Exmark Lawn Mower Lawn Mower User manual


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Exmark Lawn Mower Lawn Mower User manual | Manualzz

QUEST

®

For Serial Nos.

790,000 & Higher

Part No. 4500-373 Rev. A

WARNING

CALIFORNIA

Proposition 65 Warning

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

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

Important: This engine is not equipped with a spark arrester muffler. It is a violation of

California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian

ICES-002, ISO 14982, EN 55012.

The enclosed Engine Owner’s Manual is supplied for information regarding the US

Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance, and warranty.

Replacements may be ordered through the engine manufacturer.

For models with stated engine horsepower, the gross horsepower of the engine was laboratory rated by the engine manufacturer in accordance with SAE J1940.

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

© 2008—Exmark Mfg. Co., Inc.

Industrial Park Box 808

Beatrice, NE 68310

2

Contact us at www.Exmark.com.

Printed in the USA.

All Rights Reserved

Introduction

Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.

You may contact Exmark directly at www.Exmark.com for product and accessory information or help finding a dealer.

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

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

Figure 1 identifies the location of the model and serial

numbers on the product. Write the numbers in the space provided.

Figure 1

Behind the seat

1.

Model and serial number location

Model No.

Serial No.

3

Contents

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

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

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

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

Safety and Instructional Decals ....................... 8

Specifications ....................................................... 13

Model Numbers ............................................ 13

Systems ......................................................... 13

Dimensions................................................... 15

Torque Requirements .................................... 15

Product Overview ................................................ 16

Operation ............................................................. 16

Controls ........................................................ 16

Operating Instructions .................................. 17

Recommended Gasoline................................ 18

Checking the Engine Oil Level....................... 20

Starting the Engine ........................................ 20

Operating the Blades ..................................... 20

Stopping the Engine ...................................... 21

The Safety Interlock System........................... 21

Driving Forward or Backward........................ 22

Stopping the Machine.................................... 23

Tracking Adjustment ..................................... 23

Adjusting the Height of Cut ........................... 23

Adjusting the Anti-Scalp Rollers..................... 23

Positioning the Seat ....................................... 24

Changing the Seat Ride Suspension ................ 24

Adjusting the Motion Control Levers ............. 25

Pushing the Machine by Hand........................ 25

Side Discharge............................................... 26

Transporting ................................................. 26

Operating Tips ............................................. 27

Maintenance ......................................................... 29

Recommended Maintenance Schedule(s) ........... 29

Premaintenance Procedures .............................. 30

Raising the Seat ............................................. 30

Accessing the Battery .................................... 30

Periodic Maintenance ....................................... 30

Lubrication.................................................... 30

Engine Maintenance...................................... 31

Servicing the Engine Oil ................................ 32

Checking the Hydraulic Oil Level ................... 33

Change the Hydraulic System Filter................ 34

Servicing the Spark Plug ................................ 34

Cleaning the Blower Housing......................... 35

Fuel System Maintenance .............................. 36

Electrical System Maintenance....................... 36

Charging the Battery...................................... 37

Servicing the Fuses and Relay......................... 38

Drive System Maintenance ............................ 39

Checking the Tire Pressure ............................ 39

Mower Maintenance ...................................... 39

Servicing the Cutting Blades .......................... 39

Mower Belt Maintenance ............................... 41

Leveling the Mower Deck .............................. 42

Adjusting the Blade Slope .............................. 42

Replacing the Discharge Deflector ................. 44

Cleaning ........................................................... 45

Washing the Underside of the Mower ............. 45

Storage ................................................................. 46

Cleaning and Storage ..................................... 46

Troubleshooting ................................................... 47

Schematics ........................................................... 49

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.

1.

Safety alert symbol

Figure 2

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 meets or exceeds the safety specifications of the American National

Standards Institute B71.1-2003 in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-"personal safety instruction."

Failure to comply with the instruction may result in personal injury or death.

Safe Operating Practices

The following instructions are from ANSI standard

B71.1-2003.

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.

• 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

5

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

• Always follow the recommendations for wheel weights or counterweights.

Slope Operation

Slopes are a major factor related to loss of control and tip-over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution. If you cannot back up the slope or if you feel uneasy on it, Do Not mow it.

• Do Not mow slopes greater than 15 degrees.

• Watch for ditches, holes, rocks, dips, and rises that change the operating angle, as rough terrain could overturn the machine.

• Choose a low ground speed so you will not have to stop while operating on a slope.

• Do Not mow slopes when grass is wet. Slippery conditions reduce traction and could cause sliding and loss of control.

• Reduce speed and use extreme caution on slopes.

• Do Not make sudden turns or rapid speed changes.

• Remove or mark obstacles such as rocks, tree limbs, etc. from the mowing area. Tall grass can hide obstacles.

• Avoid sudden starts when mowing uphill because the mower may tip backwards.

• Be aware that operating on wet grass, across steep slopes or downhill may cause the mower to lose traction. Loss of traction to the drive wheels may result in sliding and a loss of braking and steering.

• Always avoid sudden starting or stopping on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope.

• Use extreme care with grass collection systems or other attachments. These can change the stability of the machine and cause loss of control.

• Do Not try to stabilize the machine by putting your foot on the ground.

• Do Not mow near drop-offs, ditches, steep banks or water. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning.

• Use a walk behind mower and/or a hand trimmer on slopes greater than 15 degrees, near drop-offs, ditches, steep banks or water.

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

• Use for towing only if equipped with an Exmark hitch kit. Do Not attach towed equipment except at the hitch point.

• Follow Exmark’s recommendation for weight limits for towed equipment and towing on slopes.

This information can be found in the hitch kit instruction sheet and on the decal.

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

• On slopes, the weight of the towed equipment may cause loss of traction and loss of control.

• Travel slowly and allow extra distance to stop.

Service

Safe Handling of Gasoline

To avoid personal injury or property damage, use extra care when handling gasoline and other fuels.

They are flammable and the vapors are explosive.

6

Safety

• Extinguish all cigarettes, cigars, pipes and other sources of ignition.

• Use only an approved container.

• Never remove the gas cap or add fuel when the engine is running. Allow the engine to cool before refueling.

• Never refuel the machine indoors.

• Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace.

• Never fill containers inside a vehicle or on a truck or trailer with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove gas-powered equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until the fueling is complete. Do Not use a nozzle lock-open device.

• If fuel is spilled on clothing, change clothing immediately.

• Never overfill the fuel tank. Replace gas cap and tighten securely.

General Service:

• Never run a machine inside a closed area.

• Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition.

• Never tamper with safety devices. Check their proper operation regularly.

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

• Stop and inspect the equipment if you strike an object. Repair, if necessary, before restarting.

• Never make any adjustments or repairs with the engine running.

• Grass collection system components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturers’ recommended parts, when necessary.

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

• Check for proper brake operation frequently.

Adjust and service as required.

• Maintain or replace safety and instruction decals as necessary.

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

Exmark Riding Mower Safety

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

• Engine exhaust contains carbon monoxide, which is an odorless, deadly poison that can kill you. Do

Not run engine indoors or in an enclosed area.

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

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

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

• Battery acid is poisonous and can cause burns.

Avoid contact with skin, eyes, and clothing.

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

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

• Use only Exmark approved attachments.

Warranty may be voided if used with unapproved attachments.

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

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

7

Safety

Safety and Instructional Decals

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

1.

Warning–Do Not operate the mower with the discharge deflector up or removed; keep the discharge deflector in place.

93-7009

2.

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

109-6008

1.

Read the Operator’s

Manual.

2.

Rotate the drive release knob to loosen, slide the knob, and tighten.

3.

Push the machine.

1.

Choke–on

2.

Throttle–fast

103-6327

3.

Continuous variable setting

4.

Throttle–slow

109-6014

Traction Drive Belt Routing

106-5517

1.

Warning–Do Not touch the hot surface.

8

109-6035

Deck Drive Belt Routing

1.

Fuse

109-9120

2.

Diode

Safety

109-6036

1.

Read the Operator’s Manual.

2.

Remove the ignition key and read the instructions before servicing or performing maintenance.

3.

Height of cut.

1.

Parking brake

2.

Fast

3.

Slow

109-9173

4.

Neutral

5.

Reverse

6.

Machine Speed

109-6210

1.

Read the Operator’s Manual.

2.

Cutting/dismemberment hazard, fan and entanglement hazard, belt–stay away from moving parts.

109-6459

1.

Entanglement hazard, belt—Do Not open or remove safety shields while engine is running, keep shields in place.

1.

Machine speed

2.

Fast

3.

Slow

109-9182

4.

Neutral

5.

Reverse

9

Safety

116-0581

110-6691

1.

Thrown objects hazard–keep bystanders a safe distance from the machine.

2.

Thrown objects hazard, mower–keep the discharge deflector or collection system in place.

3.

Cutting/dismemberment of hand or foot–stay away from moving parts.

1.

PTO—Off

PTO Symbols

2.

PTO—On

116-0531

116-0533

116-0551

10

Safety

1.

Read the instructions before servicing or performing maintenance.

2.

Time interval

3.

Check oil level.

109-6016

4.

Refer to the Operator’s manual for grease instructions.

5.

Check hydraulic oil level and refer to the Operator’s

Manual for further instructions.

6.

Check tire pressure.

1.

Warning–read the Operator’s Manual.

2.

Read the instructions before servicing or performing maintenance; apply parking brake, remove the ignition key and disconnect the spark plug wire.

3.

Thrown object hazard—keep bystanders a safe distance from the machine, pick up debris before operating, keep the discharge deflector in place.

4.

Loss of traction/control hazard, slopes–loss of traction/control on slope, disengage the blade control switch (PTO), proceed off the slope slowly.

109-8965

5.

Tipping hazard–avoid sudden and sharp turns while on slopes, only mow across slopes less than 15 degrees, keep a safe distance from water, and only mow up and down slopes less than 15 degrees.

6.

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

7.

Crushing/dismemberment hazard of bystanders, reversing–Do Not carry passengers, look behind and down when reversing.

11

Safety

1.

Explosion hazard

Battery Symbols

Some or all of these symbols are on your battery.

5.

Read the Operator’s Manual.

9.

Flush eyes immediately with water and get medical help fast.

10.

Contains lead; do not discard.

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.

12

Specifications

Specifications

Model Numbers

Serial Nos: 790,000 and Higher

QST22BE482; QST24BE522

Systems

Engine

• Engine Specifications: See your Engine Owner’s

Manual

• RPM: Full Speed: 3650 ±100 (max) RPM (No

Load) Idle: 1650 (min) RPM

Fuel System

• Capacity: 4.0 gal. (15.1 L)

• Type of Fuel: Regular unleaded gasoline, 87 octane or higher.

• Fuel Filter:

Briggs & Stratton P/N 695666

• Fuel Shut-Off Valve: 1/4 turn increments (“ON”,

“OFF”)

Electrical System

• Charging System: Flywheel Alternator

• Charging Capacity: 16 amps

• Battery Type: BCI Group U1

• Battery Voltage: 12 Volt

• Polarity: Negative Ground

• Fuses: One 25 amp, one 20 amp; one 15 amp blade type

• Diode: TVS

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 parking brake.

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

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

Seat

• Type: Standard seat with high back, foam padded with spring suspension and armrests.

• Mounting: Hinged to tilt up for access to hydraulic pumps, battery and other components.

Held in tilted position with lanyard. Adjustable fore and aft.

• Armrests: Standard–foam padded flip-up adjustable height armrests.

• Seat Safety Switch: Incorporated into the Safety

Interlock System.

Hydrostatic Ground Drive System

• Hydrostatic Pumps: Two Hydro Gear ZT2800

Integrated drive systems.

• Hydraulic Oil Type: Exmark Premium Hydro oil.

13

Specifications

• 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 & Wheels

Drive Front

Caster

Deck Size 48

Quantity 2

Pneumatic (Air-Filled) Pneumatic

(Air-Filled)

52

2

All Decks

2

Tread

Size

Turf Tec Turf Tec Smooth

20 x 8.00-8 20 x 10.00-8 10 x 4

Ply Rating 4

Pressure 13 psi

(90 kPa)

4

13 psi

(90 kPa)

13 psi

(90 kPa)

Cutting Deck

• Cutting Width:

– 48 inch Deck: 48 inches (122 cm)

– 52 inch Deck: 52 inches (132 cm)

• Discharge: Side

• Blade Size: (3 ea.)

– 48 inch Deck: 16.25 inches (41.3 cm)

– 52 inch Deck: 18.00 inches (45.7 cm)

• Blade Spindles: Solid steel spindles with no maintenance bearings.

• Deck Drive: Electric clutch mounted on vertical engine shaft. Blades are driven by one belt

(w/self-tensioning idler) direct from the engine.

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

Deck design allows for bagging, mulching or side discharge.

• Deck Depth:

– 48 inch Deck: 5.0 inches (12.7 cm)

– 52 inch Deck: 5.0 inches (12.7 cm)

• Cutting Height Adjustment: A foot deck lift lever is used to adjust the cutting height from 1 1/2 inch (3.8 cm) to 4 1/2 inches (11.4 cm) in 1/2 inch (1.3 cm) increments.

• Mulching Kit: Optional.

14

Specifications

Dimensions

Overall Width:

Without Deck

Deflector Up

48 inch Deck

45.5 inches

(116 cm)

48.3 inches

(122 cm)

Deflector Down 59.4 inches

(151 cm)

52 inch Deck

47.0 inches

(119 cm)

53.0 inches

(135 cm)

64.2 inches

(163 cm)

Overall Length:

48 inch Deck

73.4 inches (186 cm)

Overall Height:

48 inch Deck

41.8 inches (106 cm)

52 inch Deck

73.4 inches (186 cm)

52 inch Deck

41.8 inches (106 cm)

Tread Width: (Center to Center of

Tires, Widthwise)

Drive Wheels

Caster Wheels

48 inch Deck

36.0 inches

(91 cm)

33.5 inches

(85 cm)

52 inch Deck

36.8 inches

(93 cm)

33.5 inches

(85 cm)

Wheel Base: (Center of Caster Tire to

Center of Drive Tire)

48 inch Deck 52 inch Deck

48.9 inches (124 cm) 48.9 inches (124 cm)

Curb Weight:

48 inch Deck

645 lb (293 kg)

52 inch Deck

660 lb (299 kg)

Bolt Location

Blade Mounting Bolt

(lubricate with anti-seize)

Engine Mounting Bolts

Anti-Scalp Roller Nyloc

Nut

Wheel Lug Nuts

Clutch Mounting Bolt

(secured with threadlocker)

Spark Plug

Torque

32-42 ft-lb (43-57 N-m)

27-33 ft-lb (37-45 N-m)

27-33 ft-lb (37-45 N-m)

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

50-55 ft-lb (68-75 N-m)

15 ft-lb (20 N-m)

Torque Requirements

Bolt Location

Spindle Pulley Nut

Torque

75-85 ft-lb (102-115 N-m)

15

Operation

Product Overview

Figure 3

1.

Front caster wheel 8.

Engine

2.

Anti-scalp roller 9.

Seat

3.

Height of cut foot lever 10.

Armrest

4.

Discharge deflector 11.

Motion control levers

5.

Height of cut adjustment 12.

Park brake

6.

Rear drive wheel

7.

Control panel

13.

Footrest

14.

Washout fitting

Operation

Controls

Note: Become familiar with all of the controls in

Figure 3 and Figure 4 before you start the engine and

operate the machine.

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 4). Insert key into

switch and rotate clockwise to the “ON” position.

Rotate clockwise to the next position to engage the starter (key must be held against spring pressure in this position).

1.

Throttle/Choke lever

2.

Hour meter

Figure 4

3.

Blade control switch

(power take-off)

4.

Ignition switch

Note: Brake must be engaged, motion control levers out (neutral lock position) and PTO switch “OFF” to start engine. (It is not necessary for the operator to be in the seat to start the engine.)

Turning the key to the Off position will stop the engine; however, always remove the key when leaving the machine to prevent someone from accidentally starting the engine

16

Operation

Blade Control Switch (Power

Take-Off)

Located on the control panel.

The blade control switch, represented by a power take-off (PTO) symbol, engages and disengages

power to the mower blades (see Figure 4).

Pull out on the blade control switch to “On” to engage the blades.

Push the blade control switch to “Off ” to disengage the blades.

Throttle/Choke 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. Moving the throttle forward into the detent is

full throttle (see Figure 4).

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

Do Not run a warm engine with the choke in the

“ON” position. Moving the lever forward beyond the detent will put the choke in the “ON” position and moving the lever to the detent will put the choke in the “OFF” position.

Motion Control Levers

The motion control levers located on each side of

the seat (Figure 3).

The motion control levers are speed sensitive controls of independent wheel motors. Moving a lever forward or backward turns the wheel on the same side forward or in reverse; wheel speed is proportional to the amount the lever is moved. Moving the control levers outward from the center position locks them in the neutral position. Always position the motion control levers into the neutral position and engage the park brake lever when you stop the machine or leave it unattended. The unit must be tied down and brake engaged when transporting.

Parking Brake Lever

Located on left side of the console (Figure 3).

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.

Height-of-Cut Foot Lever

The height of cut lever allows the operator to lower

and raise the deck from the seated position (Figure 3).

When the lever is moved forward, away from the operator the deck is raised from the ground and when moved back, towards the operator it is lowered toward the ground. Only adjust the height of cut while machine is not moving.

Hour Meter

Located on the control panel.

The hour meter is connected to a pressure switch installed in the engine block and it records the number

of hours that the engine has run ( Figure 4). If the

ignition switch is left on without engine running, hour meter will not run.

Note: This switch is not a low oil sensor and will not alert the operator if the engine oil is low.

Operating Instructions

Think Safety First

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

Please carefully read all of the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury.

17

Operation

DANGER

Mowing on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. A loss of traction is a loss of steering control.

To avoid loss of control and possibility of rollover:

• Do Not mow near drop-offs or near water.

• Do Not mow slopes greater than 15 degrees.

• Reduce speed and use extreme caution on slopes.

• When mowing slopes, gradually work from lower to higher areas on the incline.

• Avoid sudden turns or rapid speed changes.

• Turn up, into an incline when changing directions on slopes. Turning down the slope reduces traction.

• Attachments change the handling characteristics of the machine. Use extra caution when using attachments with the machine.

See inside back cover to determine the approximate slope angle to be mowed.

Recommended Gasoline

Use UNLEADED Regular Gasoline suitable for automotive use (87 pump octane minimum).

Important: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do Not mix oil with gasoline.

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 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.

Figure 5

1.

Water

2.

Danger Zone–Use walk behind mower and/or hand trimmer on slopes greater than 15 degrees, near drop-offs and water.

3.

Safe Zone–use the Quest here.

18

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.

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.

Operation

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps gasoline fresh during storage of 30 days or less. For longer storage it is recommended that the fuel tank be drained.

• Cleans the engine while it runs.

• Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Add the correct amount of gas stabilizer/conditioner to the gas.

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Gasoline/Alcohol blends

Gasohol (up to 10 percent ethyl alcohol, 90 percent unleaded gasoline by volume) is approved for fuel use by the engine manufacturer. Other gasoline/alcohol blends are not approved.

Filling the Fuel Tank

1. Shut the engine off and set the motion controls to the neutral position and engage parking brake.

2. Clean around the fuel tank cap and remove the cap.

3. Add unleaded regular gasoline until the body of the tank is full but fuel does not fill the neck of

the tank (Figure 6). This space in the neck of the

tank allows gasoline to expand. Do Not fill the fuel tank completely full.

19

Operation

1.

Gas tank opening

2.

Fill to here, approximately

Figure 6

3.

Gas tank body

1.

Throttle/Choke lever

2.

Blade control switch—Off position

3.

Ignition key

4.

Off

Figure 7

5.

Run

6.

Start

7.

Choke

8.

Throttle–fast (detent position)

4. Install the fuel tank cap securely. Wipe up any gasoline that may have spilled.

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.

Starting the Engine

1. Sit down on the seat and move the motion controls outward to the neutral position and engage the parking brake.

2. Disengage the blades by moving the blade control

switch to Off (Figure 7).

3. Move the lever forward, beyond the detent, to engage the choke before starting a cold engine

(Figure 7).

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

4. Turn the ignition key to Start to energize the starter. When the engine starts, release the key

(Figure 7).

Important: Do Not engage the starter for more than 5 seconds at a time. If the engine fails to start, allow a 60 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.

5. Once the engine starts, move the lever to the detent position. If the engine stalls or hesitates, move the lever partially forward for a few seconds.

Operating the Blades

The blade control switch, represented by a power take-off (PTO) symbol, engages and disengages power to the mower blades. This switch controls power to any attachments that draw power from the engine, including the mower deck and cutting blades.

Engaging the Blades

1. Release pressure on the motion control levers and place the machine in neutral.

20

Operation

2. Move the throttle midway to the Fast position.

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

3. Pull out on the blade control switch, to the On

position, to engage the blades (Figure 8).

The Safety Interlock System

CAUTION

If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.

• Do Not tamper with the interlock switches.

• Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.

1.

Throttle–Midway position

Figure 8

2.

Blade control switch—On position

4. Move throttle to full forward position before mowing.

Disengaging the Blades

Set throttle to midway position. Push the blade control switch to Off to disengage the blades

(Figure 7).

Stopping the Engine

1. Move the throttle lever to between Fast and half throttle.

2. Disengage the blades by moving the blade control switch to Off.

3. Turn the ignition key to Off.

4. Pull the wire off of the spark plug(s) to prevent the possibility of someone accidentally starting the machine before transporting or storing the machine.

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 in the neutral 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.

• The parking brake is disengaged and levers are in and the operator gets off machine.

• The parking brake is engaged and motion control levers are in.

Testing the Safety Interlock System

Test the safety interlock system before you use the machine each time

1. Check starting circuit. Starter should crank with parking brake engaged , PTO disengaged and motion control levers moved out in the neutral lock position. The operator does not need to be in the seat to start the engine.

Try to start with operator in seat , parking brake disengaged, PTO disengaged and motion control levers in the neutral lock position - starter must not crank.

21

Operation

Try to start with operator in seat, parking brake engaged , PTO engaged and motion control levers in the neutral lock position starter must not crank .

Try to start with operator in seat, parking brake engaged , PTO disengaged , and the left motion control lever in , starter must not crank, repeat again with the right lever in, then with both levers in starter must not crank.

2. Check kill circuits. Run engine at one-third throttle, disengage parking brake and raise off of seat (but do not get off of machine) engine must initiate shutdown.

Run engine at one-third throttle, engage PTO and raise off of seat (but do not get off of machine) engine must initiate shutdown.

Run engine at one-third throttle, with brake disengaged, move levers in and raise off seat (but do not get off of machine) engine must initiate shutdown .

Again, run engine at one-third throttle, brake engaged , and move left motion control lever in

- engine must initiate shutdown .

Repeat again moving the right lever in , then moving both levers in - engine must initiate shutdown whether operator is on seat or not.

Note: If machine does not pass any of these tests,

Do Not operate. Contact your authorized EXMARK

SERVICE DEALER.

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

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 9).

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.

Figure 9

1.

Neutral position

2.

Center unlock position

3.

Backward

4.

Forward

To go straight, apply equal pressure to both

motion control levers (Figure 9).

To turn, pull back on the motion control lever

toward the direction you want to turn (Figure 9).

The farther you move the motion control levers in either direction, the faster the machine will move in that direction.

To stop, pull the motion control levers to neutral.

22

Operation

Backward

1. Move the levers to the center, unlocked position.

2. To go backward, slowly pull the motion control

levers rearward (Figure 9).

To go straight, apply equal pressure to both

motion control levers (Figure 9).

To turn, release the pressure on the motion control lever toward the direction you want to

turn (Figure 9).

To stop, push the motion control levers to neutral.

Stopping the Machine

To stop the machine, move the motion control levers to neutral and outward to the neutral position, disengage the blade control switch, move the throttle lever to between Fast and half throttle, and turn the ignition key to off. Remember to remove the key from the ignition switch.

Tracking Adjustment

If the machine turns right or left when handles are pushed forward together, adjust the tracking plate on

the side opposite the direction of turn (see Figure 10).

Loosen the hardware that holds the tracking plate.

Move the plate back until the unit drives straight.

Tighten the hardware to lock the tracking plate in place. Readjust handles if necessary.

CAUTION

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

Always remove the ignition key and move the motion control levers outward to the neutral position and apply the parking brake when leaving the machine unattended, even if just for a few minutes.

Adjusting the Height of Cut

1. Raise the deck to the transport position (4.5 inch

(114 mm) cut height) by pushing the foot actuated

lever forward (Figure 11). The transport lever will

automatically engage and will drop into place.

Figure 11

1.

Transport release handle 3.

Height adjuster pin

2.

Height-of-cut positions 4.

Foot actuated height-of-cut lever

1.

Control arm shaft

2.

Tracking plate nut

Figure 10

3.

Tracking plate

2. Move the deck height adjuster pin to the desired cut height.

3. Push the foot lever forward, pull the transport release handle up and let the deck lower down to the predetermined cut height by slowly decreasing foot pressure allowing the foot lever to travel rearward.

Adjusting the Anti-Scalp

Rollers

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

23

Operation

1. Stop the machine and move the drive levers to the neutral lock position.

2. Disengage the PTO.

3. Engage the park brake.

4. Stop the engine, remove the key and wait for all moving parts to stop.

5. After adjusting the height of cut, adjust the anti-scalp rollers by removing the nyloc nut.

6. Adjust the anti-scalp rollers for the normal operating conditions. Place rollers in one of

the positions shown in Figure 12. Rollers will

maintain 3/4 inches (19 mm) clearance to the ground to minimize gouging and roller wear or damage.

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.

1.

Adjustment lever

Figure 13

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

Changing the Seat Ride

Suspension

The number of seat springs can be changed to maximize rider comfort. More springs should be used with heavier operators and on rough terrain. Fewer springs should be used with lighter operators and when mowing smooth, well established lawns. Always keep the number of springs on the left and right side the same when adding and removing springs.

Figure 12

For cutting heights above 3 1/2 inches (38 mm) use the bottom hole. The rollers will still be effective against scalping.

1.

Anti-scalp roller mounting bracket

2.

Cutting height

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

Positioning the Seat

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

1. Push the adjustment lever towards the center of the machine to release the seat adjuster track

(Figure 13).

1.

Bolt

2.

Spring

Figure 14

3.

Nut

4.

Additional mounting holes

Up to five springs can be secured to the seat box with

a nut and bolt, see Figure 14.

24

Operation

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

Adjusting the Motion Control

Levers

Pushing the Machine by

Hand

Important: Always push the machine by hand.

Never tow the machine because damage may occur.

Adjusting the Height

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

1. Remove the two bolts holding the control lever to

the control arm shaft (Figure 15).

To Push the Machine

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

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

3. Locate the bypass release knobs on either side of

the engine deck (Figure 16).

1.

Bolt

2.

Washer

3.

Control lever

Figure 15

4.

Control arm shaft

5.

Nut

2. Move the control lever to the next set of holes.

Secure the lever with the two bolts.

3. Repeat the adjustment for the opposite control lever.

Adjusting the Tilt

The motion control levers can be tilted fore or aft for maximum operator comfort.

1. Loosen the upper bolt holding the control lever to the control arm shaft.

2. Loosen the lower bolt just enough to pivot the

control lever fore or aft (Figure 15). Tighten both

bolts to secure the control in the new position.

3. Repeat the adjustment for the opposite control lever.

Figure 16

1.

Front of the machine.

2.

Rotate bypass release knob counterclockwise

3.

Lever position for operating the machine.

4.

Pull lever in this direction

5.

Lever position for pushing the machine

6.

Rotate bypass release knob clockwise

7.

Release lever

4. Loosen the knob by turning counterclockwise.

Then pull the release lever on the underside of

machine (Figure 16) towards the back of the

machine and retighten the knob to hold the

25

Operation release lever back in the released state. Repeat this on each side of the machine.

5. Release the parking brake. The machine is now able to be pushed by hand.

To Operate the Machine

Loosen the bypass knob, push the release levers forward, and retighten the knob to engage the drive

system (Figure 16).

CAUTION

This unit does not have proper turn signals, lights, reflective markings, or a slow moving vehicle emblem. Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury. Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and/or fines.

Do Not drive a unit on a public street or roadway.

Side Discharge

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

DANGER

Without the discharge deflector, mulch kit, or entire grass collection system mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.

• Never remove the discharge deflector from the mower because the discharge deflector routes material down toward the turf. If the discharge deflector is ever damaged, replace it immediately.

• Never put your hands or feet under the mower.

• Never try to clear discharge area or mower blades unless you move the move the blade control switch to Off and rotate the ignition key to Off. Also remove the key and pull the wire off the spark plug(s).

WARNING

Loading a unit on a trailer or truck increases the possibility of backward tip-over.

Backward tip-over could cause serious injury or death.

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

• Use only a single, full width ramp; Do

Not use individual ramps for each side of the unit.

• If individual ramps must be used, use enough ramps to create an unbroken ramp surface wider than the unit.

• Do Not exceed a 15° angle between ramp and ground or between ramp and trailer or truck.

• Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward.

• Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward.

Transporting

Transporting a Unit

Use a heavy-duty trailer or truck to transport the machine. Lock brake and block wheels. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Be sure that the trailer or truck has all necessary lighting and marking as required by law. Secure a trailer with a safety chain.

Loading a Unit

Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit. The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides

26

Operation a surface for the frame members to contact if the unit starts to tip backward. If it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp.

Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15°. A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck. Steeper angles may also cause the unit to tip backward. If loading on or near a slope, position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible.

Important: Do Not attempt to turn the unit while on the ramp, you may lose control and drive off the side.

Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp.

Both maneuvers can cause the unit to tip backward.

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.

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

27

Operation turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Exmark replacement blade. Only Exmark blades are to be used with this unit. No other blades are approved.

28

Maintenance

Maintenance

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

WARNING

While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders.

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

WARNING

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

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

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the first 5 hours

After the first 250 hours

Before each use or daily

Every 25 hours

Every 100 hours

Every 200 hours

Every 500 hours

Before storage

Monthly

Maintenance Procedure

• Change the engine oil.

• Change the hydraulic filter.

• Check the safety interlock system.

• Check the air cleaner for dirt, looseness, or damage.

• Check the air intake and cooling areas, clean as necessary.

• Check the oil level before starting or after every 8 hours.

• Check the hydraulic oil level in the expansion tank.

• Check the mower blades.

• Clean the mower housing.

• Grease all lubrication points.

• Service the air cleaner. (May need more often under extremely dusty or dirty conditions.)

• Check the tire pressure.

• Check the belts.

• Replace the paper element. (More often under extremely dusty, dirty conditions.)

• Replace the air cleaner element.

• Change the engine oil and filter.

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

• Replace the fuel filter.

• Service the spark plug.

• Change the hydraulic filter (Every 250 hours if using Mobil 1 15W50)

• Replace the spark plug.

• Charge the battery and disconnect the battery cables.

• Perform all maintenance procedures before storage.

• Paint any chipped surfaces.

• Check the battery charge.

29

Maintenance

Important: Refer to your Engine Operator’s Manual for additional maintenance procedures.

Premaintenance

Procedures

Raising the Seat

Make sure the motion control levers are locked in the neutral position. Lift the seat forward until the lanyard is tight. The following components can be accessed by raising the seat:

• Auxiliary 12V Plug (12V accessory up to 15 amp)

• Fuses

• Battery cables

Periodic Maintenance

Lubrication

Greasing the Bearings

Service Interval: Every 25 hours

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

Grease the front caster wheels (Figure 18).

G007184

Accessing the Battery

The battery is located under the seat. To access, raise

the seat (Figure 17).

1

Figure 18

1.

Front caster tire

1.

Auxiliary 12V Plug

2.

Battery

Figure 17

3.

Seat

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

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

3. Clean the grease fittings (Figure 18 and Figure 19)

with a rag. Make sure to scrape any paint off of the front of the fitting(s).

30

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

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

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

Figure 19

Located on the back of the seat.

1.

Read the instructions before servicing or performing maintenance

2.

Grease idler pivots.

3.

Time interval.

4.

Check oil level.

5.

Check hydraulic oil level and refer to Operator’s manual for further instructions.

6.

Check tire pressure.

Engine Maintenance

Servicing the Air Cleaner

Service Interval: Before each use or daily

Every 100 hours—Replace the paper element. (More often under extremely dusty, dirty conditions.)

This engine is equipped with a replaceable, high density paper air cleaner element. Check the air cleaner daily or before starting the engine. Check for

1.

Air cleaner

2.

Knobs

Figure 20

3.

Air cleaner cover

4. Connect a grease gun to each fitting (Figure 18

and Figure 19). Pump grease into the fittings until

grease begins to ooze out of the bearings.

5. Wipe up any excess grease.

Servicing Paper Element

Service Interval: Every 25 hours (May need more often under extremely dusty or dirty conditions.)

Every 100 hours/Yearly

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

1. Remove the air cleaner cover (Figure 20).

2. Remove the air cleaner element with the integral rubber seal.

3. Remove the foam sleeve from the element.

4. Gently tap the pleated side of the paper element to dislodge dirt. Do Not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element. Handle new elements carefully; Do Not use if the rubber seal or foam sleeve is damaged.

31

Maintenance

5. Wash the foam sleeve in warm water and allow to dry. Reinstall over the paper element.

6. Clean all air cleaner components of any accumulated dirt or foreign material. Prevent any dirt from entering the carburetor.

7. Install the air cleaner element with the pleated side “out” and seat the rubber seal onto the edges of the air cleaner base.

8. Reinstall the air cleaner cover and secure with the knobs.

The oil level should be up to, but not over, the

“F” mark on the dipstick.

6. If the level is low, add oil of the proper type, up to the “F” mark on the dipstick. Always check the level with the dipstick before adding more oil.

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

Servicing the Engine Oil

Checking the Oil Level

Service Interval: Before each use or daily

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. Pull and remove the oil fill cap/dipstick; wipe oil off. Reinsert the dipstick and push firmly into

place (Figure 21).

Changing the Oil and Filter

Service Interval: After the first 5 hours

Every 100 hours/Yearly

(whichever comes first) thereafter.

Change the oil and filter while the engine is still warm. The oil will flow more freely and carry away more impurities. Make sure the engine is level when filling, checking, or changing the oil.

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

2. Disengage the blade control switch and move the motion controls outward to the neutral position and engage parking brake.

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

4. Clean the area around the drain plug and on the machine frame. Place a pan underneath machine directly below the drain hole in the frame as

shown in Figure 22.

1.

Oil dipstick

2.

Filler tube

Figure 21

3.

Oil level

5. Remove the dipstick and check the oil level.

32

1.

Oil drain

2.

Oil drain plug

Figure 22

3.

Pan

5. Remove the oil drain plug (Figure 22 ). Remove

the oil fill cap/dipstick (Figure 21).

Maintenance gasket contacts the pad, then tighten the filter an

additional 1/2 to 3/4 turn (Figure 23).

11. Slowly pour approximately 80% of the specified oil into the filler tube—use oil recommended in the Engine Owner’s Manual.

12. Install the oil fill cap/dipstick and push firmly into place.

13. Check the oil level (Figure 21); refer to

Checking the Oil Level.

14. Slowly add additional oil to bring it to the full mark. Do Not overfill.

15. Install the oil fill cap/dipstick and push firmly into place.

16. Start the engine and check for leaks.

Checking the Hydraulic Oil

Level

Service Interval: Before each use or daily

Check expansion tank and if necessary add Exmark

Premium Hydro oil to the FULL COLD line.

1.

Oil filter

Figure 23

2.

Gasket

6. Be sure to allow ample time for complete drainage.

7. Remove the old filter and wipe off the mounting

pad (Figure 23).

8. When the oil has drained completely, install the oil drain plug. Tighten the plug to 14 N-m (125 in-lb) torque. Wipe up any excess oil on the frame

(Figure 22 ).

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

9. Apply a thin film of clean oil to the rubber gasket on the new filter.

10. Install the replacement oil filter to the mounting pad. Turn the oil filter clockwise until the rubber

1.

Engine

33

Figure 24

2.

Expansion tank

Maintenance

Change the Hydraulic

System Filter

Service Interval: After the first 250 hours

Every 500 hours thereafter

(Every 250 hours if using

Mobil 1 15W50)

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

2. Locate the two filters under the transmissions.

Remove filter guards.

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

4. Unscrew filters to remove and allow oil to drain from drive system.

Important: Before reinstalling new filters, apply a thin coat of Exmark Premium Hydro oil on the surface of the filters rubber seal.

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

5. Remove the vent plug on each transmission and fill through expansion reservoir, when oil comes out of vent reinstall plug.

Exmark Premium Hydro Oil is recommended.

Refer to the chart for an acceptable alternative:

Hydro Oil Change Interval

Exmark Premium Hydro

Oil (Preferred)

Mobil 1 15W50

500 Hours

250 Hours

Torque plugs to 180 in-lb (244 N-m). Continue to add oil until it reaches the FULL COLD line on the expansion reservoir.

1.

Oil filter

2.

Vent plug

Figure 25

3.

Left rear tire

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

7. Start engine and move throttle control ahead to

1/2 throttle position. Disengage parking brake.

A. With the bypass valve open and the engine running, slowly move the directional control in both forward and reverse (5 or 6 times).

B. With the bypass valve closed and the engine running, slowly move the directional control in both forward and reverse directions (5 to

6 times). Check the oil level, and add oil as required after stopping the engine.

C. It may be necessary to repeat steps A and

B until all the air is completely purged from

the system. When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds, then the transaxle is considered purged.

Do Not change hydraulic system oil (except for what can be drained when changing filter), unless it is felt the oil has been contaminated or been extremely hot.

Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system.

Servicing the Spark Plug

Service Interval: Every 200 hours/Every 2 years (whichever comes first)

Every 500 hours—Replace the spark plug.

34

Maintenance

As stated in the maintenance intervals, remove the spark plug, check condition, and reset the gap or replace with a new plug as necessary.

The spark plug is RFI compliant. Equivalent alternate brand plugs can also be used.

Type: Champion XC92YC

Champion RC12YC or QC12C may be used if your area does not require compliance with Canadian

ICES-002, ISO 14982, or EN 55012.

Air Gap: 0.030 inch (0.76 mm)

Removing the Spark Plug

1. Disengage the blade control switch, move the motion controls outward to the park position, stop the engine, and remove the key.

2. Pull the wire off of the spark plug (Figure 26).

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

Note: Due to the deep recess around the spark plug, blowing out the cavity with compressed air is usually the most effective method for cleaning.

The spark plug is most accessible when the blower housing is removed for cleaning.

3. Remove the spark plug and metal washer.

black coating, worn electrodes, an oily film, or cracks.

2. Check the gap between the center and side

electrodes (Figure 27). Bend the side electrode if

the gap is not correct.

1.

Side electrode

2.

Center electrode insulator

Figure 27

3.

Air gap (not to scale)

Installing the Spark Plug

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).

3. Push the wire onto the spark plug (Figure 26).

Figure 26

1.

Spark plug and wire location

Checking the Spark Plug

1. Look at the center of the spark plug (Figure 27).

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

Important: Never clean the spark plug.

Always replace the spark plug when it has a

Cleaning the Blower Housing

Service Interval: Every 100 hours/Yearly

(whichever comes first)

More often under dirty conditions.

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

1. Remove the blower housing and any other cooling shrouds.

2. Clean the cooling fins and external surfaces as necessary.

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.

35

Maintenance

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.

Figure 28

1.

Fuel tank 6.

Hose clamps

2.

Fuel shut off valve—off 7.

Fuel line to engine

3.

Fuel shut off valve 8.

Filter

4.

Fuel shut off valve—on 9.

Flow direction arrow

5.

Fuel line from tank

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

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

4. Turn fuel shut off valve 90° to “off ” position.

5. Squeeze the ends of the hose clamps together and

slide them away from the filter (Figure 28).

6. Remove the filter from the fuel lines.

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

(Figure 28) to secure it in place.

8. Turn fuel shut off valve back to “on” position.

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.

36

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.

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

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

3. Raise the seat.

4. Disconnect the negative (black) ground cable

from the battery post (Figure 29). Retain all

fasteners.

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 29) and lift the

battery from the battery tray.

Charging the Battery

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.

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

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

Important: Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery (see chart below for recommended charger settings).

Figure 29

1.

Negative battery post

2.

Bolt, washer, and nut

3.

Terminal boot

4.

Positive battery post

5.

Battery strap

6.

Battery

WARNING

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

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

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

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

(black) cable.

37

Maintenance

Voltage

Reading

12.6 or greater

Percent

Charge

100%

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%

Maximum

Charger

Settings

16 volts/7 amps

16 volts/7 amps

16 volts/7 amps

14.4 volts/4 amps

14.4 volts/4 amps

14.4 volts/2 amps

Charging

Interval

No

Charging

Required

30 Minutes

1 Hour

2 Hours

3 Hours

6 Hours or

More

4. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery

posts (Figure 30).

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 29).

Servicing the Fuses and

Relay

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

There is also a replaceable relay/s next to the fuse.

Refer to your Parts manual for correct replacement components.

Fuse Block:

• Main fuse: 25 amp fuse, blade-type

• Charge Circuit: 20 amp fuse, blade-type

• Auxiliary circuit: 15 amp fuse, blade-type

• Diode: TVS

1. Raise the seat to gain access to the fuse holder

(Figure 31).

Figure 30

1.

Negative battery post

2.

Black (-) charger lead

3.

Red (+) charger lead

4.

Positive battery post

Note: Do Not run the machine with the battery disconnected, electrical damage may occur.

Installing the Battery

1. Position the battery in the tray with the terminal

posts toward the operating position (Figure 29).

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

1.

Cover

2.

Relay

3.

Auxilliary–15 amp

Figure 31

4.

Charge–20 amp

5.

Main–25 amp

6.

Diode

2. Remove cover as shown in Figure 31.

3. To replace a fuse, pull out on the fuse to remove it

38

Maintenance

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 32).

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)

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.

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 the neutral position and engage parking brake. Stop the engine, remove the key, and disconnect the spark plug wire(s) from the spark plug(s).

1.

Valve stem

Figure 32

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.

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.

Inspecting the Blades

1. Inspect the cutting edges (Figure 33). 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 33), immediately install

a new blade.

1.

Cutting edge

2.

Curved area

Figure 33

3.

Wear/slot forming

Checking for Bent Blades

1. Rotate the blades until the ends face forward

and backward (Figure 34). Measure from a level

surface to the cutting edge, of the blades. Note this dimension.

39

Maintenance

Figure 34

1.

Blades front to rear

2.

Outside cutting edges

3.

Measure here

2. Rotate the opposite ends of the blades forward.

3. Measure from a level surface to the cutting edge

of the blades at the same position as in step 1.

The difference between the dimensions obtained

in steps 1 and 3 must not exceed 1/8 inch (3

mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades and Installing the

Blades .

WARNING

A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.

• Always replace bent or damaged blade with a new blade.

• Never file or create sharp notches in the edges or surfaces of blade.

(Figure 35). Refer to

Removing the Blades and

Installing the Blades .

3. Once the blade has been removed, inspect the spring disc washer. If the washer appears to be damaged (the washer surface has been marred) or flattened, the bolt and washer assembly must be replaced.

Removing the Blades

The blades must be replaced if a solid object is hit, if the blade is out of balance, or the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Exmark replacement blades. Replacement blades made by other manufacturers may result in an unsafe machine.

Hold the blade end using a rag or thickly-padded glove (or place a wrench on the top sheave nut).

Remove the blade bolt and washer assembly, washer,

and blade from the spindle shaft (Figure 35).

Figure 35

1.

Blade

2.

Washer

3.

Bolt and washer assembly. Apply lubricant to threads—torque to 32-42 ft-lb (43-57 N-m).

Checking for Loose Blades or

Damaged Spring Disc Washers

1. Place a wrench on the blade bolt and torque to

32-42 ft lb (43-57 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

Sharpening the Blades

1. Use a file to sharpen the cutting edge at both ends

of the blade (Figure 36). Maintain the original

angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

40

Maintenance

Figure 36

1.

Sharpen at original angle

2. Check the balance of the blade by putting it on a

blade balancer (Figure 37). 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 37).

Repeat this procedure until the blade is balanced.

1.

Blade

Figure 37

2.

Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Figure 35).

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 32-42 ft-lb (43-57 N-m).

WARNING

Incorrect installation of the blade or components used to retain the blade cause the blade to come loose and could seriously injure or kill you or bystanders.

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

Mower Belt Maintenance

Inspecting the Belts

Service Interval: Every 25 hours

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

Replacing the Mower Belt

Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks, and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident.

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

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

3. Set the height-of-cut at 1-1/2 inch (38 mm).

4. Remove the belt covers over the outside spindles.

5. Pull the idler pulley in the direction shown in

Figure 38 and roll the belt off of the pulleys.

WARNING

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

Be careful when removing the belt.

1.

Outside puley

2.

Spring

3.

Idler pulley

Figure 38

4.

Mower belt

5.

Engine pulley

6.

Pull idler in this direction.

41

Maintenance

6. Route the new belt around the engine pulley and mower pulleys.

7. Pull the idler pulley in the direction shown in

Figure 38 and route the belt onto the idler pulley.

8. Install the belt covers over the outside spindles.

Leveling the Mower Deck

The mower blades must be level from side to side.

Check the side-to-side level any time you install the mower or when you see an uneven cut on your lawn.

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

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

3. Check the air pressure of all four tires. If needed, adjust to the recommended inflation; refer to

Checking the Tire Pressure in Drive System

Maintenance section. If either one is out of range then follow adjustment procedure.

4. Carefully rotate the blades side to side.

5. Measure between the outside cutting edges and

the flat surface (Figure 39). If both measurements

are not within 3/16 inch (5 mm), an adjustment is required; continue with this procedure.

7. Set anti-scalp rollers to top holes or remove completely for this adjustment.

8. Set the height-of-cut lever to the 3 inch (76 mm) position. Place two 2 1/2 inch (6.35 cm) thick blocks under the rear edge of the cutting deck skirt; one on each side of the cutting deck. Place two 2 5/16 inch (5.89 cm) blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets.

9. Carefully rotate the blades side to side (Figure 39).

10. Loosen the leveling adjust locking nuts (item 4) on all four corners so that the deck is sitting securely on all four blocks. Make sure that the deck hangers are all the way down (at the top of the slot) and the deck lift foot lever is pushed back against the stop, then tighten the four leveling adjust locking nuts

11. Recheck that blocks fit just snugly under the deck skirt. Make sure all attachment bolts are tight

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

Front-to-Rear Blade Slope.

13. Recheck blades for levelness and repeat deck leveling procedure if necessary.

Figure 39

1.

Blades side to side

2.

Outside cutting edges

3.

Measure here

1.

Deck lift arm

2.

Float retaining nut

Figure 40

3.

Deck hanger

4.

Leveling adjust locking nut

6. Check the front-to-rear blade level any time you install the mower. If the front blade tip is not

1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip, adjust the blade level. If measurements

from steps 5 or 6 are out of range, then follow

Adjusting the Blade Slope.

Adjusting the Blade Slope

1. Check the front-to-rear blade level any time you install the mower. If the front blade tip is not

1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip, adjust the blade level using the following instructions:

42

Maintenance

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

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

4. Check the air pressure of all four tires. If needed, adjust to the recommended inflation; refer to

Checking the Tire Pressure in Drive System

Maintenance section.

5. Check and adjust the side-to-side blade level if you have not checked the setting; refer to Leveling the Mower .

6. Set the height-of-cut lever to the 3 inch (76 mm) position. Place two 2 1/2 inch (6.35 cm) thick blocks under the rear edge of the cutting deck skirt; one on each side of the cutting deck. Place two 2 5/16 inch (5.89 cm) blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets.

7. Loosen the leveling adjust locking nuts (item 4) on all four corners so that the deck is sitting securely on all four blocks. Make sure that the deck hangers are all the way down (at the top of the slot) and the deck lift foot lever is pushed back against the stop, then tighten the four leveling

adjust locking nuts (Figure 41).

1.

Deck lift arm

2.

Float retaining nut

Figure 41

3.

Deck hanger

4.

Leveling adjust locking nut

8. Carefully rotate the blades so they are facing front

to rear (Figure 42).

9. Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat

surface (Figure 42). If the front blade tip is not

1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip, adjust the front deck hanger.

43

Figure 42

1.

Blades front to rear

2.

Outside cutting edges

3.

Measure here

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

Maintenance

Replacing the Discharge

Deflector

DANGER

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

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

1. Locate items shown in Figure 43.

through the front discharge deflector bracket, discharge deflector, and rear deflector bracket.

5. Make sure that the spring and rod are installed so that the rod is retained from sliding out by the front bracket and the spring holds the discharge deflector in the down position. Refer to

(Figure 43) for proper orientation.

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.

1.

Rod

2.

Spring

3.

Discharge deflector

Figure 43

4.

Mower deck

5.

Discharge deflector bracket

6.

Assembled view

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

3. Install new discharge deflector.

4. Orient the spring so that the short leg points towards the discharge deflector and the longer leg

points towards the deck as shown in Figure 43.

Place spring on rod and slide rod, straight end,

44

Maintenance

Cleaning

Washing the Underside of the Mower

Service Interval: Before each use or daily

After each use, wash the underside of the mower to prevent grass buildup for improved mulch action and clipping dispersal.

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

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

3. Attach the hose coupling to the end of the mower washout fitting, and turn the water on high

(Figure 44).

Note: Spread petroleum jelly on the washout fitting O-ring to make the coupling slide on easier and protect the O-ring.

Note: If the mower is not clean after one washing, soak it and let it stand for 30 minutes.

Then repeat the process.

8. Run the mower again for one to three minutes to remove excess water.

WARNING

A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with blade or thrown debris can cause injury or death.

• Replace broken or missing washout fitting immediately, before using mower again.

• Plug any hole(s) in mower with bolts and locknuts.

• Never put your hands or feet under the mower or through openings in the mower.

Figure 44

4. Lower the mower to the lowest height-of-cut.

5. Sit on the seat and start the engine. Engage the blade control switch and let the mower run for one to three minutes.

6. Disengage the blade control switch, stop the engine, and remove the ignition key. Wait for all moving parts to stop.

7. Turn the water off and remove the coupling from the washout fitting.

45

Storage

Storage

Cleaning and Storage

1. Disengage the blade control switch, move the motion controls outward to the neutral position, engage parking brake, stop the engine, and remove the key.

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

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

3. Service the air cleaner; refer to Servicing the Air

Cleaner in Engine Maintenance section.

4. Grease and oil the machine; refer to Lubrication section.

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

Maintenance section.

6. Check the tire pressure; refer to Checking the

Tire Pressure in Drive System Maintenance section.

7. Charge the battery; refer to Servicing the

Battery in Electrical System Maintenance section.

8. Check the condition of the blades; refer to

Servicing the Cutting Blades in Mower

Maintenance section.

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

A. Add a petroleum based stabilizer/conditioner to the fuel in the tank. Follow the mixing instructions from the stabilizer manufacturer.

Do Not use an alcohol based stabilizer

(ethanol or methanol).

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

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

C. Stop the engine and turn the fuel shut off valve 90° to the “off ” position.

D. Restart the engine and run it until it stops.

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

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

Maintenance section. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do

Not install the wire on the spark plug(s).

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

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

13. Check the condition of the drive and mower belts.

14. Check and tighten all bolts, nuts, and screws.

Repair or replace any part that is worn or damaged.

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

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

46

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. The motion control levers are not in the park position.

3. The operator is not seated.

4. The battery is dead.

5. The electrical connections are corroded or loose.

6. A fuse is blown.

7. A relay or switch is damaged.

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. Move the motion control levers outward to the park position.

3. Sit on the seat.

4. Charge the battery.

5. Check the electrical connections for good contact.

6. Replace the fuse.

7. Contact an Authorized Service Dealer.

1. Fill the fuel tank.

2. Move the choke lever to On.

3. Clean or replace the air cleaner element.

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

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.

47

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. Vent hole in the fuel cap is closed.

7. Dirt in fuel filter.

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

9. There is incorrect fuel in the fuel tank.

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. Open the vent in the fuel cap.

7. Replace the fuel filter.

8. Contact an Authorized Service Dealer.

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

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

1. Contact an Authorized Service Dealer.

2. The drive belts are off of the pulleys.

3. The drive is in bypass mode.

2. Contact an Authorized Service Dealer.

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

1. Engine mounting bolts are loose.

1. Tighten the engine mounting bolts.

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

6. Blade spindle is bent.

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.

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.

3. Deck belt is worn, loose or broken.

4. Deck belt is off pulley.

2. Install drive belt and check adjusting shafts and belt guides for correct position.

3. Install new deck belt.

4. Install deck pulley and check the idler pulley, idler arm and spring for correct position and function.

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

5. Install a new mower belt.

48

Schematics

Electrical Diagram

ENGINE

LT BLUE

5 4

PINK

PINK

ORANGE

VIOLET

BROWN

PINK

BROWN

3

2

1

4

5

GREEN

BLACK

BLACK

DK GREEN

BROWN

RED

DK BLUE

DK GREEN

Schematics

G009785

49

Schematics

Electrical Logic Schematic

RED

VIOLET

ORANGE

ORANGE

DK. GREEN

DK. GREEN

BROWN

RED

BROWN

VIOLET

VIOLET

RED

ORANGE

ORANGE

PINK

PINK

DK. BLUE

ORANGE

VIOLET

BROWN

BROWN

PINK

PINK

PINK

BROWN

GRAY

RED

DK. BLUE

DK. GREEN

DK. GREEN

BLACK

DK. GREEN

YELLOW

YELLOW

BLACK

BLACK

WHITE

BROWN

DK. GREEN

G009777

50

Consumer Warranty Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company, pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair, replace or adjust any part on these products and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of three years for residential usage of Exmark Quest turf equipment.

Residential usage means use of the product on the same lot as your home. Use at more than one location is considered commercial use, and the commercial use warranty detailed below would apply.

This warranty applies to Exmark Quest turf equipment sold in the

U.S. or Canada. This warranty may only be assigned or transferred to a second (or third) owner by an authorized Exmark dealer. The warranty period commences upon the date of the original retail purchase.

Warranty Exceptions

• Bags, Belts and Tires

• Battery

• Engine*

Warranty Period

90 days

1 Year Prorated

3-Year, 3rd Year Covered by Exmark

* Please refer to the manufacturer’s warranty statement that is included in the literature packet. The manufacturer provides a 2 year warranty. Exmark Warranty Company extends coverage for warrantable engine items as defined by the manufacturer’s original warranty during the 3rd year of warranty.

This warranty only includes the cost of parts and labor. For the first warrantable service repair, Exmark will cover up to $45 for associated pick-up and delivery charges to and from any authorized

Exmark Service Dealer. Additional transportation charges may apply, contact your Dealer for details.

Limited Warranty for Commercial Use

Exmark Quest turf equipment used for commercial, institutional, or rental use are warranted against defects in materials or workmanship for a period of 30 days from the date of original purchase.

Warranty Exception

• Air Cooled Gas Engines

Warranty Period

90 days

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized Exmark

Service Dealer beyond first warrantable service.

• Any damage or deterioration due to normal use, wear and tear, or exposure.

• Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune-up parts, and adjustments.

• Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance.

• Any repairs necessary due to use of parts, accessories or supplies, including gasoline, oil or lubricants, incompatible with the turf equipment or other than as recommended in the operator's manual or other operational instructions provided by Exmark.

There are no other express warranties except for engine and special emission system coverage.

All warranty work must be performed by an authorized Exmark

Service Dealer using Exmark approved replacement parts.

Exmark Quest Turf Equipment

3-Year Limited Consumer Warranty

(30-Day Limited Commercial Warranty)

Instructions for Obtaining Warranty Service

The product must be registered with original proof of purchase by an

Exmark Service Dealer before obtaining any warranty service.

Contact any Exmark Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.exmark.com. U.S. or Canada customers may also call

402-223-6375.

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

Exmark Customer Service Department

The Exmark Warranty Company

2101 Ashland Avenue

Beatrice, NE 68310

402-223-6375 or [email protected]

Owner’s Responsibilities

The Exmark turf equipment, including any defective part, must be returned to an authorized Exmark service dealer within the warranty period. This warranty extends only to turf equipment operated under normal conditions. You must read the operator’s manual. You must also properly service and maintain your Exmark product as described in the operator’s manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

General Conditions

The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair or replacement of defective components as set forth herein. Neither Exmark nor Exmark

Warranty Company shall be liable for any incidental or consequential loss or damage.

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other extraordinary repair charges or charges relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark Service Dealer.

• Rental of like or similar replacement equipment during the period of any warranty, repair or replacement work.

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that covered by the terms of this warranty.

• Any claims for lost revenue, lost profit or additional cost as a result of a claim of breach of warranty.

• Attorney's fees.

No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale of any Exmark mower.

All implied warranties of merchantability (that the product is fit for ordinary use) and fitness for use (that the product is fit for a particular purpose) are limited to the duration of the express warranty.

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

G4500-428

51

Notes:

52

Date:

Service Record

Description of Work Done: Service Done By:

53

54

55

SEE EXMARK’S COMPLETE LINE OF 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

ROLL OVER PROTECTION SYSTEM (ROPS)

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

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)

© 2008 Exmark Mfg. Co., Inc.

Industrial Park Box 808

Beatrice, NE 68310

All Rights Reserved

Part No. 4500-373 Rev. A

(402) 223-6300

Fax (402) 223-5489

Printed in the USA.

www.exmark.com

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