Exmark QUEST QZS708GEM50200 Operator's Manual

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Exmark QUEST QZS708GEM50200 Operator's Manual | Manualzz

QUEST

®

For Serial Nos.

402,082,300 & Higher

Part No. 4503-851 Rev. A

WARNING

CALIFORNIA

Proposition 65 Warning

This product contains a chemical or chemicals known to the State of

California to cause cancer, birth defects, or reproductive harm.

The engine exhaust from this product contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive harm.

Important: It is a violation of California Public

Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire.

To acquire a spark arrester for your unit, see your

Engine Service Dealer.

For all models that do not have Exmark engines, please refer to the engine manufacturer's information included with the machine.

For models with Exmark engines, refer to this manual for information.

The gross or net horsepower (or torque) of this engine was laboratory rated by the engine manufacturer in accordance with the Society of Automotive Engineers (SAE) J1940 or J2723.

As configured to meet safety, emission, and operating requirements, the actual engine horsepower (or torque) on this class of mower will be significantly lower.

©2018 Exmark Mfg. Co., Inc.

2101 Ashland Ave

Beatrice, NE 68310

2

Contact us at www.Exmark.com.

Printed in the USA

All Rights Reserved

Introduction

CONGRATULATIONS on the purchase of your

Exmark Mower. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation.

This manual contains operating, maintenance, adjustment, and safety instructions for your Exmark mower.

BEFORE OPERATING YOUR MOWER,

CAREFULLY READ THIS MANUAL IN ITS

ENTIRETY.

By following the operating, maintenance, and safety instructions, you will prolong the life of your mower, maintain its maximum efficiency, and promote safe operation.

Important: To maximize safety, performance, and proper operation of this machine, it is essential that all operators carefully read and fully understand the contents of the Operator’s manual provided with the product. Safe operation of Exmark equipment is essential.

Failure to comply with the operating instructions or receive proper training may result in injury.

Go to http://www.Exmark.com for additional safe operation information, such as safety tips, training materials, and Operator’s manuals.

If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor.

All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations. They carry ample stock of service parts or can secure them promptly for you from the factory.

All Exmark parts are thoroughly tested and inspected before leaving the factory, however, attention is required on your part if you are to obtain the fullest measure of satisfaction and performance.

Whenever you need service, genuine Exmark parts, or additional information, contact an Authorized

Service Dealer or Exmark Customer Service and have the model and serial numbers of your product ready.

Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.

Figure 1

1.

Model and serial number location

Model No.

Serial No.

For complete warranty details, see http://www.Exmark.com. You may also call us 402-223-6375 to request a written copy of the product’s warranty.

g236603

3

Contents

Introduction ........................................................... 3

Safety ..................................................................... 5

Safety Alert Symbol ......................................... 5

Safe Operating Practices .................................. 5

Safety and Instructional Decals ....................... 9

Specifications ........................................................15

Systems ..........................................................15

Dimensions....................................................17

Torque Requirements .....................................17

Product Overview .................................................18

Operation ..............................................................18

Controls .........................................................18

Operating Instructions ...................................20

Think Safety First ...........................................20

Recommended Gasoline.................................20

Checking the Engine Oil Level........................22

Starting the Engine .........................................22

Operating the Blades ......................................23

Stopping the Engine .......................................23

The Safety Interlock System............................24

Check Safety Interlock System ........................24

Driving Forward or Backward.........................27

Stopping the Machine.....................................28

Adjusting the Height of Cut ............................28

Adjusting the Anti-Scalp Rollers......................28

Positioning the Seat ........................................29

Changing the Seat Ride Suspension .................30

Adjusting the Motion Control Levers ..............30

Pushing the Machine by Hand.........................31

Side Discharge................................................31

Transporting the Machine...............................32

Loading the Machine ......................................32

Operating Tips ..............................................33

Maintenance ..........................................................35

Recommended Maintenance Schedule(s) ............36

Pre-Maintenance Procedures .............................37

Raising the Seat ..............................................37

Periodic Maintenance ........................................37

Lubrication.....................................................37

Engine Maintenance.......................................37

Servicing the Engine Oil .................................41

Servicing the Spark Plug-Exmark 452cc

Engine .......................................................46

Servicing the Spark Plug-Exmark 708cc

Engine .......................................................47

Cleaning the Blower Housing..........................48

Fuel System Maintenance ...............................49

Servicing the Emissions Filter .........................49

Electrical System Maintenance........................49

Charging the Battery.......................................50

Drive System Maintenance .............................53

Checking the Tire Pressure .............................53

Changing the Hydraulic System Filter and Oil––50 and 60 Inch S-Series

Only...........................................................53

Mower Maintenance .......................................55

Servicing the Cutting Blades ...........................55

Leveling the Mower Deck ...............................58

Mower Belt Maintenance ................................61

Replacing the Discharge Deflector ..................63

Cleaning ............................................................65

Clean Grass Build-Up Under Deck .................65

Clean Engine and Exhaust System

Area ...........................................................65

Clean Debris From Machine ...........................65

Storage ..................................................................66

Cleaning and Storage ......................................66

Troubleshooting ....................................................67

Schematics ............................................................69

4

Safety

Safety

Safety Alert Symbol

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.

Figure 2

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.

This machine has been designed in conformance with the American National Standards

Institute–B71.1 specifications 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.

Safe Operating Practices

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

General Operation

• Read, understand, and follow all instructions in the operator’s manual and on the machine before starting.

• Do Not place hands or feet near rotating parts or under the machine. Keep clear of the discharge opening at all times.

• Allow only responsible adults who are familiar with the instructions to operate the machine.

g000502

• Clear the area of objects such as rocks, toys, wire, etc., which could be picked up and thrown by the blade.

• 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.

• 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.

• 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.

• Operate the machine only in daylight or good artificial light.

• Do Not operate the machine while under the influence of alcohol or drugs.

• Watch for traffic when operating near or crossing roadways.

• Use extra care when loading or unloading the machine into a trailer or truck

• Always wear eye protection when operating the mower.

• 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 safely enough to protect themselves and others from serious injury.

5

Safety

• Always follow the recommendations for wheel weights or counterweights.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area,

Do Not operate the machine; seek shelter.

Slope Operation

• Slopes are a major factor related to loss of control and rollover accidents, which can result in severe injury or death. The operator is responsible for safe slope operation. Operating the machine on any slope requires extra caution. Before using the machine on a slope, the operator must:

– Review and understand the slope instructions in the manual and on the machine.

– Use an angle indicator to determine the approximate slope angle of the area.

– Never operate on slopes greater than 15 degrees.

– Evaluate the site conditions of the day to determine if the slope is safe for machine operation. Use common sense and good judgment when performing this evaluation.

Changes in the terrain, such as moisture, can quickly affect the operation of the machine on a slope.

• Identify hazards at the base of the slope. Do

Not operate the machine near drop offs, ditches, embankments, water or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge collapses. Keep a safe distance (twice the width of the machine) between the machine and any hazard. Use a walk behind machine or a hand trimmer to mow the grass in these areas.

g221745

Figure 3

1.

Safe Zone-Use the mower here on slopes less than 15 degrees

2.

Danger Zone-Use a walk-behind mower and/or hand trimmer on slopes greater than 15 degrees

3.

Water

4.

W=width of the machine

5.

Keep a safe distance (twice the width of the machine) between the machine and any hazard.

• Avoid starting, stopping or turning the machine on slopes. Avoid making sudden changes in speed or direction; turn slowly and gradually.

• Do Not operate a machine under any conditions where traction, steering or stability is in question.

Be aware that operating the machine on wet grass, across slopes or downhill may cause the machine to lose traction. Loss of traction to the drive wheels may result in sliding and a loss of braking and steering. The machine can slide even if the drive wheels are stopped.

• Remove or mark obstacles such as ditches, holes, ruts, bumps, rocks or other hidden hazards. Tall grass can hide obstacles. Uneven terrain could overturn the machine.

• Use extra care while operating with accessories or attachments, such as grass collection systems.

These can change the stability of the machine and cause a loss of control. Follow directions for counter weights.

• If possible, keep the deck lowered to the ground while operating on slopes. Raising the deck while operating on slopes can cause the machine to become unstable.

6

Safety

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity.

Never assume that children will remain where you last saw them.

• Keep children out of the mowing area and under the watchful care of another responsible adult, not the operator.

• Be alert and turn the machine off if children enter the area.

• Before and while backing or changing direction, look behind, down, and side-to-side for small children.

• Never carry children, even with the blades off.

They may fall off and be seriously injured or interfere with safe machine operation.

• Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the mower.

• Never allow children to operate the machine.

• Use extra care when approaching blind corners, shrubs, trees, the end of a fence or other objects that may obscure vision.

Towing Safety

• Do not attach towed equipment except at the hitch point.

• Follow the attachment manufacturer's recommendation for weight limits for towed equipment and towing on slopes. Towed weight must not exceed the weight of the machine, operator, and ballast. Use counterweights or wheel weights as described in the attachment, or in the pulling machine Operator’s Manual .

• Never allow children or others in or on towed equipment.

• On slopes, the weight of the towed equipment may cause loss of traction, increased risk of rollover, and loss of control. Reduce the towed weight and slow down.

• Stopping distance increases with the weight of the towed load. Travel slowly and allow extra distance to stop.

• Make wide turns to keep the attachment clear of the machine.

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.

• 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.

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 interfere with the intended function of a safety device or reduce the protection provided by a safety device. Check their proper operation regularly.

• Keep the machine free of grass, leaves, or other debris build-up. Clean up oil or fuel spillage and fuel soaked debris. Allow the machine to cool before storing.

7

Safety

• 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 replace with manufacturers’ recommended parts, when necessary.

• Mower blades are sharp and can cut. Wrap the blades or wear gloves, and use extra caution when servicing them.

• Check for proper brake operation frequently.

Adjust and service as required.

• Maintain or replace safety and instruction decals as necessary.

• Use only genuine Exmark replacement parts to ensure that original standards are maintained.

Exmark Riding Mower Safety

The following list contains safety information specific to Exmark products or other safety information that you must know that is not included in the ANSI standards.

• Only adults and mature teenagers should operate a mower, and even mature teenagers should have adult supervision. Be sure a teenager:

1.

has read and understands the Operator's

Manual and recognizes the risks involved;

2.

is sufficiently mature to use caution; and

3.

is of sufficient size and weight to operate the controls comfortably and to manage the mower without taking risks.

• 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.

• Park machine on level ground. Stop the engine, wait for all moving parts to stop, engage parking brake, disconnect spark plug wire(s) and remove key before performing any service, repairs, maintenance or adjustments.

• Keep hands, feet, hair, and loose clothing away from attachment discharge area, underside of mower and any moving parts while engine is running.

• Do Not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust or service.

• Battery acid is poisonous and can cause burns.

Avoid contact with skin, eyes, and clothing.

Protect your face, eyes, and clothing when working with a battery.

• Battery gases can explode. Keep cigarettes, sparks and flames away from battery.

• Use only Exmark approved attachments.

Warranty may be voided if used with unapproved attachments.

• If loading the machine onto a trailer or truck, use a single, full-width ramp only. The ramp angle should not exceed 15 degrees.

Note: The left and right sides of the machine are determined while sitting in the seat in the normal operating position

8

Safety

Safety and Instructional Decals

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.

decal93-7009

93-7009

1.

Warning—don't operate the mower with the deflector up or removed; keep the deflector in place.

2.

Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts.

decal105-7015

105-7015

For Models with 34 Inch or 42 Inch Mower Decks

1.

Belt routing decal99-3943

99-3943

For Models with 50 Inch or 60 Inch Mower Decks

1.

Engine decal106-8717

106-8717

For Models with 34 Inch or 42 Inch Mower Decks

1.

Read the instructions before servicing or performing maintenance.

2.

Check tire pressure every 25 operating hours.

3.

Grease every 25 operating hours.

4.

Engine

9

Safety

1.

Parking brake—disengaged decal115-9625

115-9625

2.

Parking brake—engaged

117–2718 decal117-2718

119-8871

For Models with 34 Inch or 42 Inch Models decal119-8871-1

1.

Height-of-cut decal119-8870

119-8870

For Models with 50 Inch or 60 Inch Mower Decks

1.

Height of cut decal121-2989

121-2989

1.

Bypass lever position for pushing the machine

2.

Bypass lever position for operating the machine

10

Safety decal130-0765

1.

Read the Operator's

Manual .

130-0765

3.

Remove the key from the ignition and read the

Operator's Manual before performing maintenance.

2.

Height-of-cut selection decal132-0872

132-0872

1.

Thrown object hazard—keep bystanders away from the machine.

2.

Thrown object hazard, raised baffle—do not operate the machine with an open deck; use a bagger or a baffle.

3.

Severing hazard of hand or foot—keep away from moving parts.

4.

Entanglement hazard—keep away from moving parts; keep all guards and shields in place.

1.

Oil drain

131-1097

Exmark 708cc Engine Only decal131-1097

1.

Machine speed

2.

Fast

3.

Slow

135-2310

4.

Neutral

5.

Reverse decal135-2310

11

Safety

136-5596

For Models with 50 Inch or 60 inch Decks decal136-5596

1.

Check the tire pressure every 25 operating hours.

2.

Engine oil

4.

Check the tire pressure every 25 operating hours.

5.

Read the Operator's

Manual before performing maintenance.

3.

Check the tire pressure every 25 operating hours.

PTO Switch Symbols

1.

PTO–disengage 2.

PTO–engage decalptosymbols

135-2468

42 Inch Models with Exmark 452cc Engine decal135-2468

1.

Choke

2.

Fast

3.

Slow

4.

Optional hour meter accessory

Exmark 708cc Engine Only

1.

Shut down engine at full throttle decal132-0904

12

Safety decal135-2469

135-2469

34 or 42 Inch Models with Exmark 708cc Engine

1.

Fast

2.

Slow

4.

Choke–Off

5.

Optional hour meter accessory

3.

Choke–On decal135-2470

135-2470

50 or 60 Inch Models with Exmark 708cc Engine

1.

Fast

2.

Slow

3.

Choke–On

4.

Choke–Off decal135-3295

135-3295

This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. It is important that each operator review the slope operation instructions in the operator’s manual and review the conditions in which the machine is being operated to determine if the machine may be operated in the conditions that day and on that site. Changes to terrain can result in a change in slope operation for any machine.

1.

2.

Cutting hazard. Pinch hazard—Keep hands and feet away from moving parts. Keep all guards and shields in place.

3.

Warning—Read the Operator's Manual.

Thrown object hazard—Keep bystanders a safe distance from the machine, pick up debris before operating, and keep the deflector shield down.

4.

Bodily harm hazard—Do Not carry passengers; look behind you when mowing in reverse.

5.

Ramp hazard—When loading onto a trailer, Do Not use dual ramps. Only use a singular ramp wide enough for the machine. Back up the ramp (in reverse) and drive forward off the ramp.

6.

Tipping hazard—Do Not use on slopes near open water.

Do Not use on slopes greater than 15°.

13

Safety decalbatterysymbols

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

3.

Caustic liquid/chemical burn hazard 7.

Wear eye protection; explosive gases can cause blindness and other injuries.

4.

Wear eye protection

6.

Keep bystanders a safe distance from the battery.

8.

Battery acid can cause blindness or severe burns.

9.

Flush eyes immediately with water and get medical help fast.

10.

Contains lead; do not discard.

14

Specifications

Specifications

Systems

Engine

• Engine Specifications: See your Engine Owner’s

Manual

• Engine Oil Type: Exmark 4-Cycle Premium

Engine Oil

• RPM:

Full Speed: 3300 ±100 (max) RPM (No Load)

Idle: 1650 (min) RPM

Fuel System

• Capacity: 3.0 gal. (11 L)

• Fuel Recommendations:

– For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher

((R+M)/2 rating method).

– Oxygenated fuel with up to 10% ethanol or

15% MTBE by volume is acceptable.

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

– Do Not use gasoline containing methanol.

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

– Do Not add oil to gasoline.

• Fuel Filter: In-line

Electrical System

• Charging System: Flywheel Alternator

• Charging Capacity: 15 amps

• Battery Type: 195 CCA

• Battery Voltage: 12 Volt

• Polarity: Negative Ground

• Fuses: One 30 amp, one 25 amp; blade type

Safety Interlock System

• PTO must be disengaged, brake engaged, and motion control levers out (neutral lock) to start engine. (It is not necessary for the operator to be in the seat to start the engine.)

• Operator must be in seat when PTO is engaged, brake is disengaged, or motion control levers are moved in or engine will stop.

• Engine will stop if either the left, the right, or both levers are moved from neutral lock position while brake is engaged.

Operator Controls

• Steering and Motion Control:

Note: Motion control levers are adjustable to two heights.

– Separate levers, on each side of the console, control speed and direction of travel of the respective drive wheels.

– Steering is controlled by varying the position of the levers relative to each other.

– 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.

• Parking Brake Lever: Engages/Disengages parking brake.

• Deck Height Adjustment Lever: Sets cutting height to desired position.

• Deck Lift Assist Lever: Foot pedal that assists in raising the deck.

Seat

• Type:

– E-Series models: Standard seat with high back, foam padded with spring suspension and armrests.

– S-Series models: Two tone upholstered high back, foam padded seat with spring suspension and armrests.

• Mounting: Hinged to tilt up for access to battery and other components. Adjustable fore and aft.

• Armrests (S-Series Only): Standard–padded flip-up armrests.

• Seat Safety Switch: Incorporated into the Safety

Interlock System.

Hydrostatic Ground Drive System

• Hydrostatic Pumps:

15

Specifications

– 34 and 42 inch E-Series model: Two Hydro

Gear ZT2100 Integrated drive systems.

– 50 and 60 inch S-Series model: Two Hydro

Gear ZT2800 Integrated drive systems.

• Hydraulic Oil Type: Exmark Premium Hydro Oil.

• Hydraulic Filter—50 and 60 inch S-Series: P/N

109-3321

• Hydro Service Kit—50 and 60 inch S-Series: P/N

135-2307

• 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.

Tires and Wheels

Deck Size

Quantity

Tread

Size

Ply Rating

Pressure

Deck Size

Quantity

Tread

Size

Ply Rating

Pressure

Deck Size

Quantity

Tread

Drive

Pneumatic (Air-Filled)

42 34

2

Turf Tech TL

2

Turf Tech TL

18 x 6.00-8

4

13 psi

(90 kPa)

18 x 7.50-8

4

13 psi

(90 kPa)

Drive

Pneumatic (Air-Filled)

60 50

2

Turf Tech TL

2

Turf Tech TL

20 x 10-10

4

13 psi

(90 kPa)

20 x 10-10

4

13 psi

(90 kPa)

Front Caster

Pneumatic (Air-Filled)

34 and 42 50 and 60

2

Smooth

2

Smooth

Size

Ply Rating

Pressure

11 x 4-5

2

13 psi

(90 kPa)

Front Caster

13 x 6.5-6

4

13 psi

(90 kPa)

Cutting Deck

• Cutting Width:

– 34 inch Deck: 34 inches (86 cm)

– 42 inch Deck: 42 inches (107 cm)

– 50 inch Deck: 50 inches (127 cm)

– 60 inch Deck: 60 inches (152 cm)

• Discharge: Side

• Blade Size:

– 34 inch Deck: 17.50 inches (44.5 cm)–Qty: 2

– 42 inch Deck: 21.60 inches (54.9 cm)–Qty: 2

– 50 inch Deck: 17.50 inches (44.5 cm)–Qty: 3

– 60 inch Deck: 20.50 inches (52.1 cm)–Qty: 3

• 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.

• Deck: Full floating deck is attached to out-front support frame. Maximum turf protection is provided with anti-scalp rollers.

Deck design allows for bagging, mulching or side discharge.

• Deck Depth:

– 34 inch Deck: 4.0 inches (10.2 cm)

– 42 inch Deck: 4.0 inches (10.2 cm)

– 50 inch Deck: 4.0 inches (10.2 cm)

– 60 inch Deck: 4.0 inches (10.2 cm)

• Cutting Height Adjustment: A hand deck lift lever with foot assist 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.

16

Dimensions

Overall Width:

E-Series

Without Deck

Deflector Up

34 inch Deck

35.6 inches

(90 cm)

38.5 inches

(98 cm)

Deflector Down 45.9 inches

(117 cm)

S-Series

Without Deck

50 inch Deck

47.9 inches

(122 cm)

Deflector Up 50.6 inches

(129 cm)

Deflector Down 61.7 inches

(157 cm)

42 inch Deck

39.0 inches

(99 cm)

45.3 inches

(115 cm)

53.8 inches

(137 cm)

60 inch Deck

47.9 inches

(122 cm)

62.9 inches

(160 cm)

75.2 inches

(191 cm)

Overall Length:

34 inch

Deck

75.0 inches

(191 cm)

42 inch

Deck

75.0 inches

(191 cm)

50 inch

Deck

76.0 inches

(193 cm)

60 inch

Deck

76.0 inches

(193 cm)

Overall Height:

All Units

41.5 inches (105 cm)

Tread Width: (Center to Center of

Tires, Widthwise)

Drive Wheels

Caster Wheels

34 inch Deck

28.8 inches

(73 cm)

29.5 inches

(75 cm)

42 inch Deck

31.5 inches

(80 cm)

29.5 inches

(75 cm)

Specifications

Drive Wheels

50 inch Deck

39.1 inches

(99 cm)

Caster Wheels 36.9 inches

(94 cm)

60 inch Deck

39.1 inches

(99 cm)

32.9 inches

(84 cm)

Wheel Base: (Center of Caster Tire to

Center of Drive Tire)

34 and 42 inch Decks

50 and 60 inch Decks

45.6 inches (116 cm)

48.4 inches (123 cm)

Curb Weight:

E-Series

34 inch Deck 42 inch Deck and 452 cc

Engine

42 inch Deck and 708 cc

Engine

547 lb (248 kg) 496 lb (225 kg) 562 lb (255 kg)

S-Series

50 inch Deck

752 lb (341 kg)

60 inch Deck

681 lb (309 kg)

Torque Requirements

Bolt Location

Spindle Pulley Nut

Blade Mounting Bolt

Engine Mounting Bolts

Wheel Lug Nuts

Clutch Mounting

Bolt (secured with threadlocker)

Torque

35-65 ft-lb (47-88 N-m)

35-65 ft-lb (47-88 N-m)

330-400 in-lb (37-45 N-m)

70-90 ft-lb (95-122 N-m)

50-60 ft-lb (68-81 N-m)

17

Operation

Product Overview Operation

Controls

Note: Become familiar with all of the

Figure 4 controls in and Figure 5 before you start the engine and operate the machine.

Figure 4

1.

Front caster wheel 8.

Engine

2.

Anti-scalp roller 9.

Seat

3.

Height-of-cut foot lever 10.

Fuel tank

4.

Discharge deflector

5.

Deck height adjustment lever

6.

Rear drive wheel

7.

Control panel

11.

Motion control levers

12.

Parking brake lever

13.

Footrest g236602

Ignition Switch

Located on control panel.

The ignition switch is used to start and stop the engine. The switch has three positions “OFF”,

“RUN” and “START” (Figure 5). 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).

18

Figure 5

S-Series Model Shown

1.

Ignition switch

2.

Off

3.

Run

4.

Start

5.

Blade control switch (power take-off)

6.

Choke control

7.

Throttle lever

8.

Hour meter g236698

Operation

Note: Brake must be engaged and PTO switch

“OFF” to start engine. (It is not necessary for the operator to be in the seat to start the engine.)

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.

Blade Control Switch (Power

Take-Off)

Located on control panel.

The blade control switch, represented by a power take-off (PTO) symbol, engages and disengages power to the mower blades (see Figure 5).

Pull up on the blade control switch to “ON” to engage the blades.

Push down on the blade control switch to “OFF” to disengage the blades.

Throttle Lever

Located on control panel.

The throttle is used to control engine speed. Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed (see Figure 5).

• Models with Exmark 452 cc Engine: The throttle is located with the choke control. Moving the throttle lever full forward will place the lever in the choke position.

• All other models: Moving the throttle forward until it stops is full throttle.

Motion Control Levers

The motion control levers located on each side of the seat (Figure 4).

Moving the levers outward from the center position into the T-slot locks them in the neutral position.

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 into the

T-slot locks them in the neutral position.

g236810

Figure 6

1.

Neutral lock position

(handles out)

2.

Neutral operate position

(handles in)

3.

Front of machine

4.

Forward

5.

Neutral (operate)

6.

Reverse

Choke Control

The choke is used to aid in starting a cold engine. Do

Not run a warm engine with the choke in the “ON” position.

• Models with Exmark 452 cc Engine: The choke is located with the throttle control. Moving the lever to the full forward (Choke) position will place the lever in the choke position.

• Models with Exmark 708 cc Engine: Pulling up on the choke control will put the choke in the

“ON” position and pushing down the control will put the choke in the “OFF” position.

Park Brake Lever

Located on left side of machine, just to the front of the LH motion control lever.

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.

The unit must be tied down and brake engaged when transporting.

19

Operation

Deck Height Adjustment Lever

Located below the RH motion control lever

(Figure 4).

Pull the lever inward and rearward to raise the cutting deck. Allow the handle to move forward to lower the cutting deck. Move the deck height adjustment lever outward at the desired height-of-cut. Only adjust the height of cut while the machine is not moving.

Height-of-Cut Foot Lever

Locate at the right front corner of the floor pan.

The height-of-cut foot lever allows the operator to use their leg to assist in lowering and raising the deck from the seated position (Figure 4). Push the lever forward with your foot to raise the cutting deck.

Allow the lever to move rearward to lower the cutting deck to the cut height that has been set.

Fuel Window

Located on the left side of the machine (see Figure 7).

The fuel window can be used to determine the amount of fuel in the tank.

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.

CAUTION

This machine produces sound levels in excess of

85 dBA at the operators ear and can cause hearing loss through extended periods of exposure.

Wear hearing protection when operating this machine.

g009027

1.

Wear safety glasses

Figure 8

2.

Wear hearing protection

1.

Fuel cap

Figure 7

2.

Fuel window

Hour Meter

S-Series Units Only

Located on control panel.

The hour meter records the number of hours when the operator is in the seat and the ignition switch is in the “ON” position.

g236835

Recommended Gasoline

Fill fuel tank on level ground. See Fuel

Recommendations in the Specifications section for additional gasoline information.

Do Not add oil to gasoline.

Do Not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system.

20

Operation

DANGER

In certain conditions gasoline is extremely flammable and vapors are explosive.

A fire or explosion from gasoline can burn you, others, and cause property damage.

• Fill the fuel tank outdoors on level ground, in an open area, when the engine is cold. Wipe up any gasoline that spills.

• Never refill the fuel tank or drain the machine indoors or inside an enclosed trailer.

• Do Not fill the fuel tank completely full. Add gasoline to the fuel tank until the body of the tank is full but fuel does not fill the neck of the tank. This empty space in the tank allows gasoline to expand.

• Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by spark.

• Store gasoline in an approved container and keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.

• Do Not operate without entire exhaust system in place and in proper working condition.

DANGER

In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage.

• Always place gasoline containers on the ground away from your vehicle before filling.

• Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, remove gas-powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

• If this is not possible, then refuel such equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do Not use a nozzle lock open device.

WARNING

Gasoline is harmful or fatal if swallowed.

Long-term exposure to vapors has caused cancer in laboratory animals. Failure to use caution may cause serious injury or illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank/container opening.

• Keep away from eyes and skin.

• Never siphon by mouth.

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

21

Operation 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.

Filling the Fuel Tank

the neck of the tank. This space at the base of the filler neck allows gasoline to expand. Do Not fill the fuel tank completely full. Overfilling may result in fuel leakage or damage to the engine or emissions system.

4.

Install the fuel tank cap securely and tighten until it “clicks”. Wipe up any gasoline that may have spilled.

Make sure the engine is shut off, motion controls are in neutral lock position, and parking brake is engaged.

Tank maximum capacity is 3 gallons (11 L).

Note: Use the fuel window to verify the presence of gasoline before filling the tank.

Important: Do Not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows the fuel to expand.

Overfilling may result in fuel leakage or damage to the engine or emission system.

1.

Shut the engine off, move the motion controls outward to the neutral lock position, and engage parking brake.

2.

Clean around the fuel tank cap and remove the cap.

Checking the Engine Oil

Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to

Checking the Oil Level in Engine Maintenance section.

Starting the Engine

1.

Sit down on the seat and move the motion controls out to the neutral lock position.

2.

Pull up and back on the parking brake lever to engage the parking brake.

3.

Disengage the blades by pushing down the blade control switch to “OFF”.

Figure 9

3.

Add unleaded regular gasoline until the fuel g237149

1.

Ignition

2.

Off

3.

Run

4.

Start reaches the base of the filler neck and does not fill

22 g237160

Figure 10

5.

Blade control switch–Off position

6.

Choke control

7.

Throttle lever

Operation

4.

Engage the choke before starting a cold engine

(if applicable).

Note: A warm or hot engine may not require choking.

5.

Turn the ignition key to “START” to energize the starter. When the engine starts, release the key.

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.

6.

Once the engine starts, gradually push down the choke control (if applicable) as the engine warms.

If the engine stalls or hesitates, slightly pull the control up for a few seconds.

Figure 11

1.

Throttle–Midway position 2.

Blade control switch—On position g237182

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.

5.

Move throttle to full forward position before mowing.

Disengaging the Blades

Set the throttle to the midway position. Push the blade control switch to “OFF” to disengage the blades.

Engaging the Blades

1.

Disengage the parking brake.

2.

Place the motion control levers in neutral.

3.

Move the throttle midway between the “SLOW” and “FAST” positions.

Note: Always engage the blades with the throttle in the midway position.

4.

Pull out on the blade control switch, to the “ON” position, to engage the blades.

Stopping the Engine

1.

Bring the unit to a full stop.

2.

Disengage the blades.

3.

Disengage the parking brake.

4.

Place the motion control levers in neutral.

5.

Adjust the throttle.

• For All Engines except Exmark: Place the throttle midway between the “SLOW” and

“FAST” positions.

• For Exmark Engines: Place the throttle in the

“FAST” position.

6.

Allow the engine to run for a minimum of 15 seconds, then turn the ignition switch to the

“OFF” position to stop the engine.

7.

Remove the key to prevent children or other unauthorized persons from starting engine.

23

Operation

The Safety Interlock System

CAUTION

If the 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.

Understanding the Safety Interlock

System

The safety interlock system is designed to prevent the engine from starting unless:

• The blades are disengaged.

• The motion control levers are moved outward to the neutral locked position.

• The parking brake is engaged.

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.

Check Safety Interlock System

Service Interval: Before each use or daily

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

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

Note: To prevent engine cut-outs on rough terrain, the seat has a 1/2 second time delay before the engine begins to shutdown.

Check the Normal Engine Starting Chart

Parking Brake

Engaged

PTO

Disengaged

(Blades)

System

Motion Control

Levers

Both levers out

(neutral lock)

Operator

In seat or out of the seat

Outcome

Starter should crank

State of System

24

Operation

Check Engine Starting Circuit Chart

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

Parking Brake

System

Motion Control Levers Operator Outcome

Engaged

PTO

(Blades)

Disengaged Both levers moved in, or either right or left lever moved in

Operator in seat

Starter must not crank

State of

System Disengaged Disengaged Both levers out (neutral lock) Operator in seat

Starter must not crank

Engaged Engaged Both levers out (neutral lock) Operator in seat

Starter must not crank

25

Operation

Check Shutdown Circuit Chart

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

Engine

Running idle

(1/3 throttle)

Parking

Brake

PTO

(Blades)

System

Motion Control

Levers

Disengaged Disengaged Both levers moved out (neutral lock), both levers moved in, or either right or left lever moved in

Operator

Raise off of seat (but don’t get off)

Outcome

Engine must begin shutdown within 1 second

State of

System

Running idle

(1/3 throttle)

Disengaged Engaged Both levers moved in Raise off of seat (but don’t get off)

Engine must begin shutdown within 1 second

Running idle

(1/3 throttle)

Engaged Disengaged Both levers moved in, or either right or left lever moved in

Operator in seat

Engine must begin shutdown within 1 second

26

Operation

Driving Forward or Backward

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the Fast position for best performance. Always operate in the Fast (full throttle) position.

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.

• Use caution when making turns.

• Slow the machine down before making sharp turns.

Forward

1.

Move the levers to the center, unlocked position.

2.

To go forward, slowly push the motion control levers forward (Figure 12).

Figure 13 g008952

To turn, pull back on the motion control lever toward the direction you want to turn

(Figure 12 and Figure 13).

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.

Figure 12

1.

Neutral lock position

(handles out)

2.

Neutral operate position

(handles in)

3.

Front of machine

4.

Forward

5.

Neutral (operate)

6.

Reverse g236810

Backward

Note: Always use caution when backing up and turning.

1.

Move the levers to the center, unlocked position.

2.

To go backward, slowly pull the motion control levers rearward ( and Figure 14).

To go straight, apply equal pressure to both motion control levers (Figure 12 and Figure 13).

27

Operation

CAUTION

Children or bystanders may be injured if they move or attempt to operate the mower while it is unattended.

Always move the motion control levers to the neutral lock position, disengage the blade control switch, engage the parking brake, and remove the key when leaving the machine unattended, even if just for a few minutes.

Figure 14

To go straight, apply equal pressure to both motion control levers ( and Figure 14).

To turn, release the pressure on the motion control lever toward the direction you want to turn ( and Figure 14).

To stop, push the motion control levers to neutral.

g008953

Adjusting the Height of Cut

1.

Raise the deck to the transport position (4.5 inch

(114 mm) cut height) by moving the deck height adjustment lever inward and pulling up. The height can also be adjusted by moving the deck height adjustment lever inward and pushing the height-of-cut foot lever forward (Figure 15). The transport lever will automatically engage and will drop into place.

Stopping the Machine

To stop the machine:

1.

Move the motion control levers to the neutral lock position, disengage the blade control switch, and engage the parking brake.

2.

Adjust the throttle:

• For All Engines except Exmark: Place the throttle midway between the “SLOW” and

“FAST” positions.

• For Exmark Engines: Place the throttle in the

“FAST” position.

3.

Allow the engine to run for a minimum of 15 seconds, then turn the ignition switch to the

“OFF” position. Remember to remove the key from the ignition switch.

g237189

Figure 15

1.

Height-of-cut foot lever

2.

Deck height adjustment lever

3.

Height-of-cut positions

4.

Transport position – 4.5

inch (115 mm)

2.

Push the foot lever forward, pull the deck height adjustment lever handle inward and let the deck lower down to the desired cut height by slowly decreasing foot pressure allowing the foot lever to travel rearward. Move the deck height adjustment lever outward at the desired height-of-cut.

Adjusting the Anti-Scalp

Rollers

It is recommended to change the anti-scalp roller position when the height of cut has changed.

28

Operation

1.

Stop the machine and move the motion control levers outward to the neutral locked 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 17. Rollers will maintain 3/4 inches (19 mm) clearance to the ground to minimize gouging and roller wear or damage.

g015168

Figure 17

All except 42 Inch E-Series Deck

For cutting heights above 3 1/2 inches (90 mm) use the bottom hole. The rollers will still be effective against scalping.

1.

Anti-scalp roller mounting bracket

2.

Cutting height

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.

7.

Torque hardware to 27-33 ft-lb (37-45 N-m) or loss of roller may result.

Positioning the Seat

Figure 16

42 Inch E-Series Deck g015167

The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

• E-Series Units:

1.

Tip the seat forward.

2.

Loosen the adjustment bolts.

1.

Anti-scalp roller mounting bracket

2.

Below 2 1/2 inches (64mm) cutting height

3.

2 1/2 inches (64mm) and above cutting height

29

1.

Adjustment bolt

Figure 18 g237245

Operation

3.

Move the seat to the desired position and tighten bolts.

4.

Tip the seat back to the closed position.

• S-Series Units:

1.

Push the adjustment lever towards the center of the machine to release the seat adjuster track (Figure 19).

1.

Bolt

2.

Spring

Figure 20

3.

Nut

4.

Additional mounting holes g237291

Figure 19 g237277

Up to five springs can be secured to the seat box with a nut and bolt, see Figure 20.

Refer to your Parts Manual for spring and hardware part numbers.

1.

Adjustment lever

2.

Move the seat to the desired position and release the lever to lock in that position.

Adjusting the Motion Control

Levers

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.

Adjusting the Height

The motion control levers can be adjusted higher or lower for maximum operator comfort.

1.

Remove the hardware holding the control lever to the control arm shaft (Figure 21).

30

1.

Control arm shaft

2.

Control lever

Figure 21

3.

Washer

4.

Bolt g237376

Operation

2.

Move the control lever to the next set of holes.

Secure the lever with the hardware.

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.

2.

Loosen the lower bolt just enough to pivot the control lever fore or aft (Figure 21). Tighten both bolts to secure the control in the new position.

3.

Repeat the adjustment for the opposite control lever.

Figure 22

1.

Bypass lever location 3.

Lever position for pushing the machine

2.

Lever position for operating the machine g237379

Pushing the Machine by

Hand

Important: Always push the machine by hand.

Never tow the machine because damage may occur.

To Operate the Machine

Move the bypass levers rearward through the key hole and down to lock them in place as shown in

Figure 22. Ensure this is done for each lever.

To Push the Machine

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Stop the machine and move the motion control levers outward to the neutral locked position, engage the parking brake, stop the engine, and wait for all moving parts to stop before leaving the operating position.

3.

Locate the bypass levers on the frame on both sides of the engine.

4.

Move the bypass levers forward through the key hole and down to lock them in place as shown in

Figure 22. Ensure this is done for each lever.

5.

Release the parking brake.

The machine is now able to be pushed by hand.

Side Discharge

The mower has a hinged discharge deflector that disperses clippings to the side and down toward the turf.

31

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 blade control switch to Off and rotate the ignition key to

Off. Also remove the key and pull the wire off the spark plug(s).

Transporting the Machine

Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions.

Knowing this information could help you, your family, pets, or bystanders avoid injury.

WARNING

Driving on the street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury.

Do not drive machine on a public street or roadway.

To transport the machine:

1.

If using a trailer, connect it to the towing vehicle and connect the safety chains.

2.

If applicable, connect the trailer brakes.

3.

Load the machine onto the trailer or truck.

4.

Stop the engine, remove the key, set the brake, and close the fuel valve.

5.

Tie down the machine near the front caster wheels and the rear bumper (Figure 23).

Loading the Machine

Use extreme caution when loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure. Back up ramps and drive forward down ramps (Figure 24).

1.

Back up ramps

Figure 23 g027708

Figure 24

2.

Drive forward down ramps g027995

Important: Do not use narrow individual ramps for each side of the machine.

Ensure the ramp is long enough so that the angle with the ground does not exceed 15 degrees (Figure 25).

On flat ground, this requires a ramp to be at least four times (4X) as long as the height of the trailer or truck bed to the ground. A steeper angle may cause mower components to get caught as the unit moves from the ramp to the trailer or truck. Steeper angles may also cause the machine to tip or lose control. If loading on or near a slope, position the trailer or truck so that it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle.

32

Operation

WARNING

Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death.

• Use extreme caution when operating a machine on a ramp.

• Use only a full-width ramp; do not use individual ramps for each side of the machine.

• Do not exceed a 15-degree angle between the ramp and the ground or between the ramp and the trailer or truck.

• Ensure the length of ramp is at least four times (4X) as long as the height of the trailer or truck bed to the ground. This will ensure that ramp angle does not exceed 15 degrees on flat ground.

• Back up ramps and drive forward down ramps.

• Avoid sudden acceleration or deceleration while driving the machine on a ramp as this could cause a loss of control or a tip-over situation.

g027996

1.

Full-width ramp in stowed position

Figure 25

2.

Side view of full-width ramp in loading position

3.

Not greater than

15 degrees

4.

Ramp is at least four times (4X) as long as the height of the trailer or truck bed to the ground

5.

H= height of the trailer or truck bed to the ground

6.

Trailer

Operating Tips

Fast Throttle Setting

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.

33

Operation

Cutting a Lawn for the First Time

Cut grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than six inches tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.

Cut 1/3 of the Grass Blade

It is best to cut only about 1/3 of the grass blade.

Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.

Mowing Direction

Alternate mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization.

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.

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.

34

Maintenance

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

WARNING

While maintenance or adjustments are being made, someone could start the engine.

Accidental starting of the engine could seriously injure you or other bystanders.

Remove the key from the ignition switch, engage parking brake, and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).

WARNING

The engine can become very hot. Touching a hot engine can cause severe burns.

Allow the engine to cool completely before service or making repairs around the engine area.

WARNING

Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine.

Unauthorized modifications to the original equipment or failure to use original Exmark parts could lead to serious injury or death.

Unauthorized changes to the machine, engine, fuel or venting system, may violate applicable safety standards such as: ANSI, OSHA and

NFPA and/or government regulations such as

EPA and CARB.

CAUTION

Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury.

Do Not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

35

Maintenance

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the first 5 hours

After the first 75 hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 100 hours

Every 200 hours

Every 500 hours

Before storage

Monthly

Yearly

Maintenance Procedure

• Change the engine oil (Exmark 452cc Engine).

• Change the engine oil (Exmark 708cc Engine).

• Change the hydraulic filter and fluid (50 and 60 inch S-Series only).

• Check the safety interlock system.

• Check the safety interlock system.

• Check and clean the air cleaner foam element (more often under extremely dusty, dirty conditions)(Exmark 452cc engine).

• Check the engine oil (Exmark 452cc Engine).

• Check the engine oil (Exmark 708cc Engine).

• Check the mower blades.

• Clean the grass build-up from under the cutting deck.

• Clean the engine and exhaust system area.

• Clean the grass and debris build-up from the machine and cutting deck.

• Grease all lubrication points.

• Clean the air cleaner foam element (more often in dusty, dirty conditions)(Exmark 708cc engine).

• Check the tire pressure.

• Check the belts.

• Replace the air cleaner paper element (more often under extremely dusty, dirty conditions)(Exmark 452cc engine).

• Check the spark plug (Exmark 452cc engine).

• Service the air cleaner paper element (more often in dusty, dirty conditions)(Exmark

708cc engine).

• Replace the air cleaner foam element (more often in dusty, dirty conditions)(Exmark

708cc engine).

• Change the engine oil (change it more often under a heavy load or in high temperatures)

(Exmark 452cc Engine).

• Change the engine oil (change it more often under a heavy load or in high temperatures)(Exmark 708cc Engine).

• Replace the spark plug (Exmark 452cc engine).

• Check the spark plug (Exmark 708cc engine).

• Clean the blower housing. More often under dirty conditions.

• Replace the fuel filter.

• Replace the air cleaner paper element (more often in dusty, dirty conditions)(Exmark

708cc engine).

• Replace the spark plug (Exmark 708cc engine).

• Change the hydraulic filter and fluid (50 and 60 inch S-Series only) (Every 250 hours if using Mobil 1 15W50) May need more often under severe conditions.

• Charge the battery and disconnect the battery cables.

• Perform all maintenance procedures listed above before storage.

• Paint any chipped surfaces.

• Check the battery charge.

• Inspect the emissions filter.

36

Maintenance

Pre-Maintenance

Procedures

Raising the Seat

Place the motion control levers out to the neutral lock position, engage the parking brake, and lift the seat forward.

The following components can be accessed by raising the seat:

• Serial plate

• Service decal

• Seat adjustment bolts

• Fuel filter

• Battery and battery cables

Periodic Maintenance

Lubrication

Greasing the Bearings

Service Interval: Every 25 hours/Monthly

(whichever comes first)

Grease Type: NLGI grade #2 multi-purpose gun grease.

Grease the front caster wheels (Figure 26).

37 g032432

Figure 26

1.

Front caster tire

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Move the motion control levers out to the neutral lock 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 with a rag. Make sure to scrape any paint off of the front of the fitting(s).

4.

Wipe up any excess grease.

Engine Maintenance

Important: If you are using a machine with an Exmark engine above 5,000 ft (1500 m) for a continuous period, ensure that the High Altitude

Kit has been installed so that the engine meets

CARB/EPA emission regulations. The High

Altitude Kit increases engine performance while preventing spark fouling, hard starting, and increased emissions. Once you have installed the kit, attach the high-altitude label next to the serial decal on the machine (reference

Figure 1). Contact an Authorized Service Dealer

Maintenance to obtain the proper High Altitude Kit and high-altitude label for your machine. To locate a dealer convenient to you, access our web site at http://www.Exmark.com or contact our Exmark

Customer Care Department at the number(s) listed in your Emission Control Warranty

Statement. Remove the kit from the engine and restore the engine to its original factory configuration when running the engine under

5,000 ft (1500 m). Do Not operate an engine that has been converted for high-altitude use at a lower altitudes; otherwise, you could overheat and damage the engine. If you are unsure whether or not your machine has been converted for high altitude use, look for the following label:

Note:

Note:

Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.

Service the air cleaner more often under extremely dusty, dirty conditions.

Removing the Foam and Paper Elements:

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Move the motion control levers out to the neutral lock 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 around the air cleaner cover to prevent dirt from getting into the engine and causing damage.

4.

Remove the air cleaner cover by unscrewing the two knobs (see Figure 28).

g032724

Figure 27

High Altitude Label

1.

Note: The engine on this product has been modified for use at above 5,000 feet elevation. If using below 5,000 feet, it must be revised back to original specifications.

Servicing the Air Cleaner–Exmark

452cc Engine

Service Interval: Before each use or daily—Check and clean the air cleaner foam element (more often under extremely dusty, dirty conditions)(Exmark

452cc engine).

Every 50 hours—Replace the air cleaner paper element (more often under extremely dusty, dirty conditions)(Exmark 452cc engine).

Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

1.

Air cleaner cover

Figure 28

2.

Knobs

5.

Carefully remove the foam and paper filter elements from the air cleaner housing.

g029205

38

Maintenance

2.

Install the foam and paper filter onto the air cleaner housing.

3.

Install the air cleaner cover and tighten the two knobs.

To learn more about the Exmark single-cylinder engine go to http://exmark.com/engines or scan the

QR code.

g015016 g028323 Figure 29

Figure 30

452cc Engine

6.

Separate the foam and paper elements.

Cleaning the Foam and Paper Elements:

Foam Element:

1.

Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly.

2.

Dry the element by squeezing it in a clean cloth.

Do Not oil the element.

Important: Replace the foam element if it is torn or worn.

3.

Install the foam element on a clean paper element.

Paper Element:

1.

Tap the paper element on a solid flat surface and blow it out from the inside with compressed air to remove dust and dirt.

2.

Inspect the element for tears, an oily film, and damage to the rubber seal.

Important: Do not clean the paper element with liquids, such as solvents, gasoline, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly.

3.

Clean the inside of the air cleaner cover of all dirt, dust, and debris.

Installing the Foam and Paper Elements:

Important: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed.

1.

Install the foam filter onto the paper filter.

Servicing the Air Cleaner–Exmark

708cc Engine

Service Interval: Every 100 hours/Yearly

(whichever comes first)—Service the air cleaner paper element

(more often in dusty, dirty conditions)(Exmark 708cc engine).

Every 200 hours/Every 2 years (whichever comes first)—Replace the air cleaner paper element

(more often in dusty, dirty conditions)(Exmark 708cc engine).

Every 25 hours/Monthly

(whichever comes first)—Clean the air cleaner foam element

(more often in dusty, dirty conditions)(Exmark 708cc engine).

Every 100 hours/Yearly

(whichever comes first)—Replace the air cleaner foam element

(more often in dusty, dirty conditions)(Exmark 708cc engine).

39

Maintenance

Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

Note: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.

Note: Service the air cleaner more often under extremely dusty, dirty conditions.

Removing the Elements:

1.

Park the machine on a level surface and disengage the blade control switch.

Figure 32

2.

Move the motion control levers out to the neutral lock 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 around the air cleaner cover to prevent dirt from getting into the engine and causing damage.

4.

Lift the cover and rotate the air-cleaner assembly out of the engine (see Figure 31 and Figure 32).

5.

Separate the foam and paper elements.

g027801

Figure 31 g027802

Figure 33

Cleaning the Foam and Paper Elements: g027800

Foam Element:

Wash the foam element with water.

Important: Replace the foam element if it is torn or worn.

Paper Element:

1.

Lightly tap the element on a flat surface to remove dust and dirt.

2.

Inspect the element for tears, an oily film, and damage to the seal.

Important: Do not clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged or cannot be cleaned thoroughly.

40

Maintenance

To learn more about the Exmark twin-cylinder engine go to http://exmark.com/engines or scan the QR code.

g028322

Figure 34

708cc Engine

Servicing the Engine Oil

Checking the Engine Oil

Level–Exmark 452cc Engine

Service Interval: Before each use or daily

Important: Do not overfill the crankcase with oil and run the engine; engine damage may result.

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Move the motion control levers out to the neutral lock position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Make sure the engine is stopped, level, and is cool so the oil has had time to drain into the sump.

4.

To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil fill cap/dipstick before removing it.

5.

Check the engine oil level.

Figure 35 g029368

6.

If the level is low, wipe off the area around the oil fill cap, remove cap/dipstick and add oil to the

“FULL” mark on the dipstick. Exmark 4-Cycle

Premium Engine Oil is recommended; refer to the following information for an appropriate API rating and viscosity. Always check the level with the dipstick before adding more oil.

Do Not overfill.

• Crankcase Capacity: 1.05L (36 oz) when the filter is changed.

• Recommended Oil Type: Exmark 4-Cycle

Premium Engine Oil

– API service SF, SG, SH, SJ, or higher

41

Maintenance g029683

Figure 36

Viscosity table

Note: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below the “ADD” mark or over the “FULL” mark on the dipstick.

Checking the Engine Oil

Level–Exmark 708cc Engine

Service Interval: Before each use or daily

Important: Do not overfill the crankcase with oil and run the engine; engine damage may result.

1.

Park the machine on a level surface, disengage the blade control switch, stop the engine, engage parking brake, and remove the key.

2.

Make sure the engine is stopped, level, and is cool so the oil has had time to drain into the sump.

3.

To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil fill cap/dipstick before removing it.

4.

Check the engine oil level.

Figure 37 g029368

5.

If the level is low, wipe off the area around the oil fill cap, remove cap/dipstick and add oil to the

“FULL” mark on the dipstick. Exmark 4-Cycle

Premium Engine Oil is recommended; refer to the following information for an appropriate API rating and viscosity. Always check the level with the dipstick before adding more oil.

Do Not overfill.

• Crankcase Capacity: 2.0 L (67.6 oz)

• Recommended Oil Type: Exmark 4-Cycle

Premium Engine Oil

– API service SF, SG, SH, SJ, or SL

42

Maintenance g029683

Figure 38

Viscosity table

Note: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below the “ADD” mark or over the “FULL” mark on the dipstick.

Changing the Engine Oil-Exmark

452cc Engine

Service Interval: After the first 5 hours

Every 100 hours (change it more often under a heavy load or in high temperatures) (Exmark

452cc Engine).

1.

Park the machine so that the drain side is slightly lower than the opposite side to ensure the oil drains completely.

2.

Start the engine and let it run until warm. This warms the oil so it drains better.

3.

Disengage the blade control switch and ensure the parking brake is engaged.

4.

Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

Figure 39 g029369

5.

Change the engine oil filter. Apply a thin film of clean Exmark 4-Cycle Premium Engine Oil to the rubber gasket on the new filter.

43

Maintenance g027484

Figure 41

Figure 40

Note: Ensure the oil filter gasket touches the engine, then an extra 3/4 turn is completed.

Note: Dispose of the used oil at a recycling center.

6.

Slowly pour approximately 80% of the specified oil into the filler tube—use oil recommended in the Checking the Engine Oil Level–Exmark

452cc Engine section.

g027477

7.

Check the oil level; refer to Checking the

Engine Oil Level–Exmark 452cc Engine section.

8.

Start the engine and check for leaks.

Changing the Engine Oil-Exmark

708cc Engine

Service Interval: After the first 5 hours

Every 100 hours (change it more often under a heavy load or in high temperatures)(Exmark

708cc Engine).

1.

Park the machine so that the drain side is slightly lower than the opposite side to ensure the oil drains completely.

2.

Start the engine and let it run until warm. This warms the oil so it drains better.

3.

Disengage the blade control switch and ensure the parking brake is engaged.

4.

Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

44

Figure 42 g027799

Maintenance g029570

Figure 43

5.

Change the engine oil filter. Apply a thin film of clean Exmark 4-Cycle Premium Engine Oil to the rubber gasket on the new filter.

45

Maintenance g027484

Figure 45 g027477

Figure 44

Note: Ensure the oil filter gasket touches the engine, then an extra 3/4 turn is completed.

Note: Dispose of the used oil at a recycling center.

6.

Slowly pour approximately 80% of the specified oil into the filler tube—use oil recommended in the Checking the Engine Oil Level–Exmark

708cc Engine section.

7.

Check the oil level; refer to Checking the

Engine Oil Level–Exmark 708cc Engine section.

8.

Start the engine and check for leaks.

Servicing the Spark

Plug-Exmark 452cc Engine

Service Interval: Every 50 hours

Every 100 hours—Replace the spark plug (Exmark

452cc engine).

Ensure that the air gap between the center and side electrodes is correct before installing the spark plug.

Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.

Type: Champion RC12YC or equivalent

Air Gap: 0.030 inch (.76 mm)

46

Maintenance

Removing the Spark Plug–Exmark

452cc engine

1.

Disengage the PTO and ensure the parking brake is engaged.

2.

Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Disconnect the wire from the spark plug.

2.

Check the gap between the center and side electrodes.

3.

Set the gap to 0.030 inch (.76 mm).

Installing the Spark Plug–Exmark

452cc Engine

1.

Install the spark plug. Make sure that the air gap is set correctly.

2.

Tighten the spark plug to 15 ft-lb (20 N-m).

g027478

Figure 46

4.

Clean around the spark plug to prevent dirt from falling into the engine and potentially causing damage.

5.

Remove the spark plug and metal washer.

Checking the Spark Plug–Exmark

452cc Engine

1.

Inspect the spark plug

Note: If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

Important: Do Not clean the spark plug.

Always replace the spark plug when it has a black coating, worn electrodes, an oily film, or cracks.

Figure 48

3.

Push the wire onto the spark plug.

1.

Center electrode insulator

2.

Side electrode

Figure 47

3.

Air gap (not to scale) g027479 g027480

Servicing the Spark

Plug-Exmark 708cc Engine

Service Interval: Every 100 hours/Yearly

(whichever comes first)

Every 200 hours/Every 2 years (whichever comes first)—Replace the spark plug (Exmark 708cc engine).

Ensure that the air gap between the center and side electrodes is correct before installing the spark plug.

Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.

Type: Champion RN9YC or equivalent

47

Maintenance

Air Gap: 0.030 inch (.76 mm)

Removing the Spark Plug-Exmark

708cc engine

1.

Disengage the PTO and ensure the parking brake is engaged.

2.

Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Disconnect the wire from the spark plug.

1.

Center electrode insulator

2.

Side electrode

Figure 50

3.

Air gap (not to scale) g027479

2.

Check the gap between the center and side electrodes.

3.

Set the gap to 0.030 inch (.76 mm).

Figure 49 g027478

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.

Installing the Spark Plug–Exmark

708cc Engine

1.

Install the spark plug. Make sure that the air gap is set correctly.

2.

Tighten the spark plug to 18.5–22.1 ft-lb (25–30

N-m).

Checking the Spark Plug–Exmark

708cc Engine

1.

Inspect the spark plug

Note: If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

Important: Do Not clean the spark plug(s).

Always replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks.

g027960

Figure 51

48

3.

Push the wire onto the spark plug.

Cleaning the Blower Housing

Service Interval: Every 100 hours/Yearly

(whichever comes first)

Maintenance

More often under dirty conditions.

To ensure proper cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times.

1.

Remove the blower housing and any other cooling shrouds.

2.

Clean the cooling fins and external surfaces as necessary.

3.

Make sure the cooling shrouds are reinstalled

Important: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will cause engine damage due to overheating.

Figure 52 g200004

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.

• Perform any fuel related maintenance when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.

• Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes.

Never install a dirty filter if it is removed from the fuel line.

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Move the motion control levers out to the neutral lock position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

The fuel filter is in the fuel line between the tank and engine.

4.

Squeeze the ends of the hose clamps together and slide them away from the filter.

5.

Remove the filter from the fuel lines.

6.

Install a new filter with the flow direction arrow coming from the fuel tank and pointing to the engine. Move the hose clamps close to the filter to secure it in place.

Servicing the Emissions

Filter

Service Interval: Yearly

The machine is equipped with an emissions filter connected to a tee fitting on the vent line coming from the gas tank. The filter has an open port by design. The filter should be inspected regularly.

Replace the filter if the filter is dirty or clogged.

Electrical System

Maintenance

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.

49

Maintenance

Charging the Battery

Removing the Battery

WARNING

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.

• When removing or installing the battery, Do

Not allow the battery terminals to touch any metal parts of the machine.

• Do Not allow metal tools to short between the battery terminals and metal parts of the machine.

DANGER

Charging or jump starting the battery may produce explosive gases. Battery gases can explode causing serious injury.

• Keep sparks, flames, or cigarettes away from battery.

• Ventilate when charging or using battery in an enclosed space.

• Make sure venting path of battery is always open once battery is filled with acid.

• Always shield eyes and face from battery.

CAUTION

If the ignition is in the “ON” position there is potential for sparks and engagement of components. Sparks could cause an explosion or moving parts could accidentally engage causing personal injury.

Be sure ignition switch is in the “OFF” position before charging the battery.

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Move the motion control levers out to the neutral lock position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Raise the seat.

4.

Disconnect the negative (black) ground cable from the battery post (Figure 53). Retain all fasteners.

DANGER

Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns.

Swallowing electrolyte can be fatal or if it touches skin can cause severe burns.

• Wear safety glasses to shield eyes, and rubber gloves to protect skin and clothing when handling electrolyte.

• Do Not swallow electrolyte.

• In the event of an accident, flush with water and call a doctor immediately.

Figure 53

1.

Negative battery post

2.

Bolt, washer, and nut

3.

Terminal boot

4.

Positive battery post

5.

Battery strap

6.

Battery g009783

50

Maintenance

WARNING

Incorrect battery cable routing could damage the machine and cables causing sparks.

Sparks can cause the battery gasses to explode, resulting in personal injury.

• Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

• Always connect the positive (red) battery cable before connecting the negative

(black) cable.

Voltage

Reading

12.6 or greater

Percent

Charge

100%

Maximum

Charger

Settings

16 volts/7 amps

Charging

Interval

No

Charging

Required

30 Minutes

5.

Slide the rubber cover up the positive (red) cable.

Disconnect the positive (red) cable from the battery post. Retain all fasteners.

6.

Remove the battery strap (Figure 53) and lift the battery from the battery tray.

12.4 – 12.6

75–100%

12.2 – 12.4

50–75%

12.0–12.2

25–50%

11.7–12.0

0–25%

11.7 or less 0%

16 volts/7 amps

16 volts/7 amps

14.4 volts/4 amps

14.4 volts/4 amps

14.4 volts/2 amps

1 Hour

2 Hours

3 Hours

6 Hours or

More

Checking the Battery Charge

1.

Remove the battery from the chassis; refer to

Removing the Battery .

2.

Allowing batteries to stand for an extended period without recharging them will result in reduced performance and service life. To preserve optimum battery performance and life, recharge batteries in storage when the open circuit voltage drops to 12.4 volts.

Recommended Jump Starting

Procedure

1.

Check the weak battery for terminal corrosion

(white, green, or blue “snow”), it must be cleaned off prior to jump starting. Clean and tighten connections as necessary.

CAUTION

Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure.

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

3.

Check the voltage of the battery with a digital voltmeter. Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12.6 volts or greater.

Important: Make sure the negative battery cable is disconnected and the battery charger used for charging the battery has an output of

16 volts and 7 amps or less to avoid damaging the battery (see chart below for recommended charger settings).

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

DANGER

Jump starting a weak battery that is cracked, frozen, has low electrolyte level, or an open/shorted battery cell, can cause an explosion resulting in serious personal injury.

Do Not jump start a weak battery if these conditions exist.

2.

Make sure the booster is a good and fully charged lead acid battery at 12.6 volts or greater. Use properly sized jumper cables (4 to 6 AWG) with short lengths to reduce voltage drop between systems. Make sure the cables are color coded or labeled for the correct polarity.

51

Maintenance

CAUTION

Connecting the jumper cables incorrectly

(wrong polarity) can immediately damage the electrical system.

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

Note: The following instructions are adapted from the SAE J1494 Rev. Dec. 2001 – Battery

Booster Cables – Surface Vehicle Recommended

Practice (SAE – Society of Automotive

Engineers).

WARNING

Batteries contain acid and produce explosive gases.

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

• Do Not lean over the batteries.

Note: Be sure the vent caps are tight and level.

Place a damp cloth, if available, over any vent caps on both batteries. Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only.

3.

Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 54.

Figure 54

1.

Positive (+) cable on discharged battery

2.

Positive (+) cable on booster battery

3.

Negative (–) cable on the booster battery

4.

Negative (–) cable on the engine block

5.

Booster battery

6.

Discharged battery

7.

Engine block g012785

4.

Connect the other end of the positive cable to the positive terminal of the booster battery.

5.

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

6.

MAKE THE FINAL CONNECTION ON

THE ENGINE BLOCK OF THE STALLED

VEHICLE (NOT TO THE NEGATIVE POST)

AWAY FROM THE BATTERY. STAND BACK.

7.

Start the vehicle and remove the cables in the reverse order of connection (the engine block

(black) connection is the first to disconnect).

Installing the Battery

1.

Position the battery in the tray with the terminal posts toward the operating position (Figure 53).

2.

Install the positive (red) battery cable to the positive (+) battery terminal using the fasteners removed previously.

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 strap (Figure 53).

52

Maintenance

Servicing the Fuses

Service Interval: As required

The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or short.

Fuse:

• Main F1-30 amp, blade-type

• Charge Circuit F2-25 amp, blade-type

1.

Remove and retain the screw securing the control panel to the machine.

2.

Lift the control panel up to access the main wiring harness and fuse block.

3.

To replace a fuse, pull out on the fuse to remove it (Figure 55).

1.

Valve stem

Figure 56 g007275

Changing the Hydraulic

System Filter and Oil––50 and 60 Inch S-Series Only

Service Interval: After the first 75 hours

Every 500 hours thereafter

(Every 250 hours if using

Mobil 1 15W50 thereafter)

May need more often under severe conditions.

The filter and oil are changed at the same time.

Do

Not reuse oil. Once the new filter is installed and oil is added any air in the system must be purged.

1.

Fuse

Figure 55

4.

Return the control panel to its original position and secure the panel to the machine.

g237377

Removing Hydraulic System Filters

1.

Stop engine, wait for all moving parts to stop, and allow engine to cool. Remove the key and engage the parking brake.

2.

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

Drive System Maintenance

Checking the Tire Pressure

Service Interval: Every 25 hours/Monthly

(whichever comes first)

Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut.

Check the pressure at the valve stem (Figure 56).

Check the tires when they are cold to get the most accurate pressure reading.

Rear Tires: 13 psi (90 kPa)

Front Tires (caster wheels): 13 psi (90 kPa)

1.

Jacking points

Figure 57 g237380

53

Maintenance

3.

Remove the nuts holding the transaxle support in place (Figure 58).

g010254

1.

Transaxle drive

2.

Oil filter

3.

Filter guard

Figure 59

Right side shown

4.

Screws

5.

Vent plug

Figure 58 g017660

5.

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

1.

Nut (5/16 inch) (27 to 33 ft-lb)

2.

Nut (3/8 inch) (15 to 19 ft-lb)

3.

Transaxle support

4.

Locate the filter and filter guards on each transaxle drive system (Figure 59). Remove three screws securing the filter guard and guard.

6.

Place a container below the filter to catch the oil that drains when the filter and vent plugs are removed.

7.

Locate and remove the vent plug on each transmission

8.

Unscrew the filter to remove and allow oil to drain from drive system.

Repeat this procedure for both filters.

54

Maintenance

Installing the Hydraulic System

Filters

5.

Install the transaxle guard. Refer to Figure 58 for the correct torque values for the nuts and bolts.

6.

Proceed to the Bleeding the Hydraulic System section.

Important: Failure to perform the

Bleeding the Hydraulic System

procedure after changing hydraulic filters and oil can result in irreparable damage to the transaxle drive system.

Figure 60

1.

Apply a thin coat of oil on the surface of the rubber seal of each filter.

2.

Turn the filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 3/4 to 1 full turn. Repeat for the other filter

3.

Install the filter guards over each filter as previously removed. Use the three screws to secure the filter guards.

4.

With the vent plugs removed on each transmission, insert the pump hose into the vent holes and hold while pumping. Pump in 2 quarts

(1.9 L) of oil. Continue to add a third quart until the oil is level with the vent hole (approximately

1/4 quart (.2 L)). When the oil comes out of the vent hole, reinstall the plugs.

Torque plugs to 180 in-lb (244 N-m).

g008748

Bleeding the Hydraulic System

1.

Enter the operator's position. Start engine and move throttle control ahead to 1/2 throttle position. Disengage parking brake.

A.

Move the bypass levers into the pushing the machine position; refer to the Pushing the

Machine by Hand section in Operation. With the bypass valves open and the engine running, slowly move the motion control levers in both forward and reverse (5 or 6 times).

B.

Move the bypass levers into the operating the machine position. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 to 6 times).

C.

Stop the engine and check the oil level in the vent plug holes. Add the specified oil until it comes out of the vent plug holes.

2.

Repeat step 1 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.

Check the oil level by removing the vent plugs.

Add the specified oil until it reaches the vent plug holes if necessary.

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.

55

Maintenance

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.

WARNING

A worn or damaged blade can break, and a piece of the blade could be thrown into the operator's or bystander's area, resulting in serious personal injury or death.

• Inspect the blade periodically for wear or damage.

• Replace a worn or damaged blade.

1.

Checking for Bent Blades

Note: The machine must be on a level surface for the following procedure.

Raise the mower deck to the highest height-of-cut position; also considered the 'transport' position.

2.

While wearing thickly padded gloves or other adequate hand protection slowly rotate blade to be measure into a position that allows effective measurement of the distance between the cutting edge and the level surface the machine is on.

Before Inspecting or Servicing the

Blades

Park the machine on a level surface, disengage the blade control switch, and move the motion control levers outward to neutral lock, and engage the parking brake. Stop the engine, remove the key, and disconnect the spark plug wire(s) from the spark plug(s).

1.

Deck

2.

Spindle housing

Figure 62

3.

Blade

Inspecting the Blades

1.

Inspect the cutting edges (Figure 61). If the edges are not sharp or have nicks, remove and sharpen the blades; refer to Sharpening the Blades .

2.

Inspect the blades, especially the curved area. If you notice any damage, wear, or a slot forming in this area (item 3 in Figure 61), immediately install a new blade.

3.

Measure from the tip of the blade to the flat surface here.

g014972

1.

Cutting edge

2.

Curved area

Figure 63

1.

Blade, in position for measuring

2.

Level surface

3.

Measured distance between blade and surface (A) g014973

Figure 61

3.

Wear/slot forming

4.

Damage g006530 4.

Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position.

56

Maintenance g014974 new blade. Refer to Removing the Blades and

Installing the Blades.

Note: If a bent blade is replaced with a new one and the dimension obtained continues to exceed 1/8 inch (3mm), the blade spindle could be bent. Contact an Authorized Exmark

Dealer for service.

B.

If the variance is within constraints, move to the next blade.

Figure 64

1.

Blade, side previously measured

2.

Measurement position used previously

3.

Opposing side of blade being moved into measurement position

5.

Measure from the tip of the blade to the flat surface here. The variance should be no more than 1/8 inch (3mm).

Figure 65

Repeat this procedure on each blade.

g014973

Checking for Loose Blades or

Damaged Spring Disc Washers

1.

Place a wrench on the blade bolt and torque to

35-65 ft-lb (47-88 N-m).

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

(Figure 66). 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.

1.

Opposing blade edge, in position for measuring

2.

Level surface

3.

Second measured distance between blade and surface

(B)

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.

WARNING

A worn or damaged blade can break, and a piece of the blade could be thrown into the operator's or bystander's area, resulting in serious personal injury or death.

• Inspect the blade periodically for wear or damage.

• Replace a worn or damaged blade.

Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 66).

A.

If the difference between A and B is greater than 1/8 inch (3mm) replace the blade with a

57

Maintenance

1.

Sail area of blade

2.

Blade

Figure 66

3.

Curved washer

4.

Blade bolt

Sharpening the Blades

1.

Use a file to sharpen the cutting edge at both ends of the blade (Figure 67). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

Figure 67

1.

Sharpen at original angle

2.

Check the balance of the blade by putting it on a blade balancer (Figure 68). 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 68).

Repeat this procedure until the blade is balanced.

g014975

Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting.

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.

3.

Torque the blade bolt to 35-65 ft-lb (47-88 N-m).

g007276

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.

Always install the original Exmark blades, washers and blade bolts as shown.

Leveling the Mower Deck

Check to ensure the mower deck is level any time you install the mower or when you see an uneven cut on your lawn.

The mower deck must be checked for bent blades prior to leveling; any bent blades must be removed and replaced. Refer to the Checking for Bent

Blades procedure before continuing.

The mower deck must be leveled side-to-side first then the front to rear slope can be adjusted.

Requirements:

• The machine must be on a level surface.

• All four tires must be properly inflated. Refer to

Checking the Tire Pressure in the Drive System

Maintenance section.

1.

Blade

Figure 68

2.

Balancer

Installing the Blades

g007201

1.

Install the blade onto the spindle shaft (Figure 66).

Side-to-Side Leveling

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Move the motion control levers out to the neutral lock position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Set the height-of-cut lever to middle position.

4.

Carefully rotate the blades so that they are all side to side (Figure 69 and Figure 70).

58

Maintenance

8.

Loosen the side-locking nut.

9.

Raise or lower the left side of the mower deck by rotating the rear nut. (Figure 71).

Note: Rotate the rear nut clockwise to raise the mower deck; rotate the rear nut counter-clockwise to lower the mower deck.

g009682

Figure 69

Mower Deck with 2 Blades

1.

Blades side to side

2.

Sail area of blade

3.

Outside cutting edges

4.

Measure from the tip of the blade to the flat surface here

1.

Hanger bracket

2.

Side-locking nut

Figure 71

3.

Rear-locking nut g027588

10.

Check the side-to-side adjustments again. Repeat this procedure until the measurements are correct.

g005278

11.

Continue leveling the deck by checking the front-to-rear blade slope; refer to Adjusting the

Front-to-Rear Blade Slope.

Figure 70

Mower Deck with 3 Blades

1.

Blades side to side

2.

Sail area of blade

3.

Outside cutting edges

4.

Measure from the tip of the blade to the flat surface here

5.

Measure between the outside cutting edges and the flat surface (Figure 69 and Figure 70). If both measurements are not within 3/16 inch (5 mm), an adjustment is required; continue with this procedure.

6.

Support the weight of mower deck by placing wood blocks under the edges of the deck.

Note: Avoid placing the supports under any anti-scalp rollers if present on the deck.

7.

Move to the left side of the machine.

Adjusting the Front-to-Rear Blade

Slope

Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than

5/16 inch (7.9 mm) lower than the rear of the mower, adjust the blade level using the following instructions:

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Move the motion control levers out to the neutral lock position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Set the height-of-cut lever to middle position.

59

Maintenance

Note: Check and adjust the side-to-side blade level if you have not checked the setting; refer to

Side-to-Side Leveling .

4.

Carefully rotate the blades so they are facing front to rear (Figure 72 and Figure 73).

g014634 g009658

Figure 72

Mower Deck with 2 Blades

Figure 74

1.

Adjusting rod

2.

Adjusting block

3.

Lock nut

1.

Blades front to rear

2.

Measure from the tip of the blade to the flat surface here g009659

7.

To raise the front of the mower, tighten the adjustment nut. To lower the front of the mower, loosen the adjustment nut.

8.

After adjustment, check the front-to-rear slope again. Continue adjusting the nut until the front blade tip is 1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip (Figure 72 and Figure 73).

9.

When the front-to-rear blade slope is correct check the side-to-side level of the mower again; refer to Side-to-Side Leveling .

Figure 73

Mower Deck with 3 Blades

Removing the Mower Deck

1.

Blades front to rear

2.

Outside cutting edges

3.

Measure from the tip of the blade to the flat surface here

Service Interval: As required

1.

Park the machine on a level surface and disengage the blade control switch.

5.

Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat surface (Figure 72 and Figure 73). If the front blade tip is not 1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip, adjust the front locknut.

6.

To adjust the front-to-rear blade slope, rotate the adjustment nut in the front of the mower

(Figure 74).

2.

Move the motion control levers out to the neutral lock position, engage the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Lower the height-of-cut lever to the lowest position.

4.

Remove the hairpin cotter from the front support rod and remove the rod from the deck bracket

(Figure 75). Carefully lower the front of the mower deck to the ground.

60

Maintenance g005077

1.

Mower deck

2.

Hanger bracket

Figure 77

3.

Rear lift rod g014635

1.

Front support rod

2.

Locking nut

Figure 75

3.

Deck bracket

7.

Slide the mower deck rearward to remove the mower belt from the engine pulley.

8.

Slide the mower deck out from underneath the machine.

Note: Retain all parts for future installation.

5.

Remove and retain the cotter pin and deck retention link from the each hanger bracket (see

Figure 76).

Mower Belt Maintenance

Inspecting the Belts

Service Interval: Every 25 hours/Monthly

(whichever comes first)

Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts.

Replacing the Mower Belt

1.

Hanger bracket

2.

Deck retention link

Figure 76

3.

Cotter pin

6.

Lift the mower deck and hanger brackets clear of the rear lift rod and lower the mower carefully to the ground (Figure 77).

g028329

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 out to the neutral lock position, engage the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Set the height-of-cut at the lowest cutting position

[1-1/2 inch (38 mm)].

61

Maintenance

4.

Using a spring removal tool, (P/N 92-5771), remove the idler spring from the deck hook to remove tension on the idler pulley and roll the belt off of the pulleys (Figure 78 and Figure 79).

WARNING

The spring is under tension when installed and can cause personal injury.

Be careful when removing the belt.

1.

Idler pulley

2.

Mower belt

3.

Outside pulley

Figure 79

50 and 60 Inch Decks

4.

Spring

5.

Engine pulley

6.

Spring removal tool g237467

1.

Idler pulley

2.

Mower belt

3.

Outside pulley

Figure 78

34 and 42 Inch Decks

4.

Spring

5.

Engine pulley

6.

Spring removal tool g014930

5.

Route the new belt around the engine pulley and mower pulleys (Figure 79).

6.

Using a spring removal tool, (P/N 92-5771), install the idler spring over the deck hook and placing tension on the idler pulley and mower belt

(Figure 78 and Figure 79).

Installing the Mower Deck

Service Interval: As required

1.

Park the machine on a level surface and disengage the blade control switch.

2.

Move the motion control levers out to the neutral lock position, engage the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Slide the mower deck under the machine.

4.

Lower the height-of-cut lever to the lowest position.

5.

Lift the rear of the mower deck and guide the hanger brackets over the rear lift rod (Figure 77).

62

Maintenance

6.

Attach the front support rod to the mower deck with the clevis pin and hairpin cotter (Figure 75).

7.

Install the mower belt onto the engine pulley; refer to Replacing the Mower Belt .

8.

Level the deck; refer to Leveling the Mower

Deck section.

Replacing the Discharge

Deflector

DANGER

An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury.

Also, contact with the blade could occur.

Never operate the lawn mower unless you install a mulch plate, discharge deflector, or grass collection system.

Inspect the discharge deflector for damage before each use. Replace any damaged parts before use.

• 42 inch Stamped Deck:

1.

Locate items shown in Figure 80.

3.

Slide the rod out of the short stand-off, spring, and discharge deflector . Remove the damaged or worn discharge deflector.

4.

Replace the discharge deflector.

5.

Slide rod, straight end, through the rear discharge deflector bracket.

6.

Place the spring on the rod, with end wires down, and between the discharge deflector brackets. Slide rod through second discharge deflector bracket.

7.

Insert rod at front of discharge deflector into short stand-off on deck. Secure rear end of rod into the mower with a nut (3/8 inch).

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.

• 34, 42, 50, and 60 inch Welded Decks:

1.

Disengage the spring from the notch in the deflector bracket and slide the rod out of the welded deck brackets, spring, and discharge deflector (Figure 81). Remove the damaged or worn discharge deflector.

g005192

1.

Mower deck

2.

Discharge deflector

3.

Discharge deflector bracket

4.

Rod

Figure 80

5.

Spring

6.

Nut (3/8 inch)

7.

Short stand-off

2.

Remove the nut (3/8 inch) from the rod under the mower.

63

Maintenance

1.

Rod

2.

Spring

3.

Deflector assembly g017617

Figure 81

4.

Deck brackets

5.

Spring installed over the rod g017618

Figure 82

1.

Rod and spring assembly installed

2.

Loop end of the spring installed into the notch in the deflector bracket

3.

Rod, short end, moved behind mower bracket

4.

Short end, retained by mower bracket.

5.

Secure the rod and spring assembly by twisting it so the short end of the rod can be placed behind the front bracket welded to the deck

(Figure 82).

Important: The grass deflector must be spring loaded in the down position. Lift the deflector up to test that it snaps to the full down position.

2.

Position the new discharge deflector assembly with the bracket ends between the welded brackets on the deck as shown in Figure 81.

3.

Install the spring onto the straight end of the rod. Position the spring on the rod as shown in so the shorter spring end is coming from under the rod before the bend and going over the rod as it returns from the bend.

4.

Lift the loop end of the spring and place it into the notch on the deflector assembly bracket (Figure 82).

64

Maintenance

Cleaning

Clean Grass Build-Up Under

Deck

Service Interval: Before each use or daily

1.

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

2.

Raise deck to the transport (4 1/2 inch (114 mm) cutting height) position. Lift the front of unit and support unit using jack stands or equivalent support.

CAUTION

Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall, which could cause injury.

2.

Clean all debris from rotating engine air intake screen, around engine shrouding, and exhaust system area.

3.

Wipe up any excessive grease or oil around the engine and exhaust system area.

Clean Debris From Machine

Service Interval: Before each use or daily

1.

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

2.

Clean off any oil, debris, or grass build-up on the machine and cutting deck, especially under deck belt shields, around the fuel tank, around engine and exhaust area.

Do Not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

3.

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

Clean Engine and Exhaust

System Area

Service Interval: Before each use or daily

(May be required more often in dry or dirty conditions.)

CAUTION

Excessive debris around engine cooling air intake and exhaust system area can cause engine, exhaust area, and hydraulic system to overheat which can create a fire hazard.

Clean all debris from engine and exhaust system area.

1.

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

65

Storage

Storage

Restart the engine and run it until it stops.

Cleaning and Storage

1.

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

Choke the engine. Start and run the engine until it will not start.

Dispose of fuel properly. Recycle pursuant to local codes.

2.

Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing.

3.

4.

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

Service the air cleaner; refer to Servicing the Air

Cleaner in the Engine Maintenance section.

Grease and oil the machine; refer to the

Lubrication section.

Important:

30 days.

Do not store stabilizer/conditioned gasoline over

11.

Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug in the Engine

Maintenance section. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

12.

Clean any dirt and chaff from the top of the mower.

5.

Change the crankcase oil and filter; refer to Servicing the Engine Oil in the Engine

Maintenance section.

13.

Scrape any heavy buildup of grass and dirt from the underside of the mower, then wash the mower with a garden hose.

14.

Check the condition of the drive and mower belts.

6.

Check the tire pressure; refer to Checking the

Tire Pressure in the Drive System Maintenance section.

15.

Check and tighten all bolts, nuts, and screws.

Repair or replace any part that is worn or damaged.

7.

Charge the battery; refer to Servicing the Battery in the Electrical System Maintenance section.

16.

Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer.

8.

Check the condition of the blades; refer to

Servicing the Cutting Blades in the Mower

Maintenance section.

9.

Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows.

17.

Store the machine in a clean, dry garage or storage area. Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.

10.

Add a petroleum based stabilizer/conditioner to the fuel in the tank. Follow the mixing instructions from the stabilizer manufacturer. Do not use an alcohol based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times.

Run the engine to distribute the conditioned fuel through the fuel system (5 minutes).

Stop the engine, allow it to cool, and drain the fuel tank; refer to Draining the Fuel Tank in the

Fuel System Maintenance section.

66

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.

2. Add oil to the crankcase.

3. Remove the obstruction from the cooling fins and air passages.

4. The air cleaner is dirty.

4. Clean or replace the air cleaner element.

5. Dirt, water, or stale fuel is in fuel system.

5. Contact an Authorized Service Dealer.

1. The blade control switch is engaged.

2. Parking brake is not engaged.

3. The motion control levers are not in the neutral lock position.

4. The operator is not seated.

5. Battery does not have a full charge.

6. The electrical connections are corroded or loose.

7. A fuse is blown.

8. A relay or switch is damaged.

1. Fuel tank is empty.

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.

9. The oil level in the crankcase is low.

1. Move the blade control switch to disengaged.

2. Set the parking brake.

3. Move the motion control levers outward to the neutral lock position.

4. Sit on the seat.

5. Charge the battery. See Check Battery

Charge and Recommended Jump

Starting Procedure sections in

Maintenance.

6. Check the electrical connections for good contact.

7. Replace the fuse.

8. Contact an Authorized Service Dealer.

1. Fill the fuel tank.

2. Move the choke lever to On (if applicable).

3. Clean or replace the air cleaner element.

4. Install the wire(s) on the spark plug.

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.

67

Troubleshooting

Problem

Engine loses power

The machine does not drive.

Abnormal vibration

Uneven cutting height.

Blades do not rotate.

Possible Cause Corrective Action

1. Engine load is excessive.

2. Air cleaner is dirty.

3. Oil level in the crankcase is low.

4. Cooling fins and air passages for the engine are plugged.

5. The spark plug(s) is pitted, fouled, or the gap is incorrect.

6. Dirt in fuel filter.

7. Dirt, water, or stale fuel is in the fuel system.

8. There is incorrect fuel in the fuel tank.

1. Reduce the ground speed.

2. Clean or replace the air cleaner element.

3. Add oil to the crankcase.

4. Remove the obstructions from the cooling fins and air passages.

5. Install a new, correctly gapped spark plug(s).

6. Replace the fuel filter.

7. Contact an Authorized Service Dealer.

8. Drain the tank and replace the fuel with the proper type.

1. The drive belts are worn, loose, or broken.

1. Contact an Authorized Service Dealer.

2. The drive belts are off of the pulleys.

3. The drive is in bypass mode.

2. Contact an Authorized Service Dealer.

3. Take machine out of bypass mode. Refer to Pushing the Machine by Hand section.

1. Engine mounting bolts are loose.

1. Tighten the engine mounting bolts.

2. Loose engine pulley, idler pulley, or blade pulley.

2. Tighten the appropriate pulley.

3. Engine pulley is damaged.

3. Contact an Authorized Service Dealer.

4. Cutting blade(s) is/are bent or unbalanced.

4. Install new cutting blade(s).

5. Blade is loose.

6. Blade spindle is bent.

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.

2. Cutting blade(s) is/are bent.

3. A blade is loose.

4. Mower deck is not level.

5. An anti-scalp wheel is not set correctly

6. Underside of mower is dirty.

7. Tire pressure in drive tires not correct.

8. Blade spindle bent.

1. Sharpen the blade(s).

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.

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. The mower belt is worn, loose, or broken.

3. Install a new mower belt.

68

Schematics

Electrical Logic Schematic

Schematics

TERMINAL -

TERMINAL +

GREEN

BLUE

B

P15

FLYBACK DIODE

D01

A

P15

BROWN

A

P04

PTO CLUTCH

B

P04

YELLOW

69 g201257

70

g011841

Figure 83

This page may be copied for personal use.

1.

The maximum slope you can operate the machine on is 15 degrees . Use the slope indicator to determine the degree of slope of hills before operating.

Do Not operate this machine on a slope greater than 15 degrees.

Fold along the appropriate line to match the recommended slope.

2.

Align this edge with a vertical surface, a tree, building, fence pole, etc.

3.

Example of how to compare slope with folded edge.

71

EXMARK ACCESSORIES AND OPTIONS*

MID-MOUNT RIDING ACCESSORIES AND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

12 V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OUT-FRONT RIDING ACCESSORIES AND OPTIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

*Some accessories and options not available for some models.

Place Model No. and Serial No.

Label Here (Included in the Literature

Pack) or Fill in Below

Model No.

Serial No.

Date Purchased

Engine Model No. and Spec. No.

Engine Serial No. (E/No)

©2018 Exmark Mfg. Co., Inc.

2101 Ashland Ave

Beatrice, NE 68310

All Rights Reserved

Part No. 4503-851 Rev. A

(402) 223-6375

Fax (402) 223-5489

Printed in the USA www.exmark.com

*4503-851* A

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Key Features

  • 708cc Kawasaki engine delivers reliable power and performance
  • 50" cutting deck with 3 blades provides a wide cutting path for increased productivity.
  • Hydrostatic drive system offers precise control and smooth operation
  • Adjustable seat with armrests ensures operator comfort during extended mowing sessions.
  • High-back seat provides lumbar support and reduces operator fatigue.
  • Electric blade engagement for easy and convenient blade activation
  • Large fuel tank allows for extended mowing time without frequent refueling
  • Hour meter tracks operating time for maintenance scheduling and warranty purposes.

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Frequently Answers and Questions

What type of engine does the Exmark QUEST QZS708GEM50200 have?
It has a 708cc Kawasaki engine.
How wide is the cutting deck?
The cutting deck is 50 inches wide.
Does the mower have a hydrostatic drive system?
Yes, it has a hydrostatic drive system for precise control and smooth operation.
Is the seat adjustable?
Yes, the seat is adjustable with armrests for operator comfort.
How long can I mow before refueling?
The large fuel tank allows for extended mowing time without frequent refueling.
How do I activate the blades?
The blades are activated by an electric blade engagement system for easy and convenient operation.
What is the purpose of the hour meter?
The hour meter tracks operating time for maintenance scheduling and warranty purposes.
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