leaks.
Figure 39
Changing the Engine Oil-Kohler
Engine
Note: Torque the plug to 14 N-m (125 in-lb).
5. Change the engine oil filter. Apply a thin film of
clean Exmark 4-Cycle Premium Engine Oil to the
rubber gasket on the new filter.
Service Interval: After the first 5 hours
Every 100 hours (change
it more often under a
heavy load or in high
temperatures) (Kohler
Engine).
1. Park the machine so that the drain side is slightly
lower than the opposite side to ensure the oil
drains completely.
2. Start the engine and let it run until warm. This
warms the oil so it drains better.
3. Disengage the blade control switch and ensure
the parking brake is engaged.
4. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
44
Maintenance
A
B
A
B
C
D
C
D
E
F
E
g027517
3/4
Figure 41
g027477
Figure 40
7. Check the oil level; refer to Checking the
Engine Oil–Kohler Engine section.
Note: Ensure the oil filter gasket touches the
engine, then an extra 3/4 turn is completed.
8. Start the engine and check for leaks.
Note: Dispose of the used oil at a recycling
center.
Servicing the Spark
Plug-Exmark 708cc Engine
6. Slowly pour approximately 80% of the specified
oil into the filler tube—use oil recommended in
the Checking the Engine Oil–Kohler Engine
section.
Service Interval: Every 100 hours/Yearly
(whichever comes first)
Every 200 hours/Every 2
years (whichever comes
first)—Replace the spark
plug (Exmark 708cc
engine).
Ensure that the air gap between the center and side
electrodes is correct before installing the spark plug.
Use a spark plug wrench for removing and installing
the spark plug and a gapping tool or feeler gauge to
check and adjust the air gap. Install a new spark plug
if necessary.
Type: Champion RN9YC or equivalent
Air Gap: 0.030 inch (.76 mm)
45
Maintenance
Removing the Spark Plug-Exmark
708cc engine
A
B
1. Disengage the PTO and ensure the parking brake
is engaged.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
g027479
Figure 43
3. Disconnect the wire from the spark plug.
1. Center electrode
insulator
2. Side electrode
B
A
3. Air gap (not to scale)
2. Check the gap between the center and side
electrodes.
3. Set the gap to 0.030 inch (.76 mm).
g027478
Installing the Spark Plug–Exmark
708cc Engine
Figure 42
1. Install the spark plug. Make sure that the air gap
is set correctly.
2. Tighten the spark plug to 18.5–22.1 ft-lb (25–30
N-m).
Note: Due to the deep recess around the spark
plug, blowing out the cavity with compressed air
is usually the most effective method for cleaning.
The spark plug is most accessible when the blower
housing is removed for cleaning.
B
A
Checking the Spark Plug–Exmark
708cc Engine
1. Inspect the spark plug
Note: If you see light brown or gray on the
insulator, the engine is operating properly. A
black coating on the insulator usually means the
air cleaner is dirty.
C
25-30 N-m
18.5-22.1 ft-lb
D
Important: Do Not clean the spark plug(s).
Always replace the spark plug(s) when it has:
a black coating, worn electrodes, an oily film,
or cracks.
g027960
Figure 44
3. Push the wire onto the spark plug.
Servicing the Spark
Plug-Kohler Engine
Service Interval: Every 200 hours
46
Maintenance
Important: Do Not clean the spark plug.
Always replace the spark plug when it has a
black coating, worn electrodes, an oily film,
or cracks.
Every 500 hours—Replace
the spark plug (Kohler
engine).
Ensure that the air gap between the center and side
electrodes is correct before installing the spark plug.
Use a spark plug wrench for removing and installing
the spark plug and a gapping tool or feeler gauge to
check and adjust the air gap. Install a new spark plug
if necessary.
A
B
The spark plug is RFI compliant. Equivalent alternate
brand plugs can also be used.
g027479
Figure 46
Type: Champion XC12YC or equivalent
1. Center electrode
insulator
2. Side electrode
Air Gap: 0.030 inch (.76 mm)
Removing the Spark Plug–Kohler
engine
3. Air gap (not to scale)
2. Check the gap between the center and side
electrodes.
1. Disengage the PTO and ensure the parking brake
is engaged.
3. Set the gap to 0.030 inch (.76 mm).
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Installing the Spark Plug–Kohler
Engine
3. Disconnect the wire from the spark plug.
1. Install the spark plug. Make sure that the air gap
is set correctly.
B
A
2. Tighten the spark plug to 18 to 22 ft-lb (25 to 29
N-m).
g027478
Figure 45
4. Clean around the spark plug to prevent dirt from
falling into the engine and potentially causing
damage.
5. Remove the spark plug and metal washer.
Checking the Spark Plug–Kohler
Engine
1. Inspect the spark plug
Figure 47
Note: If you see light brown or gray on the
insulator, the engine is operating properly. A
black coating on the insulator usually means the
air cleaner is dirty.
3. Push the wire onto the spark plug.
47
Maintenance
Cleaning the Blower Housing
4. Squeeze the ends of the hose clamps together and
slide them away from the filter.
Service Interval: Every 100 hours/Yearly
(whichever comes first)
More often under dirty
conditions.
To ensure proper cooling, make sure the grass screen,
cooling fins, and other external surfaces of the engine
are kept clean at all times.
1. Remove the blower housing and any other cooling
shrouds.
2. Clean the cooling fins and external surfaces as
necessary.
3. Make sure the cooling shrouds are reinstalled
Important: Operating the engine with a blocked
grass screen, dirty or plugged cooling fins,
and/or cooling shrouds removed, will cause
engine damage due to overheating.
Figure 48
1. Fuel filter-Kohler engine
Fuel System Maintenance
2. Fuel filter-Exmark engine
5. Remove the filter from the fuel lines.
Replacing the Fuel Filter
6. Install a new filter with the flow direction arrow
coming from the fuel tank and pointing to the
engine. Move the hose clamps close to the filter
to secure it in place.
Service Interval: Every 100 hours/Yearly
(whichever comes first)
DANGER
Servicing the Emissions
Filter
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Perform any fuel related maintenance when
the engine is cold. Do this outdoors in an
open area. Wipe up any gasoline that spills.
• Never smoke when draining gasoline, and
stay away from an open flame or where a
spark may ignite the gasoline fumes.
Service Interval: Yearly
The machine is equipped with an emissions filter
connected to a tee fitting on the vent line coming
from the gas tank. The filter has an open port by
design. The filter should be inspected regularly.
Replace the filter if the filter is dirty or clogged.
Never install a dirty filter if it is removed from the
fuel line.
1. Park the machine on a level surface and disengage
the blade control switch.
2. Ensure the parking brake is engaged, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
3. The fuel filter is in the fuel line between the tank
and engine.
48
Maintenance
Electrical System
Maintenance
DANGER
Battery electrolyte contains sulfuric acid, which
is poisonous and can cause severe burns.
Swallowing electrolyte can be fatal or if it touches
skin can cause severe burns.
WARNING
• Wear safety glasses to shield eyes, and rubber
gloves to protect skin and clothing when
handling electrolyte.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the State of
California to cause cancer and reproductive
harm. Wash hands after handling.
• Do Not swallow electrolyte.
• In the event of an accident, flush with water
and call a doctor immediately.
CAUTION
If the ignition is in the “ON” position there
is potential for sparks and engagement of
components. Sparks could cause an explosion or
moving parts could accidentally engage causing
personal injury.
Charging the Battery
Removing the Battery
WARNING
Be sure ignition switch is in the “OFF” position
before charging the battery.
Battery terminals or metal tools could short
against metal machine components causing
sparks. Sparks can cause the battery gasses to
explode, resulting in personal injury.
1. Park the machine on a level surface and disengage
the blade control switch.
• When removing or installing the battery, Do
Not allow the battery terminals to touch any
metal parts of the machine.
2. Ensure the parking brake is engaged, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
• Do Not allow metal tools to short between
the battery terminals and metal parts of the
machine.
3. Raise the seat.
4. Disconnect the negative (black) ground cable
from the battery post (Figure 49). Retain all
fasteners.
DANGER
Charging or jump starting the battery may
produce explosive gases. Battery gases can
explode causing serious injury.
• Keep sparks, flames, or cigarettes away from
battery.
• Ventilate when charging or using battery in
an enclosed space.
• Make sure venting path of battery is always
open once battery is filled with acid.
• Always shield eyes and face from battery.
49
Maintenance
Note: To prevent damage due to freezing,
battery should be fully charged before putting
away for winter storage.
3. Check the voltage of the battery with a digital
voltmeter. Locate the voltage reading of the
battery in the table below and charge the battery
for the recommended time interval to bring the
charge up to a full charge of 12.6 volts or greater.
Important: Make sure the negative battery
cable is disconnected and the battery charger
used for charging the battery has an output of
16 volts and 7 amps or less to avoid damaging
the battery (see chart below for recommended
charger settings).
Figure 49
1. Negative battery post
4. Positive battery post
2. Bolt, washer, and nut
5. Battery strap
3. Terminal boot
6. Battery
WARNING
Incorrect battery cable routing could damage
the machine and cables causing sparks.
Sparks can cause the battery gasses to
explode, resulting in personal injury.
• Always disconnect the negative (black)
battery cable before disconnecting the
positive (red) cable.
• Always connect the positive (red) battery
cable before connecting the negative
(black) cable.
Voltage
Reading
Percent
Charge
Maximum
Charger
Settings
Charging
Interval
12.6 or
greater
100%
16 volts/7
amps
No
Charging
Required
12.4 – 12.6
75–100%
16 volts/7
amps
30 Minutes
12.2 – 12.4
50–75%
16 volts/7
amps
1 Hour
12.0–12.2
25–50%
14.4 volts/4 2 Hours
amps
11.7–12.0
0–25%
14.4 volts/4 3 Hours
amps
11.7 or less
0%
14.4 volts/2 6 Hours or
More
amps
Recommended Jump Starting
Procedure
5. Slide the rubber cover up the positive (red) cable.
Disconnect the positive (red) cable from the
battery post. Retain all fasteners.
6. Remove the battery strap (Figure 49) and lift the
battery from the battery tray.
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.
Checking the Battery Charge
CAUTION
1. Remove the battery from the chassis; refer to
Removing the Battery.
2. Allowing batteries to stand for an extended
period 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.
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 may occur.
50
Maintenance
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.
Figure 50
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
CAUTION
6. Discharged battery
Connecting the jumper cables incorrectly
(wrong polarity) can immediately damage the
electrical system.
7. Engine block
4. Connect the other end of the positive cable to the
positive terminal of the booster battery.
Be certain of battery terminal polarity and
jumper cable polarity when hooking up
batteries.
5. Connect the black negative (–) cable to the other
terminal (negative) of the booster battery.
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).
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).
WARNING
Batteries contain acid and produce explosive
gases.
Installing the Battery
• Shield the eyes and face from the batteries
at all times.
1. Position the battery in the tray with the terminal
posts toward the operating position (Figure 49).
• Do Not lean over the batteries.
2. Install the positive (red) battery cable to the
positive (+) battery terminal using the fasteners
removed previously.
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. Install the negative battery cable to the negative
(-) battery terminal using the fasteners removed
previously.
4. Slide the red terminal boot onto the positive (red)
battery post.
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 50.
5. Secure the battery with the strap (Figure 49).
51
Maintenance
Servicing the Fuses
Front Tires (caster wheels): 13 psi (90 kPa)
Service Interval: As required
The electrical system is protected by fuses. It requires
no maintenance; however, if a fuse blows, check the
component/circuit for a malfunction or short.
Fuse:
• Main F1-30 amp, blade-type
• Charge Circuit F2-25 amp, blade-type
1. Remove the four screws securing the control
panel to the machine. Retain all fasteners
2. Lift the control pane up to access the main wiring
harness and fuse block (Figure 51).
3. To replace a fuse, pull out on the fuse to remove
it (Figure 51).
Figure 52
1. Valve stem
Releasing the Electric Brake
Service Interval: As required
The electric brake can be release by manually rotating
the link arms forward. Once the electric brake is
energized the brake will reset.
To release the brake:
30
25
30
1
25
2
G014921
Figure 51
1. Main-30 amp
2. Charge circuit-25 amp
4. Return the control panel to its original position.
Use the four screws removed previously to secure
the panel to the machine.
Figure 53
1. Rotate brake-link
arm forward on the
electric-brake-control
module
Drive System Maintenance
2. Left rear tire
1. Turn the ignition key to the “OFF” position or
disconnect the battery
2. Locate the shafts where the brake link arms are
connected on both sides of the electric brake.
3. Rotate the shaft forward to release the brake.
Checking the Tire Pressure
Service Interval: Every 25 hours/Monthly
(whichever comes first)
Maintain the air pressure in the front and rear tires as
specified. Uneven tire pressure can cause uneven cut.
Check the pressure at the valve stem (Figure 52).
Check the tires when they are cold to get the most
accurate pressure reading.
Checking the Hydraulic Oil
Level–50 Inch Only
Rear Tires: 13 psi (90 kPa)
Service Interval: Every 25 hours
52
Maintenance
Check expansion reservoir and if necessary add
Exmark Premium Hydro Oil to the FULL COLD
line.
Figure 55
1. Jacking points
3. Locate the filter and filter guards on each transaxle
drive system. Remove three screws securing the
filter guard and guard.
Figure 54
1. Expansion reservoir
3. Engine
2. Full Cold line
Changing the Hydraulic
System Filter and Oil––50
Inch Only
Service Interval: After the first 50 hours
Every 400 hours thereafter.
The filter and oil are changed at the same time. Do
Not reuse oil. Once the new filter is installed and oil
is added any air in the system must be purged.
Figure 56
Right side shown
The bleeding process is repeated until the oil remains
at the FULL COLD line in the reservoir after purging.
Failure to properly perform this procedure can
result in irreparable damage to the transaxle
drive system.
1. Transaxle drive
2. Oil filter
4. Screws
5. Vent plug
3. Filter guard
4. Carefully clean area around filters. It is important
that no dirt or contamination enter hydraulic
system.
Removing Hydraulic System Filters
1. Stop engine, wait for all moving parts to stop, and
allow engine to cool. Remove the key and engage
the parking brake.
2. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
5. Place a container below the filter to catch the
oil that drains when the filter and vent plugs are
removed.
53
Maintenance
6. Locate and remove the vent plug on each
transmission
7. Unscrew the filter to remove and allow oil to
drain from drive system.
6.
Repeat this procedure for both filters.
Installing the Hydraulic System
Filters
2
1
3
7.
8.
9.
plug holes. Stop and install that vent plug. Torque
the plug to 180 in-lb (20.3 N-m).
Continue to add oil through the expansion
reservoir until oil comes out of the remaining
vent plug hole on the second transmission. Stop
and install that vent plug. Torque the plug to 180
in-lb (20.3 N-m).
Continue to add oil through the expansion
reservoir until it reaches the FULL COLD line on
the expansion reservoir.
Install the transaxle guard.
Proceed to the Bleeding the Hydraulic System
section.
Important: Failure to perform the Bleeding
the Hydraulic System procedure after
changing hydraulic filters and oil can result
in irreparable damage to the transaxle drive
system.
4
Bleeding the Hydraulic System
5
1. Enter the operator's position. Start engine and
move throttle control ahead to 1/2 throttle
position. Disengage parking brake.
A. Move the bypass levers into the pushing
the machine position; refer to Pushing the
Machine by Hand section in Operation.
With the bypass valves open and the engine
running, slowly move the traction-control
pedal in both forward and reverse (5 or 6
times).
B. Move the bypass levers into the operating
the machine position. With the bypass valve
closed and the engine running, slowly move
the traction-control pedal in both forward and
reverse directions (5 to 6 times).
C. Stop the engine and check the oil level in the
expansion reservoir. Add the specified oil
as until it reaches the Full Cold line on the
expansion reservoir.
2. Repeat step 1 until all the air is completely purged
from the system.
6
3/4
G008748
Figure 57
1. Apply a thin coat of oil on the surface of the
rubber seal of each filter.
2. Turn the filter clockwise until rubber seal contacts
the filter adapter then tighten the filter an
additional 3/4 to 1 full turn. Repeat for the other
filter
3. Install the filter guards over each filter as
previously removed. Use the three screws to
secure the filter guards.
4. Verify the vent plugs are removed before adding
the oil.
5. Slowly pour the specified oil through expansion
reservoir until oil comes out of one of the vent
When the transaxle operates at normal noise
levels and moves smoothly forward and reverse at
normal speeds, then the transaxle is considered
purged.
3. Check the oil level in the expansion reservoir one
last time. Add the specified oil until it reaches
54
Maintenance
the Full Cold line on the expansion reservoir if
necessary.
Mower Maintenance
Servicing the Cutting Blades
Maintain sharp blades throughout the cutting season
because sharp blades cut cleanly without tearing or
shredding the grass blades. Tearing and shredding
turns grass brown at the edges, which slows growth
and increases the chance of disease.
Figure 58
Check the cutter blades daily for sharpness, and for
any wear or damage. File down any nicks and sharpen
the blades as necessary. If a blade is damaged or
worn, replace it immediately with a genuine Exmark
replacement blade. For convenient sharpening and
replacement, you may want to keep extra blades on
hand.
1. Cutting edge
3. Wear/slot forming
2. Curved area
4. Damage
Checking for Bent Blades
Note: The machine must be on a level surface for
the following procedure.
1. Raise the mower deck to the highest height-of-cut
position; also considered the 'transport' position.
2. While wearing thickly padded gloves or other
adequate hand protection slowly rotate blade to
be measured into a position that allows effective
measurement of the distance between the cutting
edge and the level surface the machine is on.
WARNING
A worn or damaged blade can break, and a piece
of the blade could be thrown into the operator's
or bystander's area, resulting in serious personal
injury or death.
• Inspect the blade periodically for wear or
damage.
• Replace a worn or damaged blade.
1
Before Inspecting or Servicing the
Blades
2
3
G014972
Park the machine on a level surface, disengage the
blade control switch, and ensure the parking brake is
engaged. Stop the engine and remove the key.
Figure 59
1. Deck
2. Spindle housing
Inspecting the Blades
Service Interval: Before each use or
daily—Check the cutting
blades.
1. Inspect the cutting edges (Figure 58). If the edges
are not sharp or have nicks, remove and sharpen
the blades; refer to Sharpening the Blades.
2. Inspect the blades, especially the curved area
(Figure 58). If you notice any damage, wear,
or a slot forming in this area (items 3 and 4 in
Figure 58), immediately install a new blade.
55
3. Blade
Maintenance
3. Measure from the tip of the blade to the flat
surface here.
1
1
G014973
3
2
G014973
3
Figure 62
2
1. Opposing blade edge, in position for measuring
Figure 60
2. Level surface
3. Second measured distance between blade and surface
(B)
1. Blade, in position for measuring
2. Level surface
3. Measured distance between blade and surface (A)
WARNING
4. Rotate the same blade 180 degrees so that the
opposing cutting edge is now in the same position.
A blade that is bent or damaged could break
apart and could seriously injure or kill you or
bystanders.
• Always replace bent or damaged blade
with a new blade.
• Never file or create sharp notches in the
edges or surfaces of blade.
3
1
A. If the difference between A and B is greater
than 1/8 inch (3mm) replace the blade with a
new blade. Refer to Removing the Blades and
Installing the Blades.
2
G014974
Figure 61
1. Blade, side previously measured
Note: If a bent blade is replaced with a new
one and the dimension obtained continues
to exceed 1/8 inch (3mm), the blade spindle
could be bent. Contact an Authorized Exmark
Dealer for service.
B. If the variance is within constraints, move to
the next blade..
2. Measurement position used previously
3. Opposing side of blade being moved into measurement
position
5. Measure from the tip of the blade to the flat
surface here. The variance should be no more
than 1/8 inch (3mm).
Repeat this procedure on each blade.
Removing the Blades
The blades must be replaced if a solid object is hit, if
the blade is out of balance, or the blade is bent. To
ensure optimum performance and continued safety
conformance of the machine, use genuine Exmark
replacement blades. Replacement blades made by
other manufacturers may result in non-conformance
with safety standards.
56
Maintenance
Installing the Blades
Hold the blade end using a rag or thickly-padded
glove. Remove the blade bolt, curved washer, and
blade from the spindle shaft (Figure 63).
1. Install the blade onto the spindle shaft (Figure 63).
Important: The curved part of the blade
must be pointing upward toward the inside of
the mower to ensure proper cutting.
2. Install the curved washer (cupped side toward the
blade) and the blade bolt (Figure 63).
3. Torque the blade bolt to 35-65 ft-lb (47-88 N-m).
Leveling the Mower Deck
Check to ensure the mower deck is level any time
you install the mower or when you see an uneven cut
on your lawn.
G027833
Figure 63
1. Sail area of blade
2. Blade
The mower deck must be checked for bent blades
prior to leveling; any bent blades must be removed
and replaced. Refer to the Checking for Bent
Blades procedure before continuing.
3. Curved washer
4. Blade bolt
The mower deck must be leveled side-to-side first
then the front to rear slope can be adjusted.
Sharpening the Blades
1. Use a file to sharpen the cutting edge at both ends
of the blade (Figure 64). Maintain the original
angle. The blade retains its balance if the same
amount of material is removed from both cutting
edges.
Requirements:
• The machine must be on a level surface.
• All four tires must be properly inflated. Refer to
Checking the Tire Pressure in the Drive System
Maintenance section.
Side-to-Side Leveling
1. Park the machine on a level surface and disengage
the blade control switch.
Figure 64
1. Sharpen at original angle
2. Ensure the parking brake is engaged, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
2. Check the balance of the blade by putting it on a
blade balancer (Figure 65). If the blade stays in a
horizontal position, the blade is balanced and can
be used. If the blade is not balanced, file some
metal off the end of the sail area only (Figure 64).
Repeat this procedure until the blade is balanced.
3. Set the height-of-cut lever to middle position.
4. Carefully rotate the blades so that they are all side
to side (Figure 66 and Figure 67).
Figure 65
1. Blade
2. Balancer
57
Maintenance
1
2
9. Raise or lower the left side of the mower deck by
rotating the rear nut. (Figure 68).
Note: Rotate the rear nut clockwise to raise the
mower deck; rotate the rear nut counter-clockwise
to lower the mower deck.
G009682
3
3
2
4
4
Figure 66
Mower Deck with 2 Blades
1. Blades side to side
3. Outside cutting edges
2. Sail area of blade
4. Measure from the tip
of the blade to the flat
surface here
G005278
Figure 68
2
1. Hanger bracket
3
3
1
2. Side-locking nut
10. Check the side-to-side adjustments again. Repeat
this procedure until the measurements are correct.
11. Continue leveling the deck by checking the
front-to-rear blade slope; refer to Adjusting the
Front-to-Rear Blade Slope.
2
4
4
Figure 67
Mower Deck with 3 Blades
1. Blades side to side
3. Outside cutting edges
2. Sail area of blade
4. Measure from the tip
of the blade to the flat
surface here
3. Rear-locking nut
Adjusting the Front-to-Rear Blade
Slope
Check the front-to-rear blade level any time you install
the mower. If the front of the mower is more than
5/16 inch (7.9 mm) lower than the rear of the mower,
adjust the blade level using the following instructions:
1. Park the machine on a level surface and disengage
the blade control switch.
2. Ensure the parking brake is engaged, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
3. Set the height-of-cut lever to middle position.
5. Measure between the outside cutting edges and
the flat surface (Figure 66 and Figure 67). If both
measurements are not within 3/16 inch (5 mm),
an adjustment is required; continue with this
procedure.
6. Support the weight of mower deck by placing
wood blocks under the edges of the deck.
Note: Check and adjust the side-to-side blade
level if you have not checked the setting; refer to
Side-to-Side Leveling.
4. Carefully rotate the blades so they are facing front
to rear (Figure 69 and Figure 70).
Note: Avoid placing the supports under any
anti-scalp rollers if present on the deck.
7. Move to the left side of the machine.
8. Loosen the side-locking nut.
58
Maintenance
2
1
G009658
2
3
Figure 69
Mower Deck with 2 Blades
1. Blades front to rear
2. Measure from the tip of the blade to the flat surface here
1
2
G014634
Figure 71
3
1. Adjusting rod
2
3. Lock nut
2. Adjusting block
1
G009659
7. To raise the front of the mower, tighten the
adjustment nut. To lower the front of the mower,
loosen the adjustment nut.
2
3
8. After adjustment, check the front-to-rear slope
again. Continue adjusting the nut until the front
blade tip is 1/16-5/16 inch (1.6-7.9 mm) lower
than the rear blade tip (Figure 69 and Figure 70).
Figure 70
Mower Deck with 3 Blades
1. Blades front to rear
2. Outside cutting edges
9. When the front-to-rear blade slope is correct
check the side-to-side level of the mower again;
refer to Side-to-Side Leveling.
3. Measure from the tip of the blade to the flat surface here
5. Measure from the tip of the front blade to the flat
surface and the tip of the rear blade to the flat
surface (Figure 69 and Figure 70). If the front
blade tip is not 1/16-5/16 inch (1.6-7.9 mm) lower
than the rear blade tip, adjust the front locknut.
Removing the Mower
Service Interval: As required
1. Park the machine on a level surface and disengage
the blade control switch.
6. To adjust the front-to-rear blade slope, rotate
the adjustment nut in the front of the mower
(Figure 71).
2. Ensure the parking brake is engaged, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
3. Lower the height-of-cut lever to the lowest
position.
4. Remove the hairpin cotter from the front support
rod and remove the rod from the deck bracket
(Figure 72). Carefully lower the front of the
mower deck to the ground.
59
Maintenance
2
2
3
3
1
2
1
G005077
Figure 74
1. Mower deck
2. Hanger bracket
3. Rear lift rod
G014635
Figure 72
1. Front support rod
7. Slide the mower deck rearward to remove the
mower belt from the engine pulley.
3. Deck bracket
2. Locking nut
8. Slide the mower deck out from underneath the
machine.
5. Remove and retain the cotter pin and deck
retention link from the each hanger bracket (see
Figure 73).
Note: Retain all parts for future installation.
Mower Belt Maintenance
Inspecting the Belts
Service Interval: Every 25 hours/Monthly
(whichever comes first)
Check the belts for cracks, frayed edges, burn marks,
or any other damage. Replace damaged belts.
Replacing the Mower Belt
Squealing when the belt is rotating, blades slipping
when cutting grass, frayed belt edges, burn marks,
and cracks are signs of a worn mower belt. Replace
the mower belt if any of these conditions are evident.
Figure 73
1. Hanger bracket
3. Cotter pin
2. Deck retention link
1. Park the machine on a level surface and disengage
the blade control switch.
6. Lift the mower deck and hanger brackets clear of
the rear lift rod and lower the mower carefully to
the ground (Figure 74).
2. Ensure the parking brake is engaged, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
3. Set the height-of-cut at the lowest cutting position
[1-1/2 inch (38 mm)].
60
Maintenance
4. Using a spring removal tool, (P/N. 92-5771),
remove the idler spring from the deck hook to
remove tension on the idler pulley and roll the
belt off of the pulleys (Figure 75 and Figure 76).
3
5
2
1
3
WARNING
The spring is under tension when installed
and can cause personal injury.
Be careful when removing the belt.
2
5
4
1
3
G014931
6
Figure 76
50 Inch Decks
4
3
G014930
Figure 75
42 Inch Decks
1. Idler pulley
4. Spring
2. Mower belt
5. Engine pulley
3. Outside pulley
6. Spring removal tool
4. Spring
5. Engine pulley
3. Outside pulley
6. Spring removal tool
5. Route the new belt around the engine pulley and
mower pulleys (Figure 76).
6. Using a spring removal tool, (P/N 92-5771),
install the idler spring over the deck hook and
placing tension on the idler pulley and mower belt
(Figure 75 and Figure 76).
4
6
1. Idler pulley
2. Mower belt
Installing the Mower
Service Interval: As required
1. Park the machine on a level surface and disengage
the blade control switch.
2. Ensure the parking brake is engaged, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
3. Slide the mower under the machine.
4. Lower the height-of-cut lever to the lowest
position.
5. Lift the rear of the mower deck and guide the
hanger brackets over the rear lift rod (Figure 74).
6. Attach the front support rod to the mower deck
with the clevis pin and hairpin cotter (Figure 72).
7. Install the mower belt onto the engine pulley;
refer to Replacing the Mower Belt.
61
Maintenance
Replacing the Discharge
Deflector
DANGER
An uncovered discharge opening could allow the
lawn mower to throw objects in the operator’s or
bystander’s direction and result in serious injury.
Also, contact with the blade could occur.
3
Never operate the lawn mower unless you install
a mulch plate, discharge deflector, or grass
collection system.
2
1
4
Inspect the discharge deflector for damage before
each use. Replace any damaged parts before use.
1. Disengage the spring from the notch in the
deflector bracket and slide the rod out of the
welded deck brackets, spring, and discharge
deflector (Figure 77). Remove the damaged or
worn discharge deflector.
g017617
5
Figure 77
1. Rod
2. Spring
4. Deck brackets
5. Spring installed over the
rod
3. Deflector assembly
2. Position the new discharge deflector assembly
with the bracket ends between the welded brackets
on the deck as shown in Figure 77.
3. Install the spring onto the straight end of the rod.
Position the spring on the rod as shown in so
the shorter spring end is coming from under the
rod before the bend and going over the rod as it
returns from the bend.
4. Lift the loop end of the spring and place it into
the notch on the deflector assembly bracket
(Figure 78).
62
Maintenance
Cleaning
2
Clean Grass Build-Up Under
Deck
1
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
3
2. Raise deck to the transport (4 1/2 inch (114 mm)
cutting height) position. Lift the front of unit
and support unit using jack stands or equivalent
support.
CAUTION
Raising the mower deck 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.
4
g017618
Figure 78
1. Rod and spring
assembly installed
3. Rod, short end, moved
behind mower bracket
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
2. Loop end of the spring
4. Short end, retained by
installed into the notch in
mower bracket.
the deflector bracket
3. Clean out any grass build-up from underside of
deck and in discharge deflector.
5. Secure the rod and spring assembly by twisting it
so the short end of the rod can be placed behind
the front bracket welded to the deck (Figure 78).
Clean Engine and Exhaust
System Area
Important: The grass deflector must be
spring loaded in the down position. Lift the
deflector up to test that it snaps to the full
down position.
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
conditions.)
CAUTION
Excessive debris around engine cooling air
intake and exhaust system area can cause engine,
exhaust area, and hydraulic system to overheat
which can create a fire hazard.
Clean all debris from engine and exhaust system
area.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
63
Maintenance
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.
Clean Debris From Machine
Service Interval: Before each use or daily
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.
64
Storage
Storage
Stop the engine, allow it to cool, and drain the
fuel tank; refer to Draining the Fuel Tank in the
Fuel System Maintenance section.
Cleaning and Storage
Restart the engine and run it until it stops.
1. Disengage the blade control switch, release the
traction-control pedal to place the machine in
neutral, engage the parking brake, stop the engine,
and remove the key.
Choke the engine (if applicable). Start and run the
engine until it will not start.
Dispose of fuel properly. Recycle pursuant to
local codes.
2. Remove grass clippings, dirt, and grime from the
external parts of the entire machine, especially the
engine. Clean dirt and chaff from the outside of
the engine cylinder head fins and blower housing.
Important: Do not store
stabilizer/conditioned gasoline over
30 days.
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, under
the seat, around the engine, hydraulic pumps,
and motors.
3. Service the air cleaner; refer to Servicing the Air
Cleaner in the Engine Maintenance section.
11. Remove the spark plug(s) and check its condition;
refer to Servicing the Spark Plug in the Engine
Maintenance section. With the spark plug(s)
removed from the engine, pour two tablespoons
of engine oil into the spark plug hole. Use the
starter to crank the engine and distribute the oil
inside the cylinder. Install the spark plug(s). Do
not install the wire on the spark plug(s).
4. Grease and oil the machine; refer to the
Lubrication section.
12. Clean any dirt and chaff from the top of the
mower.
5. Change the crankcase oil and filter; refer
to Servicing the Engine Oil in the Engine
Maintenance section.
13. Scrape any heavy buildup of grass and dirt from
the underside of the mower, then wash the mower
with a garden hose.
6. Check the tire pressure; refer to Checking the
Tire Pressure in the Drive System Maintenance
section.
14. Check the condition of the drive and mower belts.
15. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is worn or
damaged.
7. Charge the battery; refer to Servicing the Battery
in the Electrical System Maintenance section.
16. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
8. Check the condition of the blades; refer to
Servicing the Cutting Blades in the Mower
Maintenance section.
17. Store the machine in a clean, dry garage or storage
area. Remove the key from the ignition switch and
keep it in a memorable place. Cover the machine
to protect it and keep it clean.
9. Prepare the machine for storage when non-use
occurs over 30 days. Prepare the machine for
storage as follows.
10. Add a petroleum based stabilizer/conditioner
to the fuel in the tank. Follow the mixing
instructions from the stabilizer manufacturer. Do
not use an alcohol based stabilizer (ethanol or
methanol).
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh gasoline and used
at all times.
Run the engine to distribute the conditioned fuel
through the fuel system (5 minutes).
65
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
caused by an empty fuel tank.
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors DO Not pull on the wires to separate the connectors.
Problem
The engine overheats.
The starter does not crank
Engine will not start, starts hard, or fails to
keep running
Possible Cause
Corrective Action
1. The engine load is excessive.
1. Reduce ground speed.
2. The oil level in the crankcase is low.
3. The cooling fins and air passages under
the engine blower housing are plugged.
4. The air cleaner is dirty.
5. Dirt, water, or stale fuel is in fuel system.
2. Add oil to the crankcase.
3. Remove the obstruction from the cooling
fins and air passages.
4. Clean or replace the air cleaner element.
5. Contact an Authorized Service Dealer.
1. The blade control switch is engaged.
1. Move the blade control switch to
Disengaged.
2. The operator is not seated.
3. Battery does not have a full charge.
4. The electrical connections are corroded
or loose.
5. A fuse is blown.
6. A relay or switch is damaged.
2. Sit on the seat.
3. Charge the battery. See Check Battery
Charge and Recommended Jump
Starting Procedure sections in
Maintenance.
4. Check the electrical connections for good
contact.
5. Replace the fuse.
6. Contact an Authorized Service Dealer.
1. Fuel tank is empty.
1. Fill the fuel tank.
2. The choke is not on.
3. The air cleaner is dirty.
4. The spark plug wire(s) is loose or
disconnected.
5. The spark plug(s) is pitted, fouled, or the
gap is incorrect.
6. There is dirt in fuel filter.
7. Dirt, water, or stale fuel is in the fuel
system.
8. There is incorrect fuel in the fuel tank.
2. Move the choke lever to On (if applicable).
3. Clean or replace the air cleaner element.
4. Install the wire(s) on the spark plug.
9. The oil level in the crankcase is low.
66
5. Install a new, correctly gapped spark
plug(s).
6. Replace the fuel filter.
7. Contact an Authorized Service Dealer.
8. Drain the tank and replace the fuel with
the proper type.
9. Add oil to the crankcase.
Troubleshooting
Problem
Engine loses power
The machine does not drive.
Abnormal vibration
Uneven cutting height.
Possible Cause
1. Engine load is excessive.
1. Reduce the ground speed.
2. Air cleaner is dirty.
3. Oil level in the crankcase is low.
4. Cooling fins and air passages for the
engine are plugged.
5. The spark plug(s) is pitted, fouled, or the
gap is incorrect.
6. Dirt in fuel filter.
7. Dirt, water, or stale fuel is in the fuel
system.
8. There is incorrect fuel in the fuel tank.
2. Clean or replace the air cleaner element.
3. Add oil to the crankcase.
4. Remove the obstructions from the
cooling fins and air passages.
5. Install a new, correctly gapped spark
plug(s).
6. Replace the fuel filter.
7. Contact an Authorized Service Dealer.
8. Drain the tank and replace the fuel with
the proper type.
1. The drive belts are worn, loose, or broken.
1. Contact an Authorized Service Dealer.
2. The drive belts are off of the pulleys.
3. The drive is in bypass mode.
2. Contact an Authorized Service Dealer.
3. Take machine out of bypass mode. Refer
to Pushing the Machine by Hand
section.
1. Engine mounting bolts are loose.
1. Tighten the engine mounting bolts.
2. Loose engine pulley, idler pulley, or blade
pulley.
3. Engine pulley is damaged.
4. Cutting blade(s) is/are bent or unbalanced.
5. Blade is loose.
2. Tighten the appropriate pulley.
6. Blade spindle is bent.
3. Contact an Authorized Service Dealer.
4. Install new cutting blade(s).
5. Tighten the blade mounting bolt and
inspect the blade spring disc washer for
damage (See Servicing the Cutting
Blades section).
6. Contact an Authorized Service Dealer.
1. Blade(s) not sharp.
1. Sharpen the blade(s).
2. Cutting blade(s) is/are bent.
3. A blade is loose.
2. Install new cutting blade(s).
3. Tighten the blade mounting bolt and
inspect the blade spring disc washer for
damage (See Servicing the Cutting
Blades section).
4. Level mower deck from side-to-side and
front-to-rear.
5. Adjust the anti-scalp wheel height.
6. Clean the underside of the mower.
7. Adjust tire pressure.
8. Contact an Authorized Service Dealer.
4. Mower deck is not level.
5.
6.
7.
8.
Blades do not rotate.
Corrective Action
An anti-scalp wheel is not set correctly
Underside of mower is dirty.
Tire pressure in drive tires not correct.
Blade spindle bent.
1. Drive belt is worn, loose or broken.
1. Install new drive belt.
2. Drive belt is off pulley.
2. Install drive belt and check adjusting
shafts and belt guides for correct position.
3. Install a new mower belt.
3. The mower belt is worn, loose, or broken.
67
Schematics
Schematics
Electrical Diagram
68
Schematics
Electrical Logic Schematic
69
Exmark Quest Turf Equipment
3-Year Limited Consumer Warranty
(30-Day Limited Commercial Warranty)
Consumer Warranty Conditions and Products Covered
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty 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 defective in factory materials or workmanship for a
period of three years for residential usage of Exmark Quest turf
equipment.
Instructions for Obtaining Warranty Service
The product must be registered with original proof of purchase by an
Exmark Service Dealer before obtaining any warranty service.
Contact any Exmark Service Dealer to arrange service at their
dealership. To locate a dealer convenient to you, access our website at
www.exmark.com. U.S. or Canada customers may also call
402-223-6375.
If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:
Residential usage means use of the product on the same lot as your
home. Use at more than one location is considered commercial use,
and the commercial use warranty detailed below would apply.
Exmark Customer Service Department
The Exmark Warranty Company
2101 Ashland Avenue
Beatrice, NE 68310
402-223-6375 or
service@exmark.com
This warranty applies to Exmark Quest turf equipment sold in the
U.S. or Canada. This warranty may only be assigned or transferred to
a second (or third) owner by an authorized Exmark dealer. The
warranty period commences upon the date of the original retail
purchase.
Warranty Exceptions
• Bags, Belts and Tires
• Battery
• Engines
-Exmark
-Kawasaki
-Kohler
Owner’s Responsibilities
If your product requires warranty service it must be returned to an
authorized Exmark service dealer within the warranty period. This
warranty extends only to turf equipment operated under normal
conditions. You must read the operator’s manual. You must also
properly service and maintain your Exmark product as described in
the operator’s manual. Such routine maintenance, whether performed
by a dealer or by you, is at your expense.
Warranty Period
90 days
1 Year Prorated
3-Year Consumer
*
*
* Please refer to the manufacturer’s warranty statement that is
included in the literature packet.
General Conditions
The sole liability of Exmark and Exmark Warranty Company with
respect to this warranty shall be repair or replacement of defective
components as set forth herein. Neither Exmark nor Exmark
Warranty Company shall be liable for any incidental or
consequential loss or damage.
This warranty only includes the cost of parts and labor. For the first
warrantable service repair, Exmark will cover up to $45 for
associated pick-up and delivery charges to and from any authorized
Exmark Service Dealer. Additional transportation charges may apply,
contact your Dealer for details.
Such damages include but are not limited to:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other extraordinary
repair charges or charges relating to repairs or replacements
outside of normal business hours at the place of business of the
authorized Exmark Service Dealer.
• Rental of like or similar replacement equipment during the period
of any warranty, repair or replacement work.
• Any telephone or telegram charges or travel charges.
• Loss or damage to person or property other than that covered by
the terms of this warranty.
• Any claims for lost revenue, lost profit or additional cost as a result
of a claim of breach of warranty.
• Attorney's fees.
Limited Warranty for Commercial Use
Exmark Quest turf equipment used for commercial, institutional, or
rental use are warranted against defects in materials or workmanship
for a period of 30 days from the date of original purchase.
Warranty Exception
• Engines
-Exmark
-Kawasaki
-Kohler
Warranty Period
90-Day Commercial
*
*
* Please refer to the manufacturer’s warranty statement that is
included in the literature packet.
Items and Conditions Not Covered
This warranty does not cover the following:
• Pickup and delivery charges to and from any authorized Exmark
Service Dealer beyond first warrantable service.
• Any damage or deterioration due to normal use, wear and tear, or
exposure.
• Cost of regular maintenance service or parts, such as filters, fuel,
lubricants, tune-up parts, and adjustments.
• Any product or part which has been altered or misused or required
replacement or repair due to normal wear, accidents, or lack of
proper maintenance as set forth in the maintenance section of the
operator’s manual.
• Any repairs necessary due to use of parts, accessories or supplies,
including gasoline, oil or lubricants, incompatible with the turf
equipment or other than as recommended in the operator's manual
or other operational instructions provided by Exmark.
No Claim of breach of warranty shall be cause for cancellation or
rescission of the contract of sale of any Exmark mower.
All implied warranties of merchantability (that the product is fit
for ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
There are no other express warranties except for engine and special
emission system coverage.
G4500-750_D
70
Notes:
71
Notes:
72
Service Record
Date:
Description of Work Done:
73
Service Done By:
74
G011841
Figure 79
This page may be copied for personal use.
1. The maximum slope you can safely operate the machine on is 15 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 15 degrees. Fold
along the appropriate line to match the recommended slope.
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.
3. Example of how to compare slope with folded edge.
75
EXMARK ACCESSORIES AND OPTIONS*
MID-MOUNT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
OPERATOR CONTROLLED DISCHARGE
FULL SUSPENSION SEAT
SUN SHADE
DECK LIFT ASSIST KIT
TRASH CONTAINER
HITCH KIT
TURF STRIPER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
12V POWER PORT
ULTRA VAC QUICK DISPOSAL SYSTEM
MICRO-MULCH SYSTEM
OUT-FRONT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
SNOW BLADE
DUAL-TAIL WHEEL
SNOWBLOWER
FLOOR PAN EXTENDER
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
WEATHER CAB
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
TURF STRIPER
MICRO-MULCH SYSTEM
STANDON
*Some accessories and options not available for some models.
Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Model No.
Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Serial No.
©2015 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
All Rights Reserved
Part No. 4502-541 Rev. A
(402) 223-6290
Fax (402) 223-5489
Printed in the USA
www.exmark.com
*4502-541* A
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