QUEST ® For Serial Nos. 720,000 & Higher Part No. 4500-338 Rev. A WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws. This spark ignition system complies with Canadian ICES-002, ISO 14982, EN 55012. The enclosed Engine Owner’s Manual is supplied for information regarding the US Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance, and warranty. Replacements may be ordered through the engine manufacturer. For models with stated engine horsepower, the gross horsepower of the engine was laboratory rated by the engine manufacturer in accordance with SAE J1940. As configured to meet safety, emission, and operating requirements, the actual engine horsepower on this class of lawn mower will be significantly lower. © 2007–2008—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 Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Exmark directly at www.Exmark.com for product and accessory information or help finding a dealer. 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. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided. Figure 1 Behind the seat 1. Model and serial number location Model No. Serial No. 3 Contents Drive System Maintenance ............................ 39 Checking the Tire Pressure ............................ 39 Mower Maintenance ...................................... 39 Servicing the Cutting Blades .......................... 39 Mower Belt Maintenance ............................... 41 Leveling the Mower Deck .............................. 42 Adjusting the Blade Slope .............................. 42 Removing the Mower Deck ........................... 44 Installing the Mower Deck............................. 44 Replacing the Discharge Deflector ................. 45 Cleaning ........................................................... 46 Washing the Underside of the Mower ............. 46 Storage ................................................................. 47 Cleaning and Storage ..................................... 47 Troubleshooting ................................................... 48 Schematics ........................................................... 50 Introduction ........................................................... 3 Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5 Safe Operating Practices .................................. 5 Safety and Instructional Decals ....................... 8 Specifications ....................................................... 13 Model Numbers ............................................ 13 Systems ......................................................... 13 Dimensions................................................... 14 Torque Requirements .................................... 15 Product Overview ................................................ 15 Operation ............................................................. 16 Controls ........................................................ 16 Operating Instructions .................................. 17 Recommended Gasoline................................ 18 Checking the Engine Oil Level....................... 19 Starting the Engine........................................ 19 Operating the Blades ..................................... 20 Stopping the Engine ...................................... 21 The Safety Interlock System........................... 21 Driving Forward or Backward........................ 22 Stopping the Machine.................................... 23 Tracking Adjustment ..................................... 23 Adjusting the Height of Cut ........................... 23 Adjusting the Anti-Scalp Rollers..................... 24 Positioning the Seat ....................................... 24 Changing the Seat Ride Suspension ................ 24 Adjusting the Motion Control Levers ............. 25 Pushing the Machine by Hand........................ 25 Side Discharge............................................... 26 Transporting ................................................. 26 Operating Tips ............................................. 27 Maintenance ......................................................... 29 Recommended Maintenance Schedule(s) ........... 29 Premaintenance Procedures .............................. 30 Raising the Seat ............................................. 30 Accessing the Battery .................................... 30 Periodic Maintenance ....................................... 30 Lubrication.................................................... 30 Engine Maintenance...................................... 31 Servicing the Engine Oil ................................ 32 Checking the Hydraulic Oil Level ................... 34 Change the Hydraulic System Filter................ 34 Servicing the Spark Plug ................................ 35 Cleaning the Blower Housing......................... 35 Fuel System Maintenance .............................. 36 Electrical System Maintenance....................... 36 Charging the Battery...................................... 37 Servicing the Fuses and Relay......................... 38 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 • 1. Safety alert symbol 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. 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. • 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 B71.1-2003 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 B71.1-2003. • 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. • Use extra care when loading or unloading the machine into a trailer or truck General Operation • 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 Children safely enough to protect themselves and others from serious injury. • Always follow the recommendations for wheel weights or counterweights. 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. • Be aware that loss of traction may occur going downhill. Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering. • 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 rollovers, which may result in serious injury, death or drowning. • Use a walk behind mower and/or a hand trimmer near drop-offs, ditches, steep banks or water. Towing • Use for towing only if equipped with an Exmark hitch kit. Do Not attach towed equipment except at the hitch point. • Follow Exmark’s recommendation for weight limits for towed equipment and towing on slopes. This information can be found in the hitch kit instruction sheet and on the decal. • Never allow children or others in or on towed equipment. • On slopes, the weight of the towed equipment may cause loss of traction and loss of control. • Travel slowly and allow extra distance to stop. Service Safe Handling of Gasoline To avoid personal injury or property damage, use extra care when handling gasoline and other fuels. They are flammable and the vapors are explosive. 6 Safety • 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. • • • • 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. • 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. • 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. 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. • Never tamper with safety devices. 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. • Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting. • Never make any adjustments or repairs with the engine running. • 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 Note: The left and right sides of the machine are determined while sitting in the seat in the normal operating position 7 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–Do Not operate 2. Cutting/dismemberment the mower with the hazard of hand or foot, discharge deflector up mower blade–stay away or removed; keep the from moving parts. discharge deflector in place. 109-6014 Traction Drive Belt Routing 106-5517 1. Warning–Do Not touch the hot surface. 109-6008 1. Read the Operator’s Manual. 2. Rotate the drive release knob to loosen, slide the knob, and tighten. 3. Push the machine. 109-6029 1. 2. 3. 4. Engine–stop Engine–run Engine–start Power take-off (PTO), Blade control switch 5. Read the Operator’s Manual. 8 6. 7. 8. 9. Throttle–fast Choke–on Throttle–slow Choke–off Safety 109-6035 Deck Drive Belt Routing 109-8759 1. Height of cut 109-6036 1. Read the Operator’s Manual. 2. Remove the ignition key and read the instructions before servicing or performing maintenance. 3. Height of cut. 109-9120 1. Fuse 109-6210 1. Read the Operator’s Manual. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt–stay away from moving parts. 109-6459 1. Entanglement hazard, belt—Do Not open or remove safety shields while engine is running, keep shields in place. 9 2. Diode Safety 110-6691 1. Thrown objects hazard–keep bystanders a safe distance from the machine. 2. Thrown objects hazard, mower–keep the discharge deflector or collection system in place. 3. Cutting/dismemberment of hand or foot–stay away from moving parts. 109-9173 1. Parking brake 2. Fast 3. Slow 4. Neutral 5. Reverse 6. Machine Speed PTO Symbols 1. PTO—Off 109-9182 1. Machine speed 2. Fast 3. Slow 4. Neutral 5. Reverse 10 2. PTO—On Safety 109-6016 1. Read the instructions before servicing or performing maintenance. 2. Time interval 4. Refer to the Operator’s manual for grease instructions. 5. Check hydraulic oil level and refer to the Operator’s Manual for further instructions. 6. Check tire pressure. 3. Check oil level. 109-8965 5. Tipping hazard–avoid sudden and sharp turns while on slopes, only mow across slopes less than 15 degrees, keep a safe distance from water, and only mow up and down slopes less than 15 degrees. 2. Read the instructions before servicing or performing 6. Cutting/dismemberment hazard of hand or foot, mower maintenance; apply parking brake, remove the ignition key blade–stay away from moving parts. and disconnect the spark plug wire. 3. Thrown object hazard—keep bystanders a safe distance 7. Crushing/dismemberment hazard of bystanders, from the machine, pick up debris before operating, keep reversing–Do Not carry passengers, look behind and the discharge deflector in place. down when reversing. 4. Loss of traction/control hazard, slopes–loss of traction/control on slope, disengage the blade control switch (PTO), proceed off the slope slowly. 1. Warning–read the Operator’s Manual. 11 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. 7. Wear eye protection; explosive gases can cause blindness and other injuries. 8. Battery acid can cause blindness or severe burns. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 12 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard. Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher QST22BE482; QST23KC482; QST23KC522; QST24BE522 Systems engine. (It is not necessary for the operator to be in the seat to start the engine.) Engine • Operator must be in seat when PTO is engaged, brake is disengaged, or motion control levers are moved in or engine will stop. • Engine Specifications: See your Engine Owner’s Manual • RPM: Briggs & Stratton: Full Speed: 3650 ±100 (max) RPM (No Load) Idle: 1650 (min) RPM • Engine will stop if either the left, the right, or both levers are moved from neutral lock position while brake is engaged. Kohler Command: Full Speed: 3600 ±75 (max) RPM (No Load) Idle: 1750 (min) RPM Operator Controls • Steering and Motion Control: Fuel System Note: Motion control levers are adjustable to two heights. • Capacity: 4.0 gal. (15.1 L) • Type of Fuel: Regular unleaded gasoline, 87 octane or higher. • Fuel Filter: – Separate levers, on each side of the console, control speed and direction of travel of the respective drive wheels. Briggs & Stratton: Briggs & Stratton P/N 695666 – Steering is controlled by varying the position of the levers relative to each other. Kohler Command: Kohler P/N 24 050 10 • Fuel Shut-Off Valve: 1/4 turn increments (“ON”, “OFF”) – Moving motion control levers outward (in slots) locks the drive system in neutral. • PTO Engagement Switch: Engages electric clutch (to drive belt) which engages mower blades. Electrical System • Charging System: Flywheel Alternator • Charging Capacity: • Parking Brake Lever: Engages parking brake. • Deck Height Adjustment Pin: Sets cutting height to desired position. Briggs & Stratton: 16 amps • • • • • Kohler Command: 15 amps Battery Type: BCI Group U1 Battery Voltage: 12 Volt Polarity: Negative Ground Fuses: One 25 amp, one 20 amp; one 15 amp blade type Diode: TVS • Deck Lift Assist Lever: Foot pedal that assists in raising the deck. Seat • Type: Standard seat with high back, foam padded with spring suspension and armrests. • Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other components. Held in tilted position with lanyard. Adjustable fore and aft seat track. Safety Interlock System • PTO must be disengaged, brake engaged, and motion control levers out (neutral lock) to start 13 Specifications • Deck: Full floating deck is attached to out-front support frame. Maximum turf protection is provided with three anti-scalp rollers (both deck sizes). • Armrests: Standard–foam padded flip-up adjustable height armrests. • Seat Safety Switch: Incorporated into the Safety Interlock System. Deck design allows for bagging, mulching or side discharge. Hydrostatic Ground Drive System • Hydrostatic Pumps: Two Hydro Gear ZT2800 Integrated drive systems. • Hydraulic Oil Type: Use Mobil 1 15W-50 Synthetic motor oil. • 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 Depth: – 48 inch Deck: 5.0 inches (12.7 cm) – 52 inch Deck: 5.0 inches (12.7 cm) • Cutting Height Adjustment: A foot 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. Dimensions Tires & Wheels Drive Pneumatic (Air-Filled) Overall Width: Front Caster 48 inch Deck 52 inch Deck Pneumatic (Air-Filled) Without Deck 45.5 inches (116 cm) 47.0 inches (119 cm) Deflector Up 48.3 inches (122 cm) 53.0 inches (135 cm) Deflector Down 59.4 inches (151 cm) 64.2 inches (163 cm) Deck Size 48 52 All Decks Quantity 2 2 2 Tread Turf Tec Turf Tec Smooth Size 20 x 8.00-8 20 x 10.00-8 10 x 4 Ply Rating 4 4 Pressure 13 psi (90 kPa) 13 psi (90 kPa) Overall Length: 13 psi (90 kPa) Cutting Deck • Cutting Width: – 48 inch Deck: 48 inches (122 cm) – 52 inch Deck: 52 inches (132 cm) • Discharge: Side • Blade Size: (3 ea.) – 48 inch Deck: 16.25 inches (41.3 cm) – 52 inch Deck: 18.00 inches (45.7 cm) • Blade Spindles: Solid steel spindles with no maintenance bearings. • Deck Drive: Electric clutch mounted on vertical engine shaft. Blades are driven by one belt (w/self-tensioning idler) direct from the engine. 48 inch Deck 52 inch Deck 73.4 inches (186 cm) 73.4 inches (186 cm) Overall Height: 14 48 inch Deck 52 inch Deck 41.8 inches (106 cm) 41.8 inches (106 cm) Product Overview Tread Width: (Center to Center of Tires, Widthwise) 48 inch Deck 52 inch Deck Drive Wheels 36.0 inches (91 cm) 36.8 inches (93 cm) Caster Wheels 33.5 inches (85 cm) 33.5 inches (85 cm) Product Overview Wheel Base: (Center of Caster Tire to Center of Drive Tire) 48 inch Deck 52 inch Deck 48.9 inches (124 cm) 48.9 inches (124 cm) Curb Weight: 48 inch Deck 52 inch Deck 645 lb (293 kg) 660 lb (299 kg) Figure 3 1. 2. 3. 4. 5. 6. 7. Torque Requirements Bolt Location Torque Spindle Pulley Nut 95-105 ft-lb (129-142 N-m) Blade Mounting Bolt (lubricate with anti-seize) 32-42 ft-lb (43-57 N-m) Engine Mounting Bolts 27-33 ft-lb (37-45 N-m) Anti-Scalp Roller Nyloc Nut 27-33 ft-lb (37-45 N-m) Wheel Lug Nuts 70-90 ft-lb (95-122 N-m) Clutch Mounting Bolt 50-55 ft-lb (68-75 N-m) (secured with threadlocker) Spark Plug 15 ft-lb (20 N-m) 15 Front caster wheel Anti-scalp roller Height of cut foot lever Discharge deflector Height of cut adjustment Rear drive wheel Control panel 8. 9. 10. 11. 12. 13. 14. Engine Seat Armrest Motion control levers Park brake Footrest Washout fitting Operation Operation Blade Control Switch (Power Take-Off) Controls Located on the control panel. Note: Become familiar with all of the controls in Figure 3 and Figure 4 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. Ignition Switch Pull out on the blade control switch to “On” to engage the blades Located on control panel. Push 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” ( Figure 4). 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). Choke Control Located on control panel. The choke is used to aid in starting a cold engine. Do Not run a warm engine with the choke in the “ON” position. Moving the choke lever forward will put the choke in the “ON” position and moving the choke lever to the rear will put the choke in the “OFF” position (Figure 4). Throttle Control 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. Moving the throttle forward into the detent is full throttle (see Figure 4). Figure 4 1. Ignition switch 2. Blade control switch (power take-off) 3. Hour meter 4. Throttle 5. Choke Motion Control Levers The motion control levers located on each side of the seat (Figure 3). Note: Brake must be engaged, motion control levers out (neutral lock position) and PTO switch “OFF” to start engine. (It is not necessary for the operator to be in the seat to start the engine.) The motion control levers are speed sensitive controls of independent wheel motors. Moving a lever forward or backward turns the wheel on the same side forward or in reverse; wheel speed is proportional to the amount the lever is moved. Moving the control levers outward from the center position locks them in the neutral position. Always position the motion control levers into the neutral position and engage the park brake lever when you stop the machine or leave it unattended. The unit must be tied down and brake engaged when transporting. 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 16 Operation Parking Brake Lever DANGER Located on left side of the console (Figure 3). 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. The brake lever engages a parking brake on the drive wheels. Pull the lever up and rearward to engage the brake. Push the lever forward and down to disengage the brake. To avoid loss of control and possibility of rollover: Height-of-Cut Foot Lever • Do not mow near drop-offs or near water. The height of cut lever allows the operator to lower and raise the deck from the seated position (Figure 3). When the lever is moved forward, away from the operator the deck is raised from the ground and when moved back, towards the operator it is lowered toward the ground. Only adjust the height of cut while machine is not moving. • Do not mow slopes greater than 15 degrees. Hour Meter • Avoid sudden turns or rapid speed changes. Located on the control panel. • Turn up, into an incline when changing directions on slopes. Turning down the slope reduces traction. • Reduce speed and use extreme caution on slopes. • When mowing slopes, gradually work from lower to higher areas on the incline. The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run ( Figure 4). If the ignition switch is left on without engine running, hour meter will not run. • Attachments change the handling characteristics of the machine. Use extra caution when using attachments with the machine. Note: This switch is not a low oil sensor and will not alert the operator if the engine oil is low. Operating Instructions Think Safety First Note: Determine the left and right sides of the machine from the normal operating position. 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. Figure 5 1. Water 2. Use walk behind mower and/or hand trimmer near drop-offs and water. 17 3. Safe Zone-use the Quest here. Operation See inside back cover to determine the approximate slope angle to be mowed. 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. Recommended Gasoline Use UNLEADED Regular Gasoline suitable for automotive use (87 pump octane minimum). • Always place gasoline containers on the ground away from your vehicle before filling. Important: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do Not mix oil with gasoline. • 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. DANGER In certain conditions gasoline is extremely flammable and vapors are explosive. • When practical, remove gas-powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground. A fire or explosion from gasoline can burn you, others, and cause property damage. • Fill the fuel tank outdoors in an open area, when the engine is cold. Wipe up any gasoline that spills. • 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. • Never refill the fuel tank or drain the machine indoors or inside an enclosed trailer. • 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 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. WARNING • Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by spark. 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. • 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. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank/container opening. • Do Not operate without entire exhaust system in place and in proper working condition. • Keep away from eyes and skin. • Never siphon by mouth. 18 Operation 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 correct amount of gas stabilizer/conditioner to the gas. 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. Figure 6 1. Gas tank opening 2. Fill to here, approximately Gasoline/Alcohol blends 3. Gas tank body 4. Install the fuel tank cap securely. Wipe up any gasoline that may have spilled. Gasohol (up to 10 percent ethyl alcohol, 90 percent unleaded gasoline by volume) is approved for fuel use by the engine manufacturer. Other gasoline/alcohol blends are not approved. Checking the Engine Oil Level Filling the Fuel Tank 1. Shut the engine off and set the motion controls to the neutral position and engage parking brake. 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. 2. Clean around the fuel tank cap and remove the cap. Starting the Engine 3. Add unleaded regular gasoline until the body of the tank is full but fuel does not fill the neck of the tank (Figure 6). This space in the neck of the tank allows gasoline to expand. Do not fill the fuel tank completely full. 1. Sit down on the seat and move the motion controls outward to the neutral position and engage the parking brake. 2. Disengage the blades by moving the blade control switch to Off (Figure 7). 19 Operation Figure 7 1. Control panel 2. Blade control switch—Off position Figure 9 1. Ignition key—start position 2. Control panel 3. Choke 3. Move the throttle lever to midway and the choke lever forward before starting a cold engine (Figure 8). 4. Start 5. Run 6. Off 5. If the engine stalls or hesitates, move the choke lever partially forward for a few seconds (Figure 9). Note: A warm or hot engine may not require choking. Operating the Blades 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. Engaging the Blades 1. Release pressure on the motion control levers and place the machine in neutral. Figure 8 1. Control panel 2. Choke—on 3. Choke–off 2. Move the throttle midway to the Fast position. 4. Throttle—slow 5. Throttle—fast Note: Always engage the blades with the throttle in the midway position. 3. Pull out on the blade control switch to On to engage the blades (Figure 10). 4. Turn the ignition key to Start to energize the starter. When the engine starts, release the key (Figure 9). 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. 20 Operation The Safety Interlock System CAUTION 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. Figure 10 1. Control panel 2. Blade control switch—On position Understanding the Safety Interlock System 4. Move throttle to full forward position before mowing. The safety interlock system is designed to prevent the engine from starting unless: • The blades are disengaged. • The motion control levers are in the neutral position. • The parking brake is engaged. Disengaging the Blades Set throttle to midway position. Push the blade control switch to Off to disengage the blades (Figure 11). The safety interlock system is designed to initiate engine shutdown when: • The parking brake is disengaged and the operator gets off machine. • The PTO is engaged and the operator gets off machine. • The parking brake is disengaged and levers are in and the operator gets off machine. • The parking brake is engaged and motion control levers are in. Figure 11 1. Control panel 2. Blade control switch—Off position Testing the Safety Interlock System Test the safety interlock system before you use the machine each time 1. Check starting circuit. Starter should crank with parking brake engaged, PTO disengaged and motion control levers moved out in the neutral lock position. The operator does not need to be in the seat to start the engine. Stopping the Engine 1. Move the throttle lever to between Fast and half throttle (Figure 9). 2. Disengage the blades by moving the blade control switch to Off (Figure 11). 3. Turn the ignition key to Off (Figure 9). 4. Pull the wire off of the spark plug(s) to prevent the possibility of someone accidentally starting the machine before transporting or storing the machine. Try to start with operator in seat, parking brake disengaged, PTO disengaged and motion control levers in the neutral lock position - starter must not crank. 21 Operation Try to start with operator in seat, parking brake engaged, PTO engaged and motion control levers in the neutral lock position - starter must not crank. CAUTION Machine can spin very rapidly by positioning one lever too much ahead of the other. Operator may lose control of the machine, which may cause damage to the machine or injury. Try to start with operator in seat, parking brake engaged, PTO disengaged, and the left motion control lever in, starter must not crank, repeat again with the right lever in, then with both levers in - starter must not crank. • Use caution when making turns. • Slow the machine down before making sharp turns. 2. Check kill circuits. Run engine at one-third throttle, disengage parking brake and raise off of seat (but do not get off of machine) engine must initiate shutdown. Forward 1. Move the levers to the center, unlocked position. 2. To go forward, slowly push the motion control levers forward (Figure 12). Run engine at one-third throttle, engage PTO and raise off of seat (but do not get off of machine) engine must initiate shutdown. Run engine at one-third throttle, with brake disengaged, move levers in and raise off seat (but do not get off of machine) engine must initiate shutdown. Again, run engine at one-third throttle, brake engaged, and move left motion control lever in - engine must initiate shutdown. Repeat again moving the right lever in, then moving both levers in - engine must initiate shutdown whether operator is on seat or not. Note: If machine does not pass any of these tests, do not operate. Contact your authorized EXMARK SERVICE DEALER. Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing. Driving Forward or Backward Figure 12 1. Neutral position 2. Center unlock position 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. 3. Backward 4. Forward To go straight, apply equal pressure to both motion control levers (Figure 12). To turn, pull back on the motion control lever toward the direction you want to turn (Figure 12). The farther you move the motion control levers in either direction, the faster the machine will move in that direction. To stop, pull the motion control levers to neutral. 22 Operation Backward CAUTION 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion control levers rearward (Figure 12). Children or bystanders may be injured if they move or attempt to operate the mower while it is unattended. To go straight, apply equal pressure to both motion control levers (Figure 12). Always remove the ignition key and move the motion control levers outward to the neutral position and apply the parking brake when leaving the machine unattended, even if just for a few minutes. To turn, release the pressure on the motion control lever toward the direction you want to turn (Figure 12). To stop, push the motion control levers to neutral. Stopping the Machine Adjusting the Height of Cut To stop the machine, move the motion control levers to neutral and outward to the neutral position, disengage the blade control switch, move the throttle lever to between Fast and half throttle, and turn the ignition key to off. Remember to remove the key from the ignition switch. 1. Raise the deck to the transport position (4.5 inch (114 mm) cut height) by pushing the foot actuated lever forward (Figure 14). The spring loaded transport pin will automatically engage and will click into place. Tracking Adjustment If the machine turns right or left when handles are pushed forward together, adjust the stop on the side opposite the direction of turn (see Figure 13). Loosen the screws that hold the motion control limiter stop. Move the stop back until the unit drives straight. Tighten the screws to lock the stop in place. Readjust handles if necessary. Figure 14 1. Push forward 2. Foot actuated height-of-cut lever 3. Height-of-cut positions 2. Move the deck height adjuster pin to the desired cut height. 3. Push the foot lever forward, pull the transport release handle up and let the deck lower down to Figure 13 1. Control arm shaft 2. Limiter stop screws 4. Height adjuster pin 5. Transport release handle 3. Adjust stop 23 Operation Positioning the Seat the predetermined cut height by slowly decreasing foot pressure allowing the foot lever to travel rearward. The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. Adjusting the Anti-Scalp Rollers 1. Push the adjustment lever towards the center of the machine to release the seat adjuster track (Figure 16). It is recommended to change the anti-scalp roller position when the height of cut has changed. 1. Stop the machine and move the drive levers to the neutral lock position. 2. Disengage the PTO. 3. Engage the park brake. 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. 6. Adjust the anti-scalp rollers for the normal operating conditions. Place rollers in one of the positions shown in Figure 15. Rollers will maintain 3/4 inches (19 mm) clearance to the ground to minimize gouging and roller wear or damage. Figure 16 1. Adjustment lever 2. Move the seat to the desired position and release the lever to lock in that position. 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. 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 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 15 For cutting heights above 3 1/2 inches (38 mm) use the bottom hole. The rollers will still be effective against scalping. 1. Anti-scalp roller mounting bracket 2. Cutting height 7. Torque hardware to 27-33 ft-lb (37-45 N-m) or loss of roller may result. 24 Operation 2. Move the control lever to the next set of holes. Secure the lever with the two bolts. 3. Repeat the adjustment for the opposite control lever. Adjusting the Tilt The motion control levers can be tilted fore or aft for maximum operator comfort. 1. Loosen the upper bolt holding the control lever to the control arm shaft. Figure 17 1. Bolt 2. Spring 2. Loosen the lower bolt just enough to pivot the control lever fore or aft (Figure 18). Tighten both bolts to secure the control in the new position. 3. Nut 4. Additional mounting holes 3. Repeat the adjustment for the opposite control lever. Up to five springs can be secured to the seat box with a nut and bolt, see Figure 17. Refer to your Parts Manual for spring and hardware part numbers. Pushing the Machine by Hand Adjusting the Motion Control Levers Important: Always push the machine by hand. Never tow the machine because damage may occur. Adjusting the Height To Push the Machine The motion control levers can be adjusted higher or lower for maximum operator comfort. 1. Remove the two bolts holding the control lever to the control arm shaft (Figure 18). 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to 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. Locate the bypass release knobs on either side of the engine deck (Figure 19). Figure 18 1. Control arm shaft 2. Control lever 3. Washer 4. Bolt 5. Slotted holes 25 Operation 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. • 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. • Never put your hands or feet under the mower. • Never try to clear discharge area or mower blades unless you move the 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). Figure 19 1. Front of the machine. 2. Rotate bypass release knob counterclockwise 3. Lever position for operating the machine. 4. Pull lever in this direction 5. Lever position for pushing the machine 6. Rotate bypass release knob clockwise 7. Release lever Transporting Transporting a Unit 4. Loosen the knob by turning counterclockwise. Then pull the release lever on the underside of machine (Figure 19) towards the back of the machine and retighten the knob to hold the release lever back in the released state. Repeat this on each side of the machine. Use a heavy-duty trailer or truck to transport the machine. Lock brake and block wheels. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Be sure that the trailer or truck has all necessary lighting and marking as required by law. Secure a trailer with a safety chain. 5. Release the parking brake. The machine is now able to be pushed by hand. CAUTION To Operate the Machine This unit does not have proper turn signals, lights, reflective markings, or a slow moving vehicle emblem. Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury. Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and/or fines. Loosen the bypass knob, push the release levers forward, and retighten the knob to engage the drive system (Figure 19). Side Discharge The mower has a hinged discharge deflector that disperses clippings to the side and down toward the turf. Do Not drive a unit on a public street or roadway. 26 Operation Important: Do Not attempt to turn the unit while on the ramp, you may lose control and drive off the side. WARNING Loading a unit on a trailer or truck increases the possibility of backward tip-over. Backward tip-over could cause serious injury or death. Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp. Both maneuvers can cause the unit to tip backward. • Use extreme caution when operating a unit on a ramp. Operating Tips • Use only a single, full width ramp; Do Not use individual ramps for each side of the unit. Fast Throttle Setting • Do Not exceed a 15° angle between ramp and ground or between ramp and trailer or truck. 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. • Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward. Cutting a Lawn for the First Time • If individual ramps must be used, use enough ramps to create an unbroken ramp surface wider than the unit. 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. • Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward. Loading a Unit Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit. The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward. If it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp. 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. Mowing Direction Alternate mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization. Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15°. A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck. Steeper angles may also cause the unit to tip backward. If loading on or near a slope, position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible. 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. 27 Operation Cutting Speed To improve cut quality, use a slower ground speed. Avoid Cutting Too Low 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. Long Grass 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 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. 28 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. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil. After the first 200 hours • Change the hydraulic system filter. Before each use or daily • • • • • • • Check the safety interlock system. Check the air cleaner for dirty, loose, or damage. Check the air intake and cooling areas, clean as necessary. Check the oil level before starting or after every 8 hours. Check the hydraulic oil level in the expansion tank. Check the mower blades. Clean the mower housing. Every 25 hours • • • • Grease all lubrication points. Service the air cleaner. (May need more often under extremely dusty or dirty conditions.) Check the tire pressure. Check the belts. Every 100 hours • • • • • Replace the paper element. (More often under extremely dusty, dirty conditions.) Replace the air cleaner element. Change the engine oil and filter. Clean the blower housing. More often under dirty conditions. Replace the fuel filter. Every 200 hours • Service the spark plug. Every 500 hours • Replace the spark plug. Before storage Monthly • Charge the battery and disconnect the battery cables. • Perform all maintenance procedures before storage. • Paint any chipped surfaces. • Check the battery charge. 29 Maintenance Important: Refer to your Engine Operator’s Manual for additional maintenance procedures. Premaintenance Procedures Periodic Maintenance Lubrication Raising the Seat Greasing the Bearings Make sure the motion control levers are locked in the neutral position. Lift the seat forward until the lanyard is tight. The following components can be accessed by raising the seat: Grease Type: NGLI grade #2 multi-purpose gun grease. Grease the front caster pivots and wheels (Figure 21). • Auxiliary 12V Plug (12V accessory up to 15 amp) • Fuses G007184 • Battery cables Accessing the Battery The battery is located under the seat. To access, raise the seat (Figure 20). 1 Figure 21 1. Front caster tire 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to 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 (Figure 21 and Figure 22) with a rag. Make sure to scrape any paint off of the front of the fitting(s). Figure 20 1. Auxiliary 12V Plug 2. Battery 3. Seat 30 Maintenance 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. 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. Figure 22 Located on the back of the seat. 1. Read the instructions before servicing or performing maintenance 2. Grease idler pivots. 3. Time interval. 4. Check oil level. Figure 23 Briggs & Stratton engine 5. Check hydraulic oil level and refer to Operator’s manual for further instructions. 6. Check tire pressure. 1. Air cleaner 2. Knobs 3. Air cleaner cover 4. Connect a grease gun to each fitting (Figure 21 and Figure 22). Pump grease into the fittings until grease begins to ooze out of the bearings. 5. Wipe up any excess grease. Engine Maintenance Servicing the Air Cleaner Figure 24 Kohler Command engine Service Interval: Before each use or daily Every 100 hours—Replace the paper element. (More often under extremely dusty, dirty conditions.) 1. Air cleaner cover 2. Knob This engine is equipped with a replaceable, high density paper air cleaner element. Check the air 31 3. Air cleaner Maintenance Servicing Paper Element Service Interval: Every 25 hours (May need more often under extremely dusty or dirty conditions.) Every 100 hours/Yearly (whichever comes first)—Replace the air cleaner element. 1. Remove the air cleaner cover (Figure 23). 2. Remove the air cleaner element with the integral rubber seal. 3. Gently tap the pleated side of the paper element to dislodge dirt. Do Not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element. Handle new elements carefully; Do Not use if the rubber seal or foam sleeve is damaged. Figure 25 1. Oil dipstick 2. Filler tube 3. Oil level 5. Remove the dipstick and check the oil level. 4. Clean all air cleaner components of any accumulated dirt or foreign material. Prevent any dirt from entering the carburetor. The oil level should be up to, but not over, the “F” mark on the dipstick. 6. If the level is low, add oil of the proper type, up to the “F” mark on the dipstick. Always check the level with the dipstick before adding more oil. 5. Install the air cleaner element with the pleated side “out” and seat the rubber seal onto the edges of the air cleaner base. 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” mark or over the “F” mark on the dipstick. 6. Reinstall the air cleaner cover and secure with the knobs. Servicing the Engine Oil Checking the Oil Level Changing the Oil and Filter Service Interval: Before each use or daily Service Interval: After the first 5 hours Every 100 hours/Yearly (whichever comes first) thereafter. 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. Change the oil and filter while the engine is still warm. The oil will flow more freely and carry away more impurities. Make sure the engine is level when filling, checking, or changing the oil. 3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil fill cap/dipstick before removing it. 1. Start the engine and let it run until warm. This warms the oil so it drains better. 4. Pull and remove the oil fill cap/dipstick; wipe oil off. Reinsert the dipstick and push firmly into place (Figure 25). 2. Disengage the blade control switch and move the motion controls outward to the neutral position and engage parking brake. 32 Maintenance 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Remove the oil drain plug (Figure 26 and Figure 27). Remove the oil fill cap/dipstick (Figure 25). 4. Clean the area around the drain plug and on the machine frame. Place a pan underneath machine directly below the drain hole in the frame as shown in Figure 26 and Figure 27. Figure 28 1. Oil filter 2. Gasket 6. Be sure to allow ample time for complete drainage. 7. Remove the old filter and wipe off the mounting pad (Figure 28). 8. When the oil has drained completely, install the oil drain plug. Tighten the plug to 14 N-m (125 in-lb) torque. Wipe up any excess oil on the frame (Figure 26 and Figure 27). Figure 26 Briggs & Stratton engine 1. Oil drain 2. Oil drain plug Note: Dispose of the used oil at a recycling center. 3. Pan 9. Apply a thin film of clean oil to the rubber gasket on the new filter. 10. Install the replacement oil filter to the mounting pad. Turn the oil filter clockwise until the rubber gasket contacts the pad, then tighten the filter an additional 1/2 to 3/4 turn (Figure 28). 11. Slowly pour approximately 80% of the specified oil into the filler tube—use oil recommended in the Engine Owner’s Manual. 12. Install the oil fill cap/dipstick and push firmly into place. 13. Check the oil level (Figure 25); refer to Checking the Oil Level. 14. Slowly add additional oil to bring it to the full mark. Do Not overfill. Figure 27 Kohler Command engine 1. Oil drain hose 2. Oil drain plug 15. Install the oil fill cap/dipstick and push firmly into place. 3. Pan 16. Start the engine and check for leaks. 33 Maintenance Checking the Hydraulic Oil Level 5. Remove the vent plug on each transmission and fill through expansion reservoir, when oil comes out of vent reinstall plug. Torque plugs to 180 in-lb (244 N-m). Continue to add oil until it reaches the FULL COLD line on the expansion reservoir. Service Interval: Before each use or daily Check expansion tank and if necessary add MOBIL 1 15W-50 synthetic motor oil to the FULL COLD line Figure 30 1. Oil filter 2. Vent plug Figure 29 1. Engine 3. Left rear tire 2. Expansion tank 6. Raise the rear of machine up and support with jack stands (or equivalent support) just high enough to allow drive wheels to turn freely. Change the Hydraulic System Filter 7. Start engine and move throttle control ahead to 1/2 throttle position. Disengage parking brake. Service Interval: After the first 200 hours A. With the bypass valve open and the engine running, slowly move the directional control in both forward and reverse (5 or 6 times). Note: Use only MOBIL 1 15W-50 Synthetic motor oil. 1. Stop engine, wait for all moving parts to stop, and allow engine to cool. Remove key and engage parking brake. B. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 to 6 times). Check the oil level, and add oil as required after stopping the engine. 2. Locate the two filters under the transmissions. Remove filter guards. C. It may be necessary to repeat steps A and B until all the air is completely purged from the system. When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds, then the transaxle is considered purged. 3. Carefully clean area around filters. It is important that no dirt or contamination enter hydraulic system. 4. Unscrew filters to remove and allow oil to drain from drive system. Important: Before reinstalling new filters, apply a thin coat of oil on the surface of the filters rubber seal. Do Not change hydraulic system oil (except for what can be drained when changing filter), unless it is felt the oil has been contaminated or been extremely hot. Turn the filters clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 3/4 to 1 full turn. Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system. 34 Maintenance Servicing the Spark Plug Checking the Spark Plug Service Interval: Every 200 hours/Every 2 years (whichever comes first) Every 500 hours—Replace the spark plug. 1. Look at the center of the spark plug (Figure 32). 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. Important: Never clean the spark plug. Always replace the spark plug when it has a black coating, worn electrodes, an oily film, or cracks. As stated in the maintenance intervals, remove the spark plug, check condition, and reset the gap or replace with a new plug as necessary. 2. Check the gap between the center and side electrodes (Figure 32). Bend the side electrode if the gap is not correct. The spark plug is RFI compliant. Equivalent alternate brand plugs can also be used. Type: Champion XC92YC (for Briggs & Stratton) Champion RC12YC or QC12C may be used if your area does not require compliance with Canadian ICES-002, ISO 14982, or EN 55012. Type: Champion RC12YC (for Kohler Command) Air Gap: 0.030 inch (0.76 mm) Removing the Spark Plug Figure 32 1. Disengage the blade control switch, move the motion controls outward to the park position, stop the engine, and remove the key. 2. Pull the wire off of the spark plug (Figure 31). Clean around the spark plug to prevent dirt from falling into the engine and potentially causing damage. 1. Side electrode 2. Center electrode insulator 3. Air gap (not to scale) Installing the Spark Plug 1. Install the spark plug. Make sure that the air gap is set correctly. 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. 3. Remove the spark plug and metal washer. 2. Tighten the spark plug to 15 ft-lb (20 N-m). 3. Push the wire onto the spark plug (Figure 31). Cleaning the Blower Housing 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. Figure 31 1. Spark plug and wire location 3. Make sure the cooling shrouds are reinstalled 35 Maintenance 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. Fuel System Maintenance Replacing the Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) DANGER 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. Figure 33 1. 2. 3. 4. 5. • Perform any fuel related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills. Fuel tank Fuel shut off valve—off Fuel shut off valve Fuel shut off valve—on Fuel line from tank 6. 7. 8. 9. Hose clamps Fuel line to engine Filter Flow direction arrow 4. Turn fuel shut off valve 90° to “off ” position. • Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes. 5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 33). 6. Remove the filter from the fuel lines. 7. 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 (Figure 33) to secure it in place. 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. 8. Turn fuel shut off valve back to “on” position. 2. Move the motion control levers outward to 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. Electrical System Maintenance 3. The fuel filter is in the fuel line between the tank and engine. WARNING 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. 36 Maintenance Charging the 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. Removing the Battery WARNING • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. 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. • Always connect the positive (red) battery cable before connecting the negative (black) cable. • When removing or installing the battery, Do Not allow the battery terminals to touch any metal parts of the machine. 5. Slide the rubber cover up the positive (red) cable. Disconnect the positive (red) cable from the battery post. Retain all fasteners. • Do Not allow metal tools to short between the battery terminals and metal parts of the machine. 6. Remove the battery hold-down (Figure 34) and lift the battery from the battery tray. 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to 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. Charging the Battery 3. Raise the seat. 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. 1. Remove the battery from the chassis; refer to Removing the Battery. 4. Disconnect the negative (black) ground cable from the battery post (Figure 34). Retain all fasteners. 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 cables are 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 34 1. 2. 3. 4. Battery hold-down Wingnut Negative battery post Bolt, washer, and nut 5. Terminal boot 6. Positive battery post 7. Battery 37 Maintenance 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 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. 5. Secure the battery with the hold-down (Figure 34). Servicing the Fuses and Relay 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. There is also a replaceable relay/s next to the fuse. Refer to your Parts manual for correct replacement components. Fuse Block: • Main fuse: 25 amp fuse, blade-type • Charge Circuit: 20 amp fuse, blade-type • Auxiliary circuit: 15 amp fuse, blade-type • Diode: TVS 1. Raise the seat to gain access to the fuse holder (Figure 36). 4. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Figure 35). Figure 35 1. Negative battery post 2. Black (-) charger lead 3. Red (+) charger lead 4. Positive battery post Note: Do Not run the machine with the battery disconnected, electrical damage may occur. Installing the Battery Figure 36 1. Position the battery in the tray with the terminal posts toward the operating position (Figure 34). 1. 2. 3. 4. 2. Install the positive (red) battery cable to the positive (+) battery terminal using the fasteners removed previously 38 Cover Relay Auxilliary–15 amp Charge–20 amp 5. 6. 7. 8. Main–25 amp Diode Briggs & Stratton unit Kohler Command unit Maintenance 2. Remove cover as shown in Figure 36. WARNING 3. To replace a fuse, pull out on the fuse to remove it 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. Drive System Maintenance Checking the Tire Pressure • Inspect the blade periodically for wear or damage. Service Interval: Every 25 hours/Monthly (whichever comes first) • Replace a worn or damaged blade. 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 37). Before Inspecting or Servicing the Blades Check the tires when they are cold to get the most accurate pressure reading. Park the machine on a level surface, disengage the blade control switch, and move the motion control levers outward to the neutral position and engage parking brake. Stop the engine, remove the key, and disconnect the spark plug wire(s) from the spark plug(s). Rear Tires: 13 psi (90 kPa) Front Tires (caster wheels): 13 psi (90 kPa) Inspecting the Blades 1. Inspect the cutting edges (Figure 38). If the edges are not sharp or have nicks, remove and sharpen the blades; refer to Sharpening the Blades. Figure 37 2. Inspect the blades, especially the curved area. If you notice any damage, wear, or a slot forming in this area (item 3 in Figure 38), immediately install a new blade. 1. Valve stem Mower Maintenance Servicing the Cutting Blades Service Interval: Before each use or daily 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 38 1. Cutting edge 2. Curved area 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. 3. Wear/slot forming Checking for Bent Blades 1. Rotate the blades until the ends face forward and backward (Figure 39). Measure from a level surface to the cutting edge, of the blades. Note this dimension. 39 Maintenance (Figure 40). Refer to Removing the Blades and Installing the Blades. 3. Once the blade has been removed, inspect the spring disc washer. If the washer appears to be damaged (the washer surface has been marred) or flattened, the bolt and washer assembly must be replaced. 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 an unsafe machine. Figure 39 1. Blades front to rear 2. Outside cutting edges 3. Measure here 2. Rotate the opposite ends of the blades forward. Hold the blade end using a rag or thickly-padded glove (or place a wrench on the top sheave nut). Remove the blade bolt and washer assembly, washer, and blade from the spindle shaft (Figure 40). 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1. The difference between the dimensions obtained in steps 1 and 3 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades and Installing the Blades. WARNING 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. Figure 40 1. Blade 2. Washer 3. Bolt and washer assembly. Apply lubricant to threads—torque to 32-42 ft-lb (43-57 N-m). • Never file or create sharp notches in the edges or surfaces of blade. Checking for Loose Blades or Damaged Spring Disc Washers Sharpening the Blades 1. Place a wrench on the blade bolt and torque to 32-42 ft lb (43-57 N-m). 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 41). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges. 2. With the wrench still on the blade bolt, hold the blade spindle stationary and using a rag or thickly padded glove, try to rotate the blade. If the blade rotates relative to the spindle guard without further tightening the blade bolt, the spring disc washer has been flattened or damaged and the bolt and washer assembly must be replaced 40 Maintenance Mower Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours Figure 41 Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. 1. Sharpen at original angle Replacing the Mower Belt 2. Check the balance of the blade by putting it on a blade balancer (Figure 42). 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 42). Repeat this procedure until the blade is balanced. 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. 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to 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. Figure 42 1. Blade 2. Balancer 3. Set the height-of-cut at 1-1/2 inch (38 mm). 4. Remove the belt covers over the outside spindles. 5. Pull the idler pulley in the direction shown in Figure 48 and roll the belt off of the pulleys. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 40). WARNING Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting. The spring is under tension when installed and can cause personal injury. 2. Hold the blade end using a rag or thickly-padded glove (or place a wrench on the top sheave nut). Apply lubricant to the threads of the blade bolt as needed to prevent seizing. Copper based anti-seize is preferable. Grease is an acceptable substitute. Install the washer and blade bolt and washer assembly. Be careful when removing the belt. 3. Torque the blade bolt to 32-42 ft-lb (43-57 N-m). WARNING Incorrect installation of the blade or components used to retain the blade cause the blade to come loose and could seriously injure or kill you or bystanders. Figure 43 1. Outside puley 2. Spring 3. Idler pulley Always install the original Exmark blades, washers and blade bolts as shown. 41 4. Mower belt 5. Engine pulley 6. Pull idler in this direction. Maintenance 6. Route the new belt around the engine pulley and mower pulleys. 7. Pull the idler pulley in the direction shown in Figure 43 and route the belt onto the idler pulley. 8. Install the belt covers over the outside spindles. 7. Set anti-scalp rollers to top holes or remove completely for this adjustment. 8. Set the height-of-cut lever to the 3 inch (76 mm) position. Place two 2 1/2 inch (6.35 cm) thick blocks under the rear edge of the cutting deck skirt; one on each side of the cutting deck. Place two 2 5/16 inch (5.89 cm) blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets. 9. Carefully rotate the blades side to side (Figure 44). 10. Loosen the leveling adjust locking nuts (item 4) on all four corners so that the deck is sitting securely on all four blocks. Make sure that the deck hangers are all the way down (at the top of the slot) and the deck lift foot lever is pushed back against the stop, then tighten the four leveling adjust locking nuts 11. Recheck that blocks fit just snugly under the deck skirt. Make sure all attachment bolts are tight 12. Continue leveling the deck by checking the front-to-rear blade slope; refer to Adjusting the Front-to-Rear Blade Slope. 13. Recheck blades for levelness and repeat deck leveling procedure if necessary. Leveling the Mower Deck The mower blades must be level from side to side. Check the side-to-side level any time you install the mower or when you see an uneven cut on your lawn. 1. Park the machine on a level surface and disengage the blade control switch. 2. Move the motion control levers outward to 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. Check the air pressure of all four tires. If needed, adjust to the recommended inflation; refer to Checking the Tire Pressure in Drive System Maintenance section. If either one is out of range then follow adjustment procedure. 4. Carefully rotate the blades side to side. 5. Measure between the outside cutting edges and the flat surface (Figure 44). If both measurements are not within 3/16 inch (5 mm), an adjustment is required; continue with this procedure. Figure 45 1. Deck lift arm 2. Float retaining nut Figure 44 1. Blades side to side 2. Outside cutting edges 3. Measure here 3. Deck hanger 4. Leveling adjust locking nut Adjusting the Blade Slope 6. Check the front-to-rear blade level any time you install the mower. 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 blade level. If measurements from steps 5 or 6 are out of range, then follow Adjusting the Blade Slope. 1. Check the front-to-rear blade level any time you install the mower. 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 blade level using the following instructions: 42 Maintenance 2. Park the machine on a level surface and disengage the blade control switch. 3. Move the motion control levers outward to the neutral position, engage the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Check the air pressure of all four tires. If needed, adjust to the recommended inflation; refer to Checking the Tire Pressure in Drive System Maintenance section. 5. Check and adjust the side-to-side blade level if you have not checked the setting; refer to Leveling the Mower. 6. Set the height-of-cut lever to the 3 inch (76 mm) position. Place two 2 1/2 inch (6.35 cm) thick blocks under the rear edge of the cutting deck skirt; one on each side of the cutting deck. Place two 2 5/16 inch (5.89 cm) blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets. Figure 46 3. Deck hanger 4. Leveling adjust locking nut 1. Deck lift arm 2. Float retaining nut 7. Loosen the leveling adjust locking nuts (item 4) on all four corners so that the deck is sitting securely on all four blocks. Make sure that the deck hangers are all the way down (at the top of the slot) and the deck lift foot lever is pushed back against the stop, then tighten the four leveling adjust locking nuts (Figure 46). 8. Carefully rotate the blades so they are facing front to rear (Figure 47). 9. Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat surface (Figure 47). 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 deck hanger. Figure 47 1. Blades front to rear 2. Outside cutting edges 3. Measure here 10. When the front-to-rear blade slope is correct check the side-to-side level of the mower again; refer to Leveling the Mower . 43 Maintenance Removing the Mower Deck 1. Park the machine on a level surface and disengage the blade control switch 2. Move the motion control levers outward to 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. Place blocks under deck for support. Lower the height-of-cut lever to the lowest position. 4. Remove the hardware from the deck hanger and deck lift arm on both sides of the deck (Figure 48). Figure 49 1. Deck lift arm 2. Deck strut 6. Slide the mower rearward to remove the mower belt from the engine pulley. 7. Slide the mower out from underneath the machine. Note: Retain all parts for future installation. Installing the Mower Deck 1. Park the machine on a level surface and disengage the blade control switch. Figure 48 1. Deck lift arm 2. Deck hanger 2. Move the motion control levers outward to 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. 5. Remove the nut, bolt, and pivot bushing from the deck strut (Figure 48). Carefully lower the front of the mower deck to the ground (Figure 49). 3. Slide the mower under the machine. 4. Lower the height-of-cut lever to the lowest position. 5. Use the existing hardware to attach the rear deck strut of the mower to the deck lift arm (Figure 49). 6. Attach the hardware from the deck hanger and deck lift arm on both sides of the deck (Figure 48). 7. Install the mower belt onto the engine pulley; refer to Replacing the Mower Belt. 44 Maintenance Replacing the Discharge Deflector through the front discharge deflector bracket, discharge deflector, and rear deflector bracket. 5. Make sure that the spring and rod are installed so that the rod is retained from sliding out by the front bracket and the spring holds the discharge deflector in the down position. Refer to (Figure 50) for proper orientation. 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. Important: The discharge deflector must be spring loaded in the down position. Lift the deflector up to test that it snaps to the full down position. Never operate the lawn mower unless you install a mulch plate, discharge deflector, or grass collection system. 1. Locate items shown in Figure 50. Figure 50 1. Rod 2. Spring 3. Discharge deflector 4. Mower deck 5. Discharge deflector bracket 6. Assembled view 2. Slide the rod out of the short stand-off, spring, and discharge deflector. Remove the damaged or worn discharge deflector. 3. Install new discharge deflector. 4. Orient the spring so that the short leg points towards the discharge deflector and the longer leg points towards the deck as shown in Figure 50. Place spring on rod and slide rod, straight end, 45 Maintenance Cleaning Note: If the mower is not clean after one washing, soak it and let it stand for 30 minutes. Then repeat the process. Washing the Underside of the Mower 8. Run the mower again for one to three minutes to remove excess water. Service Interval: Before each use or daily WARNING After each use, wash the underside of the mower to prevent grass buildup for improved mulch action and clipping dispersal. A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with blade or thrown debris can cause injury or death. 1. Park the machine on a level surface and disengage the blade control switch. • Replace broken or missing washout fitting immediately, before using mower again. 2. Move the motion control levers outward to 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. • Plug any hole(s) in mower with bolts and locknuts. 3. Attach the hose coupling to the end of the mower washout fitting, and turn the water on high (Figure 51). • Never put your hands or feet under the mower or through openings in the mower. Note: Spread petroleum jelly on the washout fitting O-ring to make the coupling slide on easier and protect the O-ring. Figure 51 4. Lower the mower to the lowest height-of-cut. 5. Sit on the seat and start the engine. Engage the blade control switch and let the mower run for one to three minutes. 6. Disengage the blade control switch, stop the engine, and remove the ignition key. Wait for all moving parts to stop. 7. Turn the water off and remove the coupling from the washout fitting. 46 Storage Storage C. Stop the engine, allow it to cool, and drain the fuel tank; refer to Draining the Fuel Tank in Fuel System Maintenance section. Cleaning and Storage D. Restart the engine and run it until it stops. 1. Disengage the blade control switch, move the motion controls outward to the neutral position, engage parking brake, stop the engine, and remove the key. E. Choke the engine. Start and run the engine until it will not start. F. Dispose of fuel properly. Recycle as per 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, engine, hydraulic pumps, and motors. 10. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug in 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). 3. Service the air cleaner; refer to Servicing the Air Cleaner in Engine Maintenance section. 4. Grease and oil the machine; refer to Lubrication section. 11. 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 Engine Maintenance section. 12. 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 Drive System Maintenance section. 13. Check the condition of the drive and mower belts. 14. 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 Electrical System Maintenance section. 15. 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 Mower Maintenance section. 16. 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. A. 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. B. Run the engine to distribute the conditioned fuel through the fuel system (5 minutes). 47 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 motion control levers are not in the park position. 3. The operator is not seated. 4. The battery is dead. 5. The electrical connections are corroded or loose. 6. A fuse is blown. 7. A relay or switch is damaged. 2. Move the motion control levers outward to the park position. 3. Sit on the seat. 4. Charge the battery. 5. Check the electrical connections for good contact. 6. Replace the fuse. 7. 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. 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. 48 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. Vent hole in the fuel cap is closed. 7. Dirt in fuel filter. 8. Dirt, water, or stale fuel is in the fuel system. 9. 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. Open the vent in the fuel cap. 7. Replace the fuel filter. 8. Contact an Authorized Service Dealer. 9. 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 new deck belt. 4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function. 5. Install a new mower belt. 3. Deck belt is worn, loose or broken. 4. Deck belt is off pulley. 5. The mower belt is worn, loose, or broken. 49 50 HOUR METER, PTO SWITCH SOLENOID SEAT SWITCH, ACCESSORIES HOUR METER, PTO SWITCH TERMINAL B TERMINAL I TERMINAL S TERMINAL X TERMINAL Y 1 LH MOTION CONTROL RH MOTION CONTROL BRAKE SWITCH G007525 2 1 2 1 VIOLET 3 GRAY 2 2 1 1 2 5 4 5 1 1 3 2 3 4 B 7 5 6 8 1 6 4 3 4 5 1 2 FUSE BLOCK 3 8 7 2 YELLOW WHITE LIGHT BLUE VIOLET LIGHT BLUE PINK ORANGE BLACK 3 3 2 5 1 2 4 STARTER LOCKOUT & KILL RELAY 4 5 START SOLENOID GROUND 1 START SOLENOID SIGNAL 1 START SOLENOID B+ 1 A A PTO CLUTCH B BLACK DARK GREEN BLACK DARK GREEN YELLOW PINK YELLOW DARK BLUE GREEN 1 1 PINK Y S X A B DARK GREEN 2 VIOLET GREEN VIOLET 6 1 BROWN 1 2 1 2 YELLOW GRAY VIOLET 3 5 4 1 CONNECTORS VIEWED FROM WIRE END NOTE: VOLTAGE REGULATOR BATTERY TERMINAL A CONNECTIONS TERMINAL A TERMINAL IGNITION SWITCH TERMINAL Y TERMINAL X X +Y TERMINAL B B+I+S B+I+A TERMINAL S TERMINAL I 3. START 2. RUN 7 4 8 5 9 VILOET ORANGE 7 BROWN YELLOW YELLOW NONE 8 PINK DARK GREEN 1. OFF 9 2 PINK 4 RED IGNITION SWITCH RED I VIOLET ORANGE SEAT SWITCH PINK PINK DARK BLUE ORANGE ORANGE VIOLET RED CIRCUIT "MAKE" 1 2 RED VIOLET POSITION 2 3 5 4 BROWN WHITE BLACK BLACK 3 ORANGE DARK GREEN DARK GREEN BROWN BROWN PTO SWITCH 1 2 3 6 4 1 5 3 2 1 A B 4 1 5 2 3 1 B 6 3 2 A GROUND FUEL SOLENOID MAGNETO OIL SWITCH ALTERNATOR HOUR METER ACCESSORIES Schematics Schematics Electrical Diagram—Briggs & Stratton ENGINE 51 HOUR METER, PTO SWITCH SOLENOID SEAT SWITCH, ACCESSORIES HOUR METER, PTO SWITCH TERMINAL B TERMINAL I TERMINAL S TERMINAL X TERMINAL Y 1 LH MOTION CONTROL RH MOTION CONTROL BRAKE SWITCH G007526 2 1 2 1 VIOLET 6 3 2 1 1 1 2 5 4 5 1 3 2 3 4 B 7 5 6 8 1 6 4 3 4 5 1 2 FUSE BLOCK 3 8 7 2 BLUE YELLOW WHITE LIGHT BLUE VIOLET LIGHT BLUE PINK ORANGE BLACK 4 3 3 2 5 1 2 KILL RELAY 5 4 3 3 2 5 1 4 STARTER LOCKOUT SOLENOID 4 5 START SOLENOID B+ 1 A A PTO CLUTCH B BLACK DARK BLUE BLACK DARK GREEN YELLOW DARK GREEN YELLOW 2 2 PINK GREEN 1 1 1 1 DARK GREEN 2 VIOLET GREEN VIOLET GRAY Y S X A B BROWN 1 2 1 2 YELLOW GRAY VIOLET 3 5 4 1 CONNECTORS VIEWED FROM WIRE END NOTE: VOLTAGE REGULATOR BATTERY TERMINAL A CONNECTIONS TERMINAL A TERMINAL IGNITION SWITCH TERMINAL Y TERMINAL X X +Y TERMINAL B B+I+S B+I+A TERMINAL S TERMINAL I 3. START 2. RUN 7 4 8 5 9 PINK 7 BROWN YELLOW YELLOW NONE 8 PINK DARK GREEN 1. OFF 9 2 PINK 4 RED IGNITION SWITCH RED I VIOLET ORANGE SEAT SWITCH PINK PINK DARK BLUE ORANGE ORANGE VIOLET RED CIRCUIT "MAKE" 1 RED VIOLET POSITION 2 3 5 4 BROWN WHITE BLACK BLACK 2 VILOET ORANGE DARK BLUE BLUE 3 ORANGE DARK GREEN DARK GREEN BROWN BROWN PTO SWITCH 1 2 3 6 4 1 5 3 2 1 A B 4 1 5 2 1 3 B 6 3 2 A GROUND FUEL SOLENOID MAGNETO OIL SWITCH ALTERNATOR HOUR METER ACCESSORIES Schematics Electrical Diagram—Kohler Command ENGINE 3-Year Limited Consumer Warranty (30-Day Limited Commercial Warranty) Exmark Quest Riding Mowers (For units purchased on or after January 1, 2007) All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts. 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 manufactured by Exmark 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 mowers. 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. Customers may also call 402-223-6375. This warranty applies to Exmark Quest mowers purchased on or after January 1, 2007 sold in the US 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. • • • • Products Attachments Belts and Tires Battery Engine* If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at: Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice, NE 68310 402-223-6375 or firstname.lastname@example.org Warranty Period 1 year 90 days 1 Year Prorated 3-Year, 3rd Year Covered by Exmark Owner’s Responsibilities The Exmark turf equipment, including any defective part, 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. * Please refer to the manufacturer’s warranty statement that is included in the literature packet. Exmark Warranty Company extends coverage for warrantable engine items as defined by the manufacturer’s original warranty during the 3rd year of warranty. This warranty only includes the cost of parts and labor. ** 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. General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein. Neither Exmark nor Exmark Warranty Company shall have any liability for any other cost, loss or damage, including but not limited to, any incidental or consequential loss or damage. Exmark will cover up to $45 for associated pick-up and delivery charges to and from any authorized Exmark Service Dealer. This will apply to the first warrantable service repair only. Additional transportation charges may apply, contact your Dealer for details. Limited Warranty for Commercial Use Exmark Quest mowers and attachments used for commercial, institutional, or rental use are warranted against defects in materials or workmanship for the following time periods from the date of purchase: Products • Air Cooled Gas Engines • All other items In particular, we shall have no liability or responsibility for: • Expenses related to gasoline, oil or lubricants. • Travel time, overtime, after hours time or other extraordinary repair charges or charge 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. Warranty Period 90 day limited warranty 30 day limited warranty 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. • 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. Some states do not allow exclusions of incidental or consequential damages, 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 stated elsewhere herein or included with the product. G007486 52 Notes: 53 Service Record Date: Description of Work Done: 54 Service Done By: 55 © 2007—2008 Exmark Mfg. Co., Inc. Industrial Park Box 808 Beatrice, NE 68310 All Rights Reserved Part No. 4500-338 Rev. A (402) 223-6300 Fax (402) 223-5489 Printed In USA.