Exmark 4501-191 User Manual

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QUEST™

ForSerialNos. 312,000,000&Higher

PartNo.4501-191Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Theengineinthisproductisnot equippedwithasparkarrestermufer.Itisa violationofCaliforniaPublicResourceCode (CPRC)Section4442touseoroperatethis engineonanyforest-covered,brush-covered, orgrass-coveredlandasdenedinCPRC4126. Otherstatesorfederalareasmayhavesimilar laws.

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

Thissparkignitionsystemcomplieswiththe CanadianstandardICES-002.

WARNING

Removingstandardoriginalequipmentparts andaccessoriesmayalterthewarranty,traction, andsafetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.Makingunauthorizedchangestothe engineorfuelsystem,mayviolateEPAand CARBregulations.

Replaceallpartsincluding,butnotlimitedto, tires,belts,blades,andfuelsystemcomponents withoriginalExmarkparts.

TheenclosedEngineOwner’sManualis suppliedforinformationregardingtheUS EnvironmentalProtectionAgency(EPA)and theCaliforniaEmissionControlRegulationof emissionsystems,maintenance,andwarranty. Replacementsmaybeorderedthroughthe enginemanufacturer.

Formodelswithstatedenginehorsepower,thegross horsepoweroftheenginewaslaboratoryratedbythe enginemanufacturerinaccordancewithSAEJ1940. Asconguredtomeetsafety,emission,andoperating requirements,theactualenginehorsepoweronthis classoflawnmowerwillbesignicantlylower.

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Introduction

Readthisinformationcarefullytolearnhowto operateandmaintainyourproductproperlyandto avoidinjuryandproductdamage.Youareresponsible foroperatingtheproductproperlyandsafely .

Exmarkpartsmanualsareavailableonlineat http://www.exmark.com.YoumaycontactExmark directlyatwww .Exmark.comforproductand accessoryinformationorhelpndingadealer.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready. Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Figure1

Undertheseat

Contents

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

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

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.......................9

Specications........................................................14

ModelNumbers.............................................14

Systems..........................................................14

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

TorqueRequirements.....................................16

ProductOverview.................................................16

Operation..............................................................17

Controls.........................................................17

OperatingInstructions...................................18

RecommendedGasoline.................................19

CheckingtheEngineOilLevel........................20

StartingtheEngine.........................................20

OperatingtheBlades......................................21

StoppingtheEngine.......................................21

TheSafetyInterlockSystem............................22

DrivingForwardorBackward.........................22

StoppingtheMachine.....................................24

AdjustingtheHeightofCut............................24

AdjustingtheAnti-ScalpRollers......................24

PositioningtheSeat........................................25

ChangingtheSeatRideSuspension.................26

AdjustingtheMotionControlLevers..............26

PushingtheMachinebyHand.........................26

SideDischarge................................................27

Transporting..................................................27

OperatingTips..............................................28

Maintenance..........................................................30

RecommendedMaintenanceSchedule(s)............30

PremaintenanceProcedures...............................31

RaisingtheSeat..............................................31

PeriodicMaintenance........................................31

Lubrication.....................................................31

EngineMaintenance.......................................32

ServicingtheEngineOil.................................32

ServicingtheSparkPlug.................................34

CleaningtheBlowerHousing..........................35

FuelSystemMaintenance...............................35

ServicingtheEmissionsFilter.........................35

ElectricalSystemMaintenance........................36

ChargingtheBattery.......................................36

DriveSystemMaintenance.............................39

CheckingtheTirePressure.............................39

CheckingtheHydraulicOilLevel....................39

ChangingtheHydraulicSystemFilterand

Oil..............................................................40

MowerMaintenance.......................................42

ServicingtheCuttingBlades...........................42

LevelingtheMowerDeck...............................45

MowerBeltMaintenance................................48

ReplacingtheDischargeDeector..................50

Cleaning............................................................52

WashingtheUndersideoftheMower..............52

CleanEngineandExhaustSystem

Area...........................................................52

Storage..................................................................53

CleaningandStorage......................................53

Troubleshooting....................................................54

Schematics............................................................56

Safety

SafetyAlertSymbol

Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.

Figure2

SafetyAlertSymbol

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

Thismachinemeetsorexceedsthesafety specicationsoftheAmericanNational StandardsInstituteB71.1-2003ineffectatthe timeofproduction.However,improperuse ormaintenancebytheoperatororownercan resultininjury.Toreducethepotentialfor injury,complywiththesesafetyinstructions andalwayspayattentiontothesafetyalert symbol,whichmeansCAUTION,WARNING, orDANGER-"personalsafetyinstruction." Failuretocomplywiththeinstructionmayresult inpersonalinjuryordeath.

•Allowonlyresponsibleadultswhoarefamiliar withtheinstructionstooperatethemachine.

•Cleartheareaofobjectssuchasrocks,toys,wire, etc.,whichcouldbepickedupandthrownbythe blade.

•Besuretheareaisclearofotherpeoplebefore mowing.Stopthemachineifanyoneentersthe area.

•Nevercarrypassengers.

•DoNotmowinreverseunlessabsolutely necessary.Alwayslookdownandbehindbefore andwhilebackingup.

•Beawareofthemowerdischargedirectionand DoNotpointitatanyone.Avoiddischarging materialagainstawallorobstruction.Material mayricochetbacktowardtheoperator.Stopthe bladeswhencrossinggravelsurfaces.

•DoNotoperatethemowerwithouteitherthe entiregrasscollectionsystemorthedischarge deectorinplace.

•Bealert,slowdownandusecautionwhen makingturns.Lookbehindandtothesidebefore changingdirections.

•Neverleavearunningmachineunattended. Alwaysturnoffblades,engageparkingbrake, stopengine,andremovekeybeforedismounting.

•Turnoffbladeswhennotmowing.Stopthe engine,waitforallpartstocometoacomplete stop,engageparkingbrake,andremovekey beforecleaningthemachine,removingthegrass oruncloggingthedeector.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.1-2003.

Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

GeneralOperation

•Read,understand,andfollowallinstructionsin theoperator’smanualandonthemachinebefore starting.

•DoNotplacehandsorfeetnearrotatingpartsor underthemachine.Keepclearofthedischarge openingatalltimes.

•Operatethemachineonlyindaylightorgood articiallight.

•DoNotoperatethemachinewhileunderthe inuenceofalcoholordrugs.

•Watchfortrafcwhenoperatingnearorcrossing roadways.

•Useextracarewhenloadingorunloadingthe machineintoatrailerortruck

•Alwaysweareyeprotectionwhenoperatingthe mower.

•Dataindicatesthatoperators,age60yearsand above,areinvolvedinalargepercentageofriding mower-relatedinjuries.Theseoperatorsshould evaluatetheirabilitytooperatetheridingmower

Safety

safelyenoughtoprotectthemselvesandothers fromseriousinjury.

•Alwaysfollowtherecommendationsforwheel weightsorcounterweights.

SlopeOperation

Slopesareamajorfactorrelatedtolossofcontrol andtip-overaccidents,whichcanresultinsevere injuryordeath.Operationonallslopesrequiresextra caution.Ifyoucannotbackuptheslopeorifyoufeel uneasyonit,DoNotmowit.

•DoNotmowslopesgreaterthan15degrees.

•Watchforditches,holes,rocks,dips,andrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.

•Choosealowgroundspeedsoyouwillnothave tostopwhileoperatingonaslope.

•DoNotmowslopeswhengrassiswet.Slippery conditionsreducetractionandcouldcausesliding andlossofcontrol.

•Reducespeedanduseextremecautiononslopes.

•DoNotmakesuddenturnsorrapidspeed changes.

•Removeormarkobstaclessuchasrocks,tree limbs,etc.fromthemowingarea.Tallgrasscan hideobstacles.

•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Useextremecarewithgrasscollectionsystemsor otherattachments.Thesecanchangethestability ofthemachineandcauselossofcontrol.

•DoNottrytostabilizethemachinebyputting yourfootontheground.

•DoNotmowneardrop-offs,ditches,steepbanks orwater.Wheelsdroppingoveredgescancause rollovers,whichmayresultinseriousinjury,death ordrowning.

•Useawalkbehindmowerand/orahandtrimmer onslopesgreaterthan15degrees,neardrop-offs, ditches,steepbanksorwater.

Children

Tragicaccidentscanoccuriftheoperatorisnot alerttothepresenceofchildren.Childrenareoften attractedtothemachineandthemowingactivity. Neverassumethatchildrenwillremainwhereyou lastsawthem.

•Keepchildrenoutofthemowingareaandunder thewatchfulcareofanotherresponsibleadult, nottheoperator.

•Bealertandturnthemachineoffifchildrenenter thearea.

•Beforeandwhilebackingorchangingdirection, lookbehind,down,andside-to-sideforsmall children.

•Nevercarrychildren,evenwiththebladesoff. Theymayfalloffandbeseriouslyinjuredor interferewithsafemachineoperation.

•Childrenwhohavebeengivenridesinthepast maysuddenlyappearinthemowingareafor anotherrideandberunoverorbackedoverby themower.

•Neverallowchildrentooperatethemachine.

•Useextracarewhenapproachingblindcorners, shrubs,trees,theendofafenceorotherobjects thatmayobscurevision.

Towing

•UsefortowingonlyifequippedwithanExmark hitchkit.DoNotattachtowedequipmentexcept atthehitchpoint.

•FollowExmark’ srecommendationforweight limitsfortowedequipmentandtowingonslopes. Thisinformationcanbefoundinthehitchkit instructionsheetandonthedecal.

•Neverallowchildrenorothersinorontowed equipment.

•Onslopes,theweightofthetowedequipment maycauselossoftractionandlossofcontrol.

•Travelslowlyandallowextradistancetostop.

Service

SafeHandlingofGasoline

Toavoidpersonalinjuryorpropertydamage,use extracarewhenhandlinggasolineandotherfuels. Theyareammableandthevaporsareexplosive.

Safety

•Extinguishallcigarettes,cigars,pipesandother sourcesofignition.

•Useonlyanapprovedcontainer.

•Neverremovethegascaporaddfuelwhenthe engineisrunning.Allowtheenginetocoolbefore refueling.

•Neverrefuelthemachineindoors.

•Neverstorethemachineorfuelcontainerinside wherethereisanopename,suchasnearawater heaterorfurnace.

•Neverllcontainersinsideavehicleorona truckortrailerwithaplasticliner.Alwaysplace containersonthegroundawayfromyourvehicle beforelling.

•Removegas-poweredequipmentfromthetruck ortrailerandrefuelitontheground.Ifthisis notpossible,thenrefuelsuchequipmentwitha portablecontainer,ratherthanfromagasoline dispensernozzle.

•Keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil thefuelingiscomplete.DoNotuseanozzle lock-opendevice.

•Iffuelisspilledonclothing,changeclothing immediately.

•Neveroverllthefueltank.Replacegascapand tightensecurely.

GeneralService:

•Neverrunamachineinsideaclosedarea.

•Keepnutsandboltstight,especiallytheblade attachmentbolts.Keepequipmentingood condition.

•Nevertamperwithsafetydevices.Checktheir properoperationregularly.

•Keepthemachinefreeofgrass,leaves,orother debrisbuild-up.Cleanupoilorfuelspillageand fuelsoakeddebris.Allowthemachinetocool beforestoring.

•Stopandinspecttheequipmentifyoustrikean object.Repair,ifnecessary,beforerestarting.

•Nevermakeanyadjustmentsorrepairswiththe enginerunning.

•Grasscollectionsystemcomponentsaresubject towear,damageanddeterioration,whichcould exposemovingpartsorallowobjectstobe

thrown.Frequentlycheckcomponentsand replacewithmanufacturers’recommendedparts, whennecessary.

•Mowerbladesaresharpandcancut.Wrapthe bladesorweargloves,anduseextracautionwhen servicingthem.

•Checkforproperbrakeoperationfrequently. Adjustandserviceasrequired.

•Maintainorreplacesafetyandinstructiondecals asnecessary.

•UseonlygenuineExmarkreplacementpartsto ensurethatoriginalstandardsaremaintained.

ExmarkRidingMowerSafety

Thefollowinglistcontainssafetyinformationspecic toExmarkproductsorothersafetyinformationthat youmustknowthatisnotincludedintheANSI standards.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

•Engineexhaustcontainscarbonmonoxide,which isanodorless,deadlypoisonthatcankillyou.Do Notrunengineindoorsorinanenclosedarea.

•Parkmachineonlevelground.Stoptheengine, waitforallmovingpartstostop,engageparking brake,disconnectsparkplugwire(s)andremove keybeforeperforminganyservice,repairs, maintenanceoradjustments.

•Keephands,feet,hair,andlooseclothingaway fromattachmentdischargearea,undersideof mowerandanymovingpartswhileengineis running.

•DoNottouchequipmentorattachmentparts whichmaybehotfromoperation.Allowtocool beforeattemptingtomaintain,adjustorservice.

•Batteryacidispoisonousandcancauseburns. Avoidcontactwithskin,eyes,andclothing. Protectyourface,eyes,andclothingwhen workingwithabattery.

Safety

•Batterygasescanexplode.Keepcigarettes,sparks andamesawayfrombattery.

•UseonlyExmarkapprovedattachments. Warrantymaybevoidedifusedwithunapproved attachments.

•Ifloadingthemachineontoatrailerortruck,use asingle,full-widthramponly .Therampangle shouldnotexceed15degrees.

Note:Theleftandrightsidesofthemachineare determinedwhilesittingintheseatinthenormal operatingposition

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.

93-7009

1.Warning—don'toperatethemowerwiththedeectorup orremoved;keepthedeectorinplace.

2.Cutting/dismembermenthazardofhandorfoot,mower blade—stayawayfrommovingparts.

Safety

105-7015

ForModelswith42InchDecks

1.Beltrouting

99-3943

ForModelswith50InchDecks

1.Engine

1.Readtheinstructionsbeforeservicingorperforming maintenance.

2.Checktirepressureevery25operatinghours.

3.Greaseevery25operatinghours.

4.Engine

106-8717

Safety

110-6691

1.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.

2.Thrownobjecthazard,mower—donotoperatewithout thedeector,dischargecover,orgrasscollection systeminplace.

3.Cutting/dismembermentofhandorfoot—stayaway frommovingparts.

112-9840

1.ReadtheOperator's Manual.

2.Heightofcut

3.Removetheignitionkey andreadtheinstructions beforeservicingor performingmaintenance.

119-8814

1.Parkingposition4.Neutral

2.Fast5.Reverse

3.Slow

119-8815

1.Parkingposition4.Neutral

2.Fast5.Reverse

3.Slow

114-1606

1.Entanglementhazard,belt—keepallguardsinplace.

119-8870

50InchModel

1.Height-of-cut

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

Safety

1.Height-of-cut

1.Bypassleverpositionfor pushingthemachine

119-8871

42InchModel

121-2989

42InchModel

2.Bypassleverpositionfor operatingthemachine

Safety

116-4220

50InchModel

1.Fast

2.Continuousvariablesetting4.Choke

120-5462

42InchModel

1.Fast

2.Continuousvariablesetting4.Choke

3.Slow

Safety

120-2239

1.Warning—readtheOperator'sManual.5.Warning—donotusesplitramps,useafullrampswhen

2.Warning—readtheinstructionsbeforeservicingor performingmaintenance;movethemotioncontrollevers tothepark(brake)position,removetheignitionkeyand disconnectthesparkplugwire.

3.Cutting/dismembermenthazard,mowerblade; entanglementhazard,belt—stayawayfrommovingparts, keepallguardsandshieldsinplace.

4.Thrownobjecthazard—keepbystandersasafedistance fromthemachine,pickupdebrisbeforeoperating,keep deectorinplace.

transportingmachine.

6.Lossoftraction/controlhazard,slopes—lossof traction/controlonaslope,disengagethebladecontrol switch(PTO),proceedofftheslopeslowly.

7.Crushing/dismembermenthazardofbystanders,reversing; crushing/dismembermenthazardofbystanders—donot carrypassengers,lookbehindanddownwhenreversing.

8.Tippinghazard—donotmowslopesgreaterthan15 degrees,avoidsuddenandsharpturnswhileonslopes.

BatterySymbols

Someorallofthesesymbolsareonyourbattery .

1.Explosionhazard

2.Nore,openames,orsmoking6.Keepbystandersasafedistance

3.Causticliquid/chemicalburnhazard

4.Weareyeprotection8.Batteryacidcancauseblindnessor

5.ReadtheOperator'sManual.

fromthebattery .

7.Weareyeprotection;explosive gasescancauseblindnessand otherinjuries.

severeburns.

9.Flusheyesimmediatelywithwater andgetmedicalhelpfast.

10.Containslead;donotdiscard.

Specications

ModelNumbers

SerialNos:312,000,000andHigher

QTE651KA421;QTE691KA501;QTS691KA502

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’ s Manual

•EngineOilT ype:Exmark4-CyclePremium EngineOil

•RPM: FullSpeed:3300±100(max)RPM(NoLoad) Idle:1650(min)RPM

FuelSystem

•Capacity:3.0gal.(11.4L)

•FuelRecommendations:

–Forbestresults,useonlyclean,fresh,unleaded

gasolinewithanoctaneratingof87orhigher ((R+M)/2ratingmethod).

–Oxygenatedfuelwithupto10%ethanolor

15%MTBEbyvolumeisacceptable.

–DoNotuseethanolblendsofgasoline(such

asE15orE85)withmorethan10%ethanol byvolume.Performanceproblemsand/or enginedamagemayresultwhichmaynotbe coveredunderwarranty.

–DoNotusegasolinecontainingmethanol.

–DoNotstorefueleitherinthefueltankor

fuelcontainersoverthewinterunlessafuel stabilizerisused.

–DoNotaddoiltogasoline.

•FuelFilter:

•Polarity:NegativeGround

•Fuses:One30amp,one25amp;bladetype

SafetyInterlockSystem

•PTOmustbedisengaged,motioncontrollevers out(brakeengaged)tostartengine.(Itisnot necessaryfortheoperatortobeintheseatto starttheengine.)

•OperatormustbeinseatwhenPTOisengaged ormotioncontrolleversaremovedinorengine willstop.

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutraland appliestheparkingbrake.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•DeckHeightAdjustmentLever:Setscutting heighttodesiredposition.

•DeckLiftAssistLever:Footpedalthatassistsin raisingthedeck.

KawasakiP/N49019-7005

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:195CCA

•BatteryVoltage:12Volt

Seat

•Type:

–42inchunit:Standardseatwithhighback,

foampaddedwithspringsuspensionand armrests.

–50inchunit:Twotoneupholsteredseatwith

springsuspensionandarmrests.

Specications

•Mounting:Hingedtotiltupforaccesstobattery andothercomponents.Adjustableforeandaft.

•Armrests:Standard–paddedip-uparmrests.

•SeatSafetySwitch:IncorporatedintotheSafety InterlockSystem.

HydrostaticGroundDriveSystem

•HydrostaticPumps:

–42inchunit:TwoHydroGearZT2100

Integrateddrivesystems.

–50inchE-Seriesunit:TwoHydroGear

ZT2200Integrateddrivesystems.

–50inchS-Seriesunit:TwoHydroGear

ZT2800Integrateddrivesystems.

•HydraulicOilType:ExmarkPremiumHydroOil.

•Speeds:

–0-7.0mph(11.3km/hr)forward.

–0-5.0mph(8.0km/hr)reverse.

•Drivewheelreleases,locatedonleftandright sidesofenginedeck,allowmachinetobemoved whentheengineisnotrunningandbrakeisoff.

CuttingDeck

•CuttingWidth:

–42inchDeck:42inches(107cm)

–50inchDeck:50inches(127cm)

•Discharge:Side

•BladeSize:

–42inchDeck:21.60inches(54.9cm)–Qty:2

–50inchDeck:17.50inches(44.5cm)–Qty:3

•BladeSpindles:Solidsteelspindleswithno maintenancebearings.

•DeckDrive:Electricclutchmountedonvertical engineshaft.Bladesaredrivenbyonebelt (w/self-tensioningidler)directfromtheengine.

•Deck:Fulloatingdeckisattachedtoout-front supportframe.Maximumturfprotectionis providedwithanti-scalprollers.

Deckdesignallowsforbagging,mulchingorside discharge.

•DeckDepth:

–42inchDeck:4.0inches(10.2cm)

TiresandWheels

Drive

Pneumatic(Air-Filled)

DeckSize

Quantity

Tread

Size18x7.50-818x9.50-820x8-10

PlyRating

Pressure

DeckSize

Quantity

Tread

Size

PlyRating

Pressure

4250E-Series50S-Series

222

Hoosier Premium

13psi (90kPa)

4250

Smooth

410/350x4

20psi (138kPa)

Hoosier Premium

13psi (90kPa)

FrontCaster

Pneumatic(Air-Filled)

Ribbed

13x5-6

13psi (90kPa)

CarlisleTurf Master

13psi (90kPa)

–50inchDeck:4.0inches(10.2cm)

•CuttingHeightAdjustment:Ahanddeckliftlever withfootassistisusedtoadjustthecuttingheight from11/2inch(3.8cm)to41/2inches(11.4 cm)in1/2inch(1.3cm)increments.

•MulchingKit:Optional.

Dimensions

OverallWidth:

42inchDeck50inchDeck

WithoutDeck39.0inches

(99cm)

DeectorUp45.3inches

(115cm)

DeectorDown53.8inches

(137cm)

OverallLength:

42inchDeck50inchDeck

71.8inches(182cm)72.9inches(185cm)

46.3inches (118cm)

54.6inches (139cm)

63.0inches (160cm)

ProductOverview

OverallHeight:

AllUnits

41.5inches(105cm)

TreadWidth:(CentertoCenterof Tires,Widthwise)

42inchDeck50inchDeck

DriveWheels31.5inches

(80cm)

CasterWheels29.5inches

(75cm)

37.4inches (95cm)

36.9inches (94cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

AllUnits

45.6inches(116cm)

CurbWeight:

42inchDeck50inchE-Series

Deck

531lb(241kg)614lb(279kg)672lb(305kg)

50inchS-Series Deck

ProductOverview

Figure3

1.Frontcasterwheel

2.Anti-scalproller9.Engine

3.Height-of-cutfootlever10.Seat

4.Dischargedeector

5.Deckheightadjustment lever

6.Washouttting

7.Reardrivewheel14.Footrest

8.Controlpanel

11.Fueltank

12.Armrest

13.Motioncontrollevers

TorqueRequirements

BoltLocation

SpindlePulleyNut35-65ft-lb(47-88N-m)

BladeMountingBolt35-65ft-lb(47-88N-m)

EngineMountingBolts

WheelLugNuts

ClutchMountingBolt (securedwiththreadlocker)

Torque

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

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

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

Operation

Controls

Note:Becomefamiliarwithallofthecontrolsin

Figure3andFigure4beforeyoustarttheengineand operatethemachine.

IgnitionSwitch

Locatedoncontrolpanel.

Theignitionswitchisusedtostartandstopthe engine.Theswitchhasthreepositions“OFF”, “RUN”and“START”( switchandrotateclockwisetothe“ON”position. Rotateclockwisetothenextpositiontoengagethe starter(keymustbeheldagainstspringpressurein thisposition).

Figure4).Insertkeyinto

BladeControlSwitch(Power Take-Off)

Locatedonthecontrolpanel.

Thebladecontrolswitch,representedbyapower take-off(PTO)symbol,engagesanddisengages powertothemowerblades(see

Pulloutonthebladecontrolswitchto“On”to engagetheblades.

Pushthebladecontrolswitchto“Off”todisengage theblades.

Figure4).

ThrottleLever

Locatedoncontrolpanel.

Thethrottleisusedtocontrolenginespeed.Moving throttleleverforwardwillincreaseenginespeedand movingthrottlelevertotherearwilldecreaseengine speed.Movingthethrottleforwarduntilitstopsis fullthrottle(see

Figure4).

Figure4

1.Ignitionswitch

2.Throttlelever4.Bladecontrolswitch

Note:Brakemustbeengaged(motioncontrollevers out)andPTOswitch“OFF”tostartengine.(Itis notnecessaryfortheoperatortobeintheseatto starttheengine.)

TurningthekeytotheOffpositionwillstopthe engine;however,alwaysremovethekeywhenleaving themachinetopreventsomeonefromaccidentally startingtheengine.

3.Chokecontrol

(powertake-off)

ChokeControl

Thechokeisusedtoaidinstartingacoldengine. Pullinguponthechokecontrolwillputthechokein the“ON”positionandpushingdownthecontrolwill putthechokeinthe“OFF”position.DoNotruna warmenginewiththechokeinthe“ON”position.

MotionControlLeversandParking BrakePosition

Themotioncontrolleverslocatedoneachsideof theseat(Figure3).

Themotioncontrolleversarespeedsensitivecontrols ofindependentwheelmotors.Movingalever forwardorbackwardturnsthewheelonthesameside forwardorinreverse;wheelspeedisproportionalto theamounttheleverismoved.Movingthecontrol leversoutwardfromthecenterpositionengagesthe parkingbrakeonthedrivewheels.Alwaysposition themotioncontrolleversintotheparkingbrake positionwhenyoustopthemachineorleaveit unattended.Theunitmustbetieddownandbrake engagedwhentransporting.

DeckHeightAdjustmentLever

LocatedbelowtheRHmotioncontrollever (Figure3).

Operation

Pulltheleverinwardandrearwardtoraisethecutting deck.Allowthehandletomoveforwardtolowerthe cuttingdeck.Movethedeckheightadjustmentlever outwardatthedesiredheight-of-cut.Onlyadjustthe heightofcutwhilethemachineisnotmoving.

Height-of-CutFootLever

Theheight-of-cutfootleverallowstheoperatorto usetheirlegtoassistinloweringandraisingthedeck fromtheseatedposition(Figure3).Whenthelever ismovedforward,awayfromtheoperatorthedeck israisedfromthegroundandwhenmovedback, towardstheoperatoritisloweredtowardtheground.

FuelWindow

Locatedontheleftsideofthemachine(seeFigure5).

Thefuelwindowcanbeusedtoverifythepresence offuelinthetank.

DANGER

Mowingonwetgrassorsteepslopescancause slidingandlossofcontrol.Wheelsdropping overedgescancauserollovers,whichmayresult inseriousinjury,deathordrowning.Alossof tractionisalossofsteeringcontrol.

Toavoidlossofcontrolandpossibilityofrollover:

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon slopes.

•Whenmowingslopes,graduallyworkfrom lowertohigherareasontheincline.

•Avoidsuddenturnsorrapidspeedchanges.

•Turnup,intoaninclinewhenchanging directionsonslopes.Turningdowntheslope reducestraction.

•Attachmentschangethehandling characteristicsofthemachine.Useextra cautionwhenusingattachmentswiththe machine.

Figure5

1.Fuelcap2.Fuelwindow

OperatingInstructions

ThinkSafetyFirst

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Pleasecarefullyreadallofthesafetyinstructionsand decalsinthesafetysection.Knowingthisinformation couldhelpyou,yourfamily,petsorbystandersavoid injury.

Figure6

1.Water

2.DangerZone–Usewalkbehindmowerand/orhand trimmeronslopesgreaterthan15degrees,near drop-offsandwater.

3.SafeZone–usetheQuesthere.

Seeinsidebackcovertodeterminetheapproximate slopeangletobemowed.

Operation

RecommendedGasoline

Fillfueltankonlevelground.SeeFuel RecommendationsintheSpecicationssectionfor

additionalgasolineinformation.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe tankallowsgasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineoremission system.

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburnyou, others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground,in anopenarea,whentheengineiscold.Wipe upanygasolinethatspills.

•Neverrellthefueltankordrainthemachine indoorsorinsideanenclosedtrailer.

•DoNotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthebodyofthe tankisfullbutfueldoesnotlltheneckof thetank.Thisemptyspaceinthetankallows gasolinetoexpand.

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Never buymorethana30-daysupplyofgasoline.

•DoNotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcause propertydamage.

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebeforelling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowtheloss ofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimes untilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascausedcancer inlaboratoryanimals.Failuretousecautionmay causeseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof30daysor less.Forlongerstorageitisrecommendedthat thefueltankbedrained.

•Cleanstheenginewhileitruns.

•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstartingAddthe

Operation

correctamountofgasstabilizer/conditionerto thegas.

Note:Afuelstabilizer/conditionerismosteffective whenmixedwithfreshgasoline.Tominimizethe chanceofvarnishdepositsinthefuelsystem,usefuel stabilizeratalltimes.

FillingtheFuelTank

Makesuretheengineisshutoffandthemotion controlsareintheparkposition.Tankmaximum capacityis2.9gallons.

Important:DoNotoverllfueltank.Fillthe fueltanktothebottomofthellerneck.The emptyspaceinthetankallowsthefueltoexpand. Overllingmayresultinfuelleakageordamage totheengineoremissionsystem.

1.Shuttheengineoffandmovethemotioncontrols outwardtoengageparkingbrake.

2.Cleanaroundthefueltankcapandremovethe cap.

Figure7

1.Fuelcap4.Fillopening

2.Fuelwindow

3.Emptyspaceforfuel expansion

5.Baseofllerneck,DO

NOTFILLPASTHERE

6.Fuel

3.Addunleadedregulargasolineuntilthefuel reachesthebaseofthellerneckanddoesnot lltheneckofthetank(

Figure7).Thisspace atthebaseofthellerneckallowsgasolineto expand.DoNotllthefueltankcompletelyfull. Overllingmayresultinfuelleakageordamage totheengineoremissionssystem.

4.Installthefueltankcapsecurelyandtightenuntil it“clicks”.Wipeupanygasolinethatmayhave spilled.

CheckingtheEngineOil Level

Beforeyoustarttheengineandusethemachine, checktheoillevelintheenginecrankcase;referto CheckingtheOilLevelinEngineMaintenance section.

StartingtheEngine

1.Sitdownontheseatandmovethemotion controlsoutwardtoengagetheparkingbrake.

2.Disengagethebladesbymovingthebladecontrol switchtoOff(Figure8).

Figure8

1.Ignitionkey5.Throttlelever

2.Off6.Chokecontrol

3.Run7.Bladecontrol switch—Offposition

4.Start

Operation

2.MovethethrottlemidwaytotheFastposition.

Note:Alwaysengagethebladeswiththethrottle inthemidwayposition.

3.Pulloutonthebladecontrolswitch,totheOn position,toengagetheblades(

Figure9).

3.Pulluponthechokecontroltoengagethechoke beforestartingacoldengine(Figure8).

Note:Awarmorhotenginemaynotrequire choking.

4.TurntheignitionkeytoStarttoenergizethe starter.Whentheenginestarts,releasethekey

Figure8).

(

Important:DoNotengagethestarterfor morethan5secondsatatime.Iftheengine failstostart,allowa60secondcool-down periodbetweenattempts.Failuretofollow theseinstructionscanburnoutthestarter motor.

5.Oncetheenginestarts,graduallypushdownthe chokecontrolastheenginewarms.Iftheengine stallsorhesitates,slightlypullthecontrolupfor afewseconds.

OperatingtheBlades

Thebladecontrolswitch,representedbyapower take-off(PTO)symbol,engagesanddisengages powertothemowerblades.Thisswitchcontrols powertoanyattachmentsthatdrawpowerfromthe engine,includingthemowerdeckandcuttingblades.

EngagingtheBlades

Figure9

1.Throttle–Midwayposition2.Bladecontrol switch—Onposition

4.Movethrottletofullforwardpositionbefore mowing.

DisengagingtheBlades

Setthrottletomidwayposition.Pushtheblade controlswitchtoOfftodisengagetheblades (Figure8).

StoppingtheEngine

1.Bringtheunittoafullstop.

2.Disengagetheblades.

3.Movethemotioncontrolleversouttoengagethe parkingbrake.

4.Placethethrottlemidwaybetweenthe“SLOW” and“FAST”positions.

5.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

6.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

1.Releasepressureonthemotioncontrolleversand placethemachineinneutral.

Operation

TheSafetyInterlockSystem

CAUTION

Ifthesafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitches beforeoperatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:

•Thebladesaredisengaged.

•Themotioncontrolleversareintheneutral position.

•Theparkingbrakeisengaged.

Thesafetyinterlocksystemisdesignedtoinitiate engineshutdownwhen:

•Theparkingbrakeisdisengagedandtheoperator getsoffmachine.

•ThePTOisengagedandtheoperatorgetsoff machine.

•Theparkingbrakeisdisengagedandleversarein andtheoperatorgetsoffmachine.

TestingtheSafetyInterlockSystem

donotgetoffofmachine)enginemustinitiate shutdown.

Runengineatone-thirdthrottle,withbrake disengaged,moveleversinandraiseoffseat(but donotgetoffofmachine)enginemustinitiate shutdown.

Note:Ifmachinedoesnotpassanyofthesetests, DoNotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

DrivingForwardorBackward

Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolintheFastpositionforbest performance.AlwaysoperateintheFast(fullthrottle) position.

CAUTION

Machinecanspinveryrapidlybypositioningone levertoomuchaheadoftheother.Operatormay losecontrolofthemachine,whichmaycause damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

Testthesafetyinterlocksystembeforeyouusethe machineeachtime

1.Checkstartingcircuit.Startershouldcrankwith thePTOdisengagedandmotioncontrollevers movedoutintheparkingbrakeposition.The operatordoesnotneedtobeintheseattostart theengine.

Trytostartwithoperatorinseat,PTO disengagedandmotioncontrolleversinthe parkingbrakeposition-startermustnotcrank.

Trytostartwithoperatorinseat,PTO

disengaged,andtheleftmotioncontrollever in,startermustnotcrank,repeatagainwiththe rightleverin,thenwithbothleversin-starter mustnotcrank.

2.Checkkillcircuits.Runengineatone-third throttle,engagePTOandraiseoffofseat(but

Forward

1.Movetheleverstothecenter,unlockedposition.

2.Togoforward,slowlypushthemotioncontrol leversforward(

Figure10).

Operation

G008952

Figure10

1.Parkingbrakeposition (engaged)

2.Centerunlockposition (neutral)

3.Frontofunit

4.Forward

5.Backward

Togostraight,applyequalpressuretoboth motioncontrollevers(

Figure10andFigure11).

Figure11

Toturn,pullbackonthemotioncontrol levertowardthedirectionyouwanttoturn (Figure10andFigure11).

Thefartheryoumovethemotioncontrollevers ineitherdirection,thefasterthemachinewill moveinthatdirection.

Tostop,pullthemotioncontrolleverstoneutral.

Backward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotioncontrol leversrearward(Figure10andFigure12).

Operation

G008953

adjustmentleverinwardandpullingup.The heightcanalsobeadjustedbymovingthedeck heightadjustmentleverinwardandpushingthe height-of-cutfootleverforward( transportleverwillautomaticallyengageandwill dropintoplace.

Figure12

Figure13).The

Togostraight,applyequalpressuretoboth motioncontrollevers(Figure10andFigure12).

Toturn,releasethepressureonthemotion controllevertowardthedirectionyouwantto turn(Figure10andFigure12).

Tostop,pushthemotioncontrolleverstoneutral.

StoppingtheMachine

Tostopthemachine,movethemotioncontrollevers toneutral,disengagethebladecontrolswitch,move themotioncontrolleversoutwardtoengagethe parkingbrake,movethethrottlelevertobetween Fastandhalfthrottle,andturntheignitionkeyto off.Remembertoremovethekeyfromtheignition switch.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemowerwhileit isunattended.

Alwaysremovetheignitionkeyandmove themotioncontrolleversoutwardtoapply theparkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.

AdjustingtheHeightofCut

1.Raisethedecktothetransportposition(4.5inch (114mm)cutheight)bymovingthedeckheight

Figure13

1.Height-of-cutfootlever3.Height-of-cutpositions

2.Deckheightadjustment lever

2.Pushthefootleverforward,pullthedeckheight adjustmentleverhandleinwardandletthedeck lowerdowntothedesiredcutheightbyslowly decreasingfootpressureallowingthefootleverto travelrearward.Movethedeckheightadjustment leveroutwardatthedesiredheight-of-cut.

4.Transportposition–4.5 inch(115mm)

AdjustingtheAnti-Scalp Rollers

Itisrecommendedtochangetheanti-scalproller positionwhentheheightofcuthaschanged.

1.Stopthemachineandmovethedriveleversto theneutralposition.

2.DisengagethePTO.

3.Movethemotioncontrolleversoutwardto engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingthenylocnut.

6.Adjusttheanti-scalprollersforthenormal operatingconditions.Placerollersinoneof

Operation

G014477

thepositionsshowninFigure15.Rollerswill maintain3/4inches(19mm)clearancetothe groundtominimizegougingandrollerwearor damage.

Note:ForMaximumDeckFlotation,place therollersoneholepositionlower.Rollersshould maintain1/4inch(6.35mm)clearancetothe ground.DoNotadjustrollerstosupportthe deck.

Figure14

42InchDeck

1.Anti-scalprollermountingbracket

2.Below21/2inches(64mm)cuttingheight

3.21/2inches(64mm)andabovecuttingheight

1.Tiptheseatforward.

2.Loosentheadjustmentbolts.

Figure16

1.Adjustmentbolt

3.Movetheseattothedesiredpositionand tightenbolts.

4.Tiptheseatbacktotheclosedposition.

•50InchUnits:

1.Pushtheadjustmentlevertowardsthecenter ofthemachinetoreleasetheseatadjuster

Figure17).

track(

Figure15

50InchDeck

Forcuttingheightsabove31/2inches(90mm)

usethebottomhole.Therollerswillstillbeeffective

againstscalping.

1.Anti-scalproller mountingbracket

7.Torquehardwareto27-33ft-lb(37-45N-m)or

2.Cuttingheight

Figure17

lossofrollermayresult.

1.Adjustmentlever

PositioningtheSeat

2.Movetheseattothedesiredpositionand

Theseatcanmoveforwardandbackward.Position

releasethelevertolockinthatposition.

theseatwhereyouhavethebestcontrolofthe machineandaremostcomfortable.

•42InchUnit:

Operation

ChangingtheSeatRide Suspension

Thenumberofseatspringscanbechangedto maximizeridercomfort.Morespringsshouldbeused withheavieroperatorsandonroughterrain.Fewer springsshouldbeusedwithlighteroperatorsand whenmowingsmooth,wellestablishedlawns.Always keepthenumberofspringsontheleftandrightside thesamewhenaddingandremovingsprings.

Figure19

Figure18

1.Bolt3.Nut

2.Spring

Uptovespringscanbesecuredtotheseatboxwith anutandbolt,seeFigure18.

RefertoyourPartsManualforspringandhardware partnumbers.

4.Additionalmounting holes

1.Controlarmshaft

2.Controllever

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththehardware.

3.Repeattheadjustmentfortheoppositecontrol lever.

3.Washer

4.Bolt

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraft( boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

Figure19).Tightenboth

AdjustingtheMotionControl Levers

AdjustingtheHeight

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethehardwareholdingthecontrolleverto thecontrolarmshaft(Figure19).

PushingtheMachineby Hand

Important:Alwayspushthemachinebyhand.

Nevertowthemachinebecausedamagemay occur.

Thismachinehasanelectricbrakemechanismandto pushthemachinetheignitionkeyneedstobeinthe Runposition.Thebatteryneedstobechargedand functioningfortheelectricbraketobedisengage.

ToPushtheMachine

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

Operation

g017303

1 2

2.Movethemotioncontrolleversoutwardtopark position,stoptheengine,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Locatethebypassleversontheframeonboth sidesoftheengine.

4.Movethebypassleversforwardthroughthekey holeanddowntolocktheminplaceasshownin Figure20.Ensurethisisdoneforeachlever.

5.Movethemotioncontrolleversinwardtothe neutralpositionandturntheignitionkeytothe runposition.DoNotstartthemachine.

Themachineisnowabletobepushedbyhand.

SideDischarge

Themowerhasahingeddischargedeectorthat dispersesclippingstothesideanddowntowardthe turf.

DANGER

Withoutthedischargedeector,mulchkit,or entiregrasscollectionsystemmountedinplace, youandothersareexposedtobladecontactand throwndebris.Contactwithrotatingmower blade(s)andthrowndebriswillcauseinjuryor death.

•Neverremovethedischargedeectorfrom themowerbecausethedischargedeector routesmaterialdowntowardtheturf.Ifthe dischargedeectoriseverdamaged,replace itimmediately.

•Neverputyourhandsorfeetunderthe mower.

•Nevertrytocleardischargeareaormower bladesunlessyoumovethemovetheblade controlswitchtoOffandrotatetheignition keytoOff.Alsoremovethekeyandpullthe wireoffthesparkplug(s).

Figure20

1.Bypassleverlocation

2.Leverpositionfor operatingthemachine

3.Leverpositionfor pushingthemachine

6.Whennished,ensurethekeyhasbeenreturned totheStoppositiontoavoiddrainingthebattery charge.

Ifthemachinefailstomovetheelectricbrakemay stillbeengaged.Ifnecessarytheelectricbrakecan bereleasedmanually.RefertotheReleasingthe ElectricBrakeprocedureinDriveMaintenance.

ToOperatetheMachine

Movethebypassleversrearwardthroughthekey holeanddowntolocktheminplaceasshownin Figure20.Ensurethisisdoneforeachlever.

Transporting

TransportingaUnit

Useaheavy-dutytrailerortrucktotransportthe machine.Lockbrakeandblockwheels.Securely fastenthemachinetothetrailerortruckwithstraps, chains,cable,orropes.Besurethatthetrailerortruck hasallnecessarylightingandmarkingasrequiredby law .Secureatrailerwithasafetychain.

CAUTION

Thisunitdoesnothaveproperturnsignals, lights,reectivemarkings,oraslowmoving vehicleemblem.Drivingonastreetorroadway withoutsuchequipmentisdangerousand canleadtoaccidentscausingpersonalinjury. Drivingonastreetorroadwaywithoutsuch equipmentmayalsobeaviolationofStatelaws andtheoperatormaybesubjecttotrafctickets and/ornes.

DoNotdriveaunitonapublicstreetorroadway.

Operation

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over.Backward tip-overcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit onaramp.

•Useonlyasingle,fullwidthramp;DoNot useindividualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.

•DoNotexceeda15°anglebetweenrampand groundorbetweenrampandtrailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

LoadingaUnit

Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinstead ofindividualrampsforeachsideoftheunit.The lowerrearsectionofthetractorframeextendsback betweentherearwheelsandservesasastopfor tippingbackward.Havingafullwidthrampprovides asurfacefortheframememberstocontactifthe unitstartstotipbackward.Ifitisnotpossibletouse onefullwidthramp,useenoughindividualrampsto simulateafullwidthcontinuousramp.

Rampshouldbelongenoughsothattheangles betweentherampandthegroundandtherampand thetrailerortruckDoNotexceed15°.Asteeper anglemaycausemowerdeckcomponentstoget caughtastheunitmovesfromramptotraileror truck.Steeperanglesmayalsocausetheunittotip backward.Ifloadingonornearaslope,position thetrailerortrucksoitisonthedownsideofthe slopeandtherampextendsuptheslope.Thiswill minimizetherampangle.Thetrailerortruckshould beaslevelaspossible.

OperatingTips

FastThrottleSetting

Forbestmowingandmaximumaircirculation, operatetheengineattheFastposition.Airisrequired tothoroughlycutgrassclippings,soDoNotsetthe height-of-cutsolowastototallysurroundthemower byuncutgrass.Alwaystrytohaveonesideofthe mowerfreefromuncutgrass,whichallowsairtobe drawnintothemower.

CuttingaLawnfortheFirstTime

Cutgrassslightlylongerthannormaltoensurethat thecuttingheightofthemowerdoesnotscalpany unevenground.However,thecuttingheightusedin thepastisgenerallythebestonetouse.Whencutting grasslongerthansixinchestall,youmaywanttocut thelawntwicetoensureanacceptablequalityofcut.

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrowsmore slowly.

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhich enhancesdecompositionandfertilization.

MowatCorrectIntervals

Normally,moweveryfourdays.Butremember, grassgrowsatdifferentratesatdifferenttimes. Sotomaintainthesamecuttingheight,whichisa goodpractice,mowmoreofteninearlyspring.As thegrassgrowthrateslowsinmidsummer,mow lessfrequently.Ifyoucannotmowforanextended period,rstmowatahighcuttingheight;thenmow againtwodayslateratalowerheightsetting.

CuttingSpeed

Important:DoNotattempttoturntheunit

whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

Toimprovecutquality ,useaslowergroundspeed.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthe moweryoupreviouslyused,raisethecuttingheight toensurethatuneventurfisnotcuttooshort.

LongGrass

Ifthegrassiseverallowedtogrowslightlylonger thannormal,orifitcontainsahighdegreeof moisture,raisethecuttingheighthigherthanusual andcutthegrassatthissetting.Thencutthegrass againusingthelower,normalsetting.

WhenStopping

Ifthemachine’sforwardmotionmustbestopped whilemowing,aclumpofgrassclippingsmaydrop ontoyourlawn.T oavoidthis,moveontoapreviously cutareawiththebladesengaged.

KeeptheUndersideoftheMower Clean

Cleanclippingsanddirtfromtheundersideofthe moweraftereachuse.Ifgrassanddirtbuildupinside themower,cuttingqualitywilleventuallybecome unsatisfactory.

Operation

BladeMaintenance

Maintainasharpbladethroughoutthecuttingseason becauseasharpbladecutscleanlywithouttearingor shreddingthegrassblades.Tearingandshredding turnsgrassbrownattheedges,whichslowsgrowth andincreasesthechanceofdisease.Checkthe cutterbladesdailyforsharpness,andforanywearor damage.Filedownanynicksandsharpentheblades asnecessary.Ifabladeisdamagedorworn,replace itimmediatelywithagenuineExmarkreplacement blade.OnlyExmarkbladesaretobeusedwiththis unit.Nootherbladesareapproved.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

Removethekeyfromtheignitionswitch,engage parkingbrake,andpullthewire(s)offthespark plug(s)beforeyoudoanymaintenance.Also pushthewire(s)asidesoitdoesnotaccidentally contactthesparkplug(s).

WARNING

Theenginecanbecomeveryhot.T ouchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

RecommendedMaintenanceSchedule(s)

WARNING

Replaceallpartsincluding,butnotlimitedto, tires,belts,blades,andfuelsystemcomponents withoriginalExmarkparts.

MaintenanceService

Interval

Aftertherst5hours

Aftertherst50hours

Beforeeachuseordaily

Every25hours

Every100hours

Every200hours

Every400hours

MaintenanceProcedure

•Changetheengineoil.

•Changethehydraulicsystemlterandoil.

•Checkthesafetyinterlocksystem.

•Checktheoillevelbeforestartingorafterevery8hours.

•Checkthemowerblades.

•Cleanthemowerhousing.

•Cleantheengineandexhaustsystemarea.

•Greasealllubricationpoints.

•Checktheaircleanerfordirt,looseness,ordamage.(Mayneedmoreoftenunderextremely dustyordirtyconditions.)

•Checkthetirepressure.

•Checkthehydraulicoillevelintheexpansiontank.

•Checkthebelts.

•Servicethepaperelement.(moreoftenindusty ,dirtyconditions)

•Changetheengineoilandlter.

•Cleantheblowerhousing.Moreoftenunderdirtyconditions.

•Replacethefuellter.

•Replacethepaperelement.(moreoftenindusty,dirtyconditions)

•Servicethesparkplug.

•Changethehydraulicsystemlterandoil.

Every500hours

•Replacethesparkplug.

Maintenance

G007184

MaintenanceService

Interval

Beforestorage

Monthly

Yearly

Important:RefertoyourEngineOperator'sManualforadditionalmaintenanceprocedures.

Premaintenance

MaintenanceProcedure

•Chargethebatteryanddisconnectthebatterycables.

•Performallmaintenanceprocedureslistedabovebeforestorage.

•Paintanychippedsurfaces.

•Checkthebatterycharge.

•Inspecttheemissionslter.

PeriodicMaintenance

Procedures

Lubrication

RaisingtheSeat

Makesurethemotioncontrolleversarelockedinthe parkposition.Lifttheseatforward.

Thefollowingcomponentscanbeaccessedbyraising theseat:

•Serialplate

•Servicedecal

GreasingtheBearings

ServiceInterval:Every25hours/Monthly

(whichevercomesrst)

GreaseType:NGLIgrade#2multi-purposegun grease.

Greasethefrontcasterwheels(Figure21).

•Seatadjustmentbolts

•Fuellter

•Batteryandbatterycables

Figure21

1.Frontcastertire

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardto engageparkingbrake,stoptheengine,removethe key,andwaitforallmovingpartstostopbefore leavingtheoperatingposition.

3.Cleanthegreasettingsshownin arag.Makesuretoscrapeanypaintoffofthe frontofthetting(s).

Figure22with

Maintenance

G014908

Figure22

Locatedontheseatpan

1.Readtheinstructionsbeforeservicingorperforming maintenance.

2.Checktirepressureevery25operatinghours.

3.Greaseevery25operatinghours.

4.Engine

4.Wipeupanyexcessgrease.

Figure23

EngineMaintenance

1.Cover

2.Paperelement

3.Hoseclamp

ServicingtheAirCleaner

ServiceInterval:Every25hours/Monthly

(whichevercomesrst) (Mayneedmoreoften underextremelydustyor dirtyconditions.)

Checktheaircleanerdailyorbeforestartingthe engine.Checkforabuildupofdirtanddebrisaround theaircleanersystem.Keepthisareaclean.Also checkforlooseordamagedcomponents.Replaceall bentordamagedaircleanercomponents.

Note:Operatingtheenginewithlooseordamaged aircleanercomponentscouldallowunlteredairinto theenginecausingprematurewearandfailure.

Note:Servicetheaircleanermoreoftenunder extremelydusty,dirtyconditions.

1.Parkthemachineonalevelsurface,disengagethe bladecontrolswitch,movethemotioncontrol leverstothebrakeposition,stoptheengine,and removethekey .

2.Cleanaroundtheaircleanercovertopreventdirt fromgettingintotheengineandcausingdamage. Liftthecoverandremovethehoseclampsecuring theaircleanerassemblytotheengine(

Figure23).

3.Loosenthehoseclampandremovethepaper element(Figure23).

CleaningtheElement

ServiceInterval:Every100hours—Service

thepaperelement.(more oftenindusty ,dirty conditions)

Every200hours/Yearly (whichevercomes rst)—Replacethepaper element.(moreoftenin dusty,dirtyconditions)

1.Lightlytaptheelementonaatsurfacetoremove dustanddirt.

2.Inspecttheelementfortears,anoilylm,and damagetotheseal.

Important:Nevercleanthepaperelement withpressurizedairorliquids,suchas solvent,gas,orkerosene.Replacethepaper elementifitisdamagedorcannotbecleaned thoroughly.

ServicingtheEngineOil

CheckingtheOilLevel

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface,disengage thebladecontrolswitch,stoptheengine,engage parkingbrake,andremovethekey.

Maintenance

2.Makesuretheengineisstopped,level,andiscool sotheoilhashadtimetodrainintothesump.

3.Tokeepdirt,grassclippings,etc.,outof theengine,cleantheareaaroundtheoilll cap/dipstickbeforeremovingit.

4.Removetheoilllcap/dipstick;wipeoiloff. Reinsertthedipstickpushintoplace,butDoNot screwitin(

Figure24).

Changetheoilandlterwhiletheengineisstill warm.Theoilwillowmorefreelyandcarryaway moreimpurities.Makesuretheengineislevelwhen lling,checking,orchangingtheoil.

1.Starttheengineandletitrununtilwarm.This warmstheoilsoitdrainsbetter.

2.Disengagethebladecontrolswitchandmovethe motioncontrolsoutwardtotheparkingbrake position.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Cleantheareaaroundtheoildrainvalveandon themachineframe.

5.Installtheoildrainhose,locatedintheliterature pack,ontotheoildrainvalve(

Figure25).Remove

theoilllcap/dipstick.

Figure24

1.Oildipstick3.Oillevel

2.Fillertube

5.Removethedipstickandchecktheoillevel.

Theoillevelshouldbeupto,butnotover,the “FULL”markonthedipstick.

6.Ifthelevelislow ,wipeofftheareaaroundtheoil llcap,removecapandaddoiltothe“FULL” markonthedipstick.Exmark4-CyclePremium EngineOilisrecommended;refertotheEngine Owner'smanualforanacceptablealternative. Alwayscheckthelevelwiththedipstickbefore addingmoreoil.DoNotoverll.

Note:Topreventextensiveenginewearor damage,alwaysmaintaintheproperoillevelinthe crankcase.Neveroperatetheenginewiththeoil levelbelowthe“ADD”markoroverthe“FULL” markonthedipstick.

Figure25

1.Oillter4.Oildrainhose

2.Oilllcap/dipstick

3.Oildrainvalve

5.Pan

6.Placeapanundertheopenendofthehose.

7.Openthedrainvalvebyturninghexend counterclockwise.Besuretoallowampletime forcompletedrainage.

ChangingtheOilandFilter

ServiceInterval:Aftertherst5hours

Every100hours/Yearly (whichevercomesrst) thereafter.

8.Removetheoldlterandwipeoffthemounting pad.

9.Whentheoilhasdrainedcompletely ,closetheoil drainvalvebyrotatingitclockwiseandremove

Maintenance

andretainthehose.Wipeupanyexcessoilon theframe(Figure25).

Note:Disposeoftheusedoilatarecycling center.

10.ApplyathinlmofcleanExmark4-Cycle PremiumEngineOiltotherubbergasketonthe newlter.

11.Installthereplacementoilltertothemounting pad.Turntheoillterclockwiseuntiltherubber gasketcontactsthepad,thentightenthelteran additional1/2to3/4turn.

12.Slowlypourapproximately80%ofthespecied oilintothellertube—useoilrecommendedin theCheckingtheOilLevelsection.

13.Installtheoilllcap/dipstickandpushintoplace, butDoNotscrewitin.

14.Checktheoillevel(

Figure24);refertoChecking

theOilLevelsection.

15.Slowlyaddadditionaloiltobringittothefull mark.DoNotoverll.

16.Installtheoilllcap/dipstick.

17.Starttheengineandcheckforleaks.

ServicingtheSparkPlug

ServiceInterval:Every200hours/Every2

years(whichevercomes rst)

Every500hours—Replace thesparkplug.

Note:Duetothedeeprecessaroundthespark

plug,blowingoutthecavitywithcompressedair isusuallythemosteffectivemethodforcleaning. Thesparkplugismostaccessiblewhentheblower housingisremovedforcleaning.

3.Removethesparkplugandmetalwasher.

Figure26

1.Sparkplugandwirelocation

CheckingtheSparkPlug

1.Lookatthecenterofthesparkplug(Figure27). Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingon theinsulatorusuallymeanstheaircleanerisdirty.

Important:Nevercleanthesparkplug. Alwaysreplacethesparkplugwhenithasa blackcoating,wornelectrodes,anoilylm, orcracks.

2.Checkthegapbetweenthecenterandside electrodes( thegapisnotcorrect.

Figure27).Bendthesideelectrodeif

Asstatedinthemaintenanceintervals,removethe sparkplug,checkcondition,andresetthegapor replacewithanewplugasnecessary.

ThesparkplugisRFIcompliant.Equivalentalternate brandplugscanalsobeused.

Type:NGKBPR4ES(orequivalent)

AirGap:0.030inch(0.76mm)

RemovingtheSparkPlug

1.Disengagethebladecontrolswitch,movethe motioncontrolsoutwardtotheparkposition, stoptheengine,andremovethekey.

2.Pullthewireoffofthesparkplug(Figure26). Cleanaroundthesparkplugtopreventdirtfrom fallingintotheengineandpotentiallycausing damage.

Figure27

1.Sideelectrode3.Airgap(nottoscale)

2.Centerelectrode insulator

InstallingtheSparkPlug

1.Installthesparkplug.Makesurethattheairgap issetcorrectly.

2.Tightenthesparkplugto16ft-lb(22N-m).

3.Pushthewireontothesparkplug(

Figure26).

Maintenance

CleaningtheBlowerHousing

ServiceInterval:Every100hours/Yearly

(whichevercomesrst) Moreoftenunderdirty conditions.

Toensurepropercooling,makesurethegrassscreen, coolingns,andotherexternalsurfacesoftheengine arekeptcleanatalltimes.

1.Removetheblowerhousingandanyothercooling shrouds.

2.Cleanthecoolingnsandexternalsurfacesas necessary.

3.Makesurethecoolingshroudsarereinstalled

Important:Operatingtheenginewithablocked grassscreen,dirtyorpluggedcoolingns, and/orcoolingshroudsremoved,willcause enginedamageduetooverheating.

FuelSystemMaintenance

3.Thefuellterisinthefuellinebetweenthetank andengine.

Figure28

1.Teetting,ventline5.In-linefuellter

2.Emissionslter

3.Openport

4.Fuellinefromtank

6.Flowdirectionarrow

7.Fuellinetoengine

8.Hoseclamp

ReplacingtheFuelFilter

ServiceInterval:Every100hours/Yearly

(whichevercomesrst)

DANGER

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areor explosionfromgasolinecanburnyouandothers andcandamageproperty.

•Performanyfuelrelatedmaintenancewhen theengineiscold.Dothisoutdoorsinan openarea.Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,and stayawayfromanopenameorwherea sparkmayignitethegasolinefumes.

Neverinstalladirtylterifitisremovedfromthe fuelline.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

4.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure28).

5.Removethelterfromthefuellines.

6.Installanewlterwiththeowdirectionarrow comingfromthefueltankandpointingtothe engine.Movethehoseclampsclosetothelter

Figure28)tosecureitinplace.

(

ServicingtheEmissions Filter

ServiceInterval:Yearly

Themachineisequippedwithaemissionslter (Figure28)connectedtoateettingontheventline comingfromthegastank.Thelterhasanopenport bydesign.Theltershouldbeinspectedregularly. Replacethelterifthelterisdirtyorclogged.

2.Movethemotioncontrolleversoutwardto engageparkingbrake,stoptheengine,removethe key,andwaitforallmovingpartstostopbefore leavingtheoperatingposition.

Maintenance

ElectricalSystem Maintenance

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

ChargingtheBattery

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,Do Notallowthebatteryterminalstotouchany metalpartsofthemachine.

•DoNotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

DANGER

Batteryelectrolytecontainssulfuricacid,which ispoisonousandcancausesevereburns. Swallowingelectrolytecanbefatalorifittouches skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber glovestoprotectskinandclothingwhen handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately.

CAUTION

Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagementof components.Sparkscouldcauseanexplosionor movingpartscouldaccidentallyengagecausing personalinjury.

Besureignitionswitchisinthe“OFF”position beforechargingthebattery.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardto engageparkingbrakestoptheengine,removethe key,andwaitforallmovingpartstostopbefore leavingtheoperatingposition.

3.Raisetheseat.

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesawayfrom battery.

•Ventilatewhenchargingorusingbatteryin anenclosedspace.

•Makesureventingpathofbatteryisalways openoncebatteryislledwithacid.

•Alwaysshieldeyesandfacefrombattery.

4.Disconnectthenegative(black)groundcable fromthebatterypost( fasteners.

Figure29).Retainall

Maintenance

Note:Topreventdamageduetofreezing,

batteryshouldbefullychargedbeforeputting awayforwinterstorage.

3.Checkthevoltageofthebatterywithadigital voltmeter.Locatethevoltagereadingofthe batteryinthetablebelowandchargethebattery fortherecommendedtimeintervaltobringthe chargeuptoafullchargeof12.6voltsorgreater.

Important:Makesurethenegativebattery cableisdisconnectedandthebatterycharger usedforchargingthebatteryhasanoutputof 16voltsand7ampsorlesstoavoiddamaging thebattery(seechartbelowforrecommended chargersettings).

Figure29

1.Negativebatterypost4.Positivebatterypost

2.Bolt,washer,andnut5.Batterystrap

3.Terminalboot6.Battery

WARNING

Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks. Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.

•Alwaysdisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.

•Alwaysconnectthepositive(red)battery cablebeforeconnectingthenegative (black)cable.

5.Slidetherubbercoverupthepositive(red)cable. Disconnectthepositive(red)cablefromthe batterypost.Retainallfasteners.

6.Removethebatterystrap(Figure29)andliftthe batteryfromthebatterytray.

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

14.4volts/2 amps

RecommendedJumpStarting Procedure

1.Checktheweakbatteryforterminalcorrosion (white,green,orblue“snow”),itmustbecleaned offpriortojumpstarting.Cleanandtighten connectionsasnecessary.

Charging Interval

No Charging Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

CheckingtheBatteryCharge

1.Removethebatteryfromthechassis;referto RemovingtheBattery.

2.Allowingbatteriestostandforanextended periodwithoutrechargingthemwillresultin reducedperformanceandservicelife.T opreserve optimumbatteryperformanceandlife,recharge batteriesinstoragewhentheopencircuitvoltage dropsto12.4volts.

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe enginemayoccur.

Maintenance

DANGER

Jumpstartingaweakbatterythatiscracked, frozen,haslowelectrolytelevel,oran open/shortedbatterycell,cancausean explosionresultinginseriouspersonalinjury.

DoNotjumpstartaweakbatteryifthese conditionsexist.

2.Makesuretheboosterisagoodandfullycharged leadacidbatteryat12.6voltsorgreater.Use properlysizedjumpercables(4to6AWG)with shortlengthstoreducevoltagedropbetween systems.Makesurethecablesarecolorcodedor labeledforthecorrectpolarity .

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricalsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

Figure30

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

5.Connecttheblacknegative(–)cabletotheother terminal(negative)oftheboosterbattery.

Note:Thefollowinginstructionsareadapted fromtheSAEJ1494Rev.Dec.2001–Battery BoosterCables–SurfaceV ehicleRecommended Practice(SAE–SocietyofAutomotive Engineers).

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

Note:Besuretheventcapsaretightandlevel. Placeadampcloth,ifavailable,overanyvent capsonbothbatteries.Besurethevehiclesdo nottouchandthatbothelectricalsystemsare offandatthesameratedsystemvoltage.These instructionsarefornegativegroundsystemsonly .

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure30.

6.MAKETHEFINALCONNECTIONON THEENGINEBLOCKOFTHESTALLED VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK.

7.Startthevehicleandremovethecablesinthe reverseorderofconnection(theengineblock (black)connectionisthersttodisconnect).

InstallingtheBattery

1.Positionthebatteryinthetraywiththeterminal poststowardtheoperatingposition(Figure29).

2.Installthepositive(red)batterycabletothe positive(+)batteryterminalusingthefasteners removedpreviously.

3.Installthenegativebatterycabletothenegative (-)batteryterminalusingthefastenersremoved previously.

4.Slidetheredterminalbootontothepositive(red) batterypost.

5.Securethebatterywiththestrap(Figure29).

Maintenance

G014921

G015000

ServicingtheFuses

ServiceInterval:Asrequired

Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance;however,ifafuseblows,checkthe component/circuitforamalfunctionorshort.

Fuse:

•MainF1-30amp,blade-type

•ChargeCircuitF2-25amp,blade-type

1.Removethefourscrewssecuringthecontrol paneltothemachine.Retainallfasteners

2.Liftthecontrolpaneuptoaccessthemainwiring harnessandfuseblock(Figure31).

3.Toreplaceafuse,pulloutonthefusetoremove

Figure31).

it(

FrontTires(casterwheels):

•Ribbed:13psi(90kPa)

•Smooth:20psi(138kPa)

Figure32

1.Valvestem

ReleasingtheElectricBrake

ServiceInterval:Asrequired

Theelectricbrakecanbereleasebymanuallyrotating thelinkarmsforward.Oncetheelectricbrakeis energizedthebrakewillreset.

Figure31

1.Main-30amp

2.Chargecircuit-25amp

4.Returnthecontrolpaneltoitsoriginalposition. Usethefourscrewsremovedpreviouslytosecure thepaneltothemachine.

DriveSystemMaintenance

CheckingtheTirePressure

ServiceInterval:Every25hours/Monthly

Maintaintheairpressureinthefrontandreartiresas specied.Uneventirepressurecancauseunevencut. Checkthepressureatthevalvestem(Figure32).

Checkthetireswhentheyarecoldtogetthemost accuratepressurereading.

(whichevercomesrst)

Toreleasethebrake:

Figure33

1.Brakelinkarmontheelectricbrakecontrolmodule

1.Locatetheshaftontheelectricbrakewherethe brakelinkarmsareconnected.

2.Rotatetheshaftforwardtoreleasethebrake.

CheckingtheHydraulicOil Level

RearTires:13psi(90kPa)

ServiceInterval:Every25hours

Maintenance

g017656

g017658

g017660

1 2 3

2 1

Checkexpansionreservoirandifnecessaryadd 20W-50engineoiltotheFULLCOLDline.

Figure35

1.Jackingpoints

3.Removethenutsholdingthetransaxlesupportin place(Figure36).

Figure34

1.Expansionreservoir3.Engine

2.FullColdline

ChangingtheHydraulic SystemFilterandOil

ServiceInterval:Aftertherst50hours

Every400hoursthereafter.

Thelterandoilarechangedatthesametime.Do Notreuseoil.Oncethenewlterisinstalledandoil

isaddedanyairinthesystemmustbepurged.

Thebleedingprocessisrepeateduntiltheoilremains attheFULLCOLDlineinthereservoirafterpurging.

Failuretoproperlyperformthisprocedurecan resultinirreparabledamagetothetransaxle drivesystem.

RemovingHydraulicSystemFilters

1.Stopengine,waitforallmovingpartstostop,and allowenginetocool.Removethekeyandengage theparkingbrake.

2.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

Figure36

1.Nut(5/16inch)(27to33 ft-lb)

2.Nut(3/8inch)(15to19 ft-lb)

3.Transaxlesupport

4.Locatethelterandlterguardsoneachtransaxle drivesystem(Figure37).Removethreescrews securingthelterguardandguard.

G010254

Rightsideshown

G008748

3/4

Maintenance

InstallingtheHydraulicSystem Filters

Figure37

1.Transaxledrive

2.Oillter

3.Filterguard

5.Carefullycleanareaaroundlters.Itisimportant thatnodirtorcontaminationenterhydraulic system.

6.Placeacontainerbelowtheltertocatchthe oilthatdrainswhenthelterandventplugsare removed.

7.Locateandremovetheventplugoneach transmission

8.Unscrewtheltertoremoveandallowoilto

Repeatthisprocedureforbothlters.

drainfromdrivesystem.

4.Screws

5.Ventplug

Figure38

1.Applyathincoatofoilonthesurfaceofthe rubbersealofeachlter.

2.Turnthelterclockwiseuntilrubbersealcontacts thelteradapterthentightenthelteran additional3/4to1fullturn.Repeatfortheother lter

3.Installthelterguardsovereachlteras previouslyremoved.Usethethreescrewsto securethelterguards.

4.Verifytheventplugsareremovedbeforeadding theoil.

5.Slowlypourthespeciedoilthroughexpansion reservoiruntiloilcomesoutofoneofthevent plugholes.Stopandinstallthatventplug.T orque theplugto180in-lb(20.3N-m).

6.Continuetoaddoilthroughtheexpansion reservoiruntiloilcomesoutoftheremaining ventplugholeonthesecondtransmission.Stop

Maintenance

andinstallthatventplug.T orquetheplugto180 in-lb(20.3N-m).

7.Continuetoaddoilthroughtheexpansion reservoiruntilitreachestheFULLCOLDlineon theexpansionreservoir.

8.Installthetransaxleguard.Referto thecorrecttorquevaluesforthenutsandbolts.

9.ProceedtotheBleedingtheHydraulicSystem section.

Important:Failuretoperformthe

the Hy draulic System

changinghydraulicltersandoilcanresult inirreparabledamagetothetransaxledrive system.

procedureafter

Figure36for

BleedingtheHydraulicSystem

1.Entertheoperator'sposition.Startengineand movethrottlecontrolaheadto1/2throttle position.Disengageparkingbrake.

A.Movethebypassleversintothepushingthe

machineposition;refertothePushingthe MachinebyHandsectioninOperation.With thebypassvalvesopenandtheenginerunning, slowlymovethemotioncontrolleversinboth forwardandreverse(5or6times).

B.Movethebypassleversintotheoperating

themachineposition.Withthebypassvalve closedandtheenginerunning,slowlymove thedirectionalcontrolinbothforwardand reversedirections(5to6times).

C.Stoptheengineandchecktheoillevelinthe

expansionreservoir.Addthespeciedoilas untilitreachestheFULLCOLDlineonthe expansionreservoir.

MowerMaintenance

ServicingtheCuttingBlades

ServiceInterval:Beforeeachuseordaily

Maintainsharpbladesthroughoutthecuttingseason becausesharpbladescutcleanlywithouttearingor shreddingthegrassblades.Tearingandshredding turnsgrassbrownattheedges,whichslowsgrowth andincreasesthechanceofdisease.

Bleeding

Checkthecutterbladesdailyforsharpness,andfor anywearordamage.Filedownanynicksandsharpen thebladesasnecessary.Ifabladeisdamagedor worn,replaceitimmediatelywithagenuineExmark replacementblade.Forconvenientsharpeningand replacement,youmaywanttokeepextrabladeson hand.

WARNING

Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownintotheoperator's orbystander'sarea,resultinginseriouspersonal injuryordeath.

•Inspectthebladeperiodicallyforwearor damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

Parkthemachineonalevelsurface,disengagethe bladecontrolswitch,andmovethemotioncontrol leversoutwardtoengageparkingbrake.Stopthe engine,removethekey,anddisconnectthesparkplug wire(s)fromthesparkplug(s).

2.Repeatstep1untilalltheairiscompletelypurged fromthesystem.

Whenthetransaxleoperatesatnormalnoise levelsandmovessmoothlyforwardandreverseat normalspeeds,thenthetransaxleisconsidered purged.

3.Checktheoillevelintheexpansionreservoirone lasttime.Addthespeciedoilasuntilitreaches theFULLCOLDlineontheexpansionreservoir ifnecessary.

InspectingtheBlades

1.Inspectthecuttingedges(Figure39).Iftheedges arenotsharporhavenicks,removeandsharpen theblades;refertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea.If younoticeanydamage,wear,oraslotformingin thisarea(item3in anewblade.

Figure39),immediatelyinstall

Figure39

G014972

G014973

G014974

1.Cuttingedge3.Wear/slotforming

2.Curvedarea

4.Damage

CheckingforBentBlades

Note:Themachinemustbeonalevelsurfacefor

thefollowingprocedure.

1.Raisethemowerdecktothehighestheight-of-cut position;alsoconsideredthe'transport'position.

Maintenance

Figure41

1.Blade,inpositionformeasuring

2.Levelsurface

3.Measureddistancebetweenbladeandsurface(A)

4.Rotatethesameblade180degreessothatthe opposingcuttingedgeisnowinthesameposition.

2.Whilewearingthicklypaddedglovesorother adequatehandprotectionslowlyrotatebladeto bemeasureintoapositionthatallowseffective measurementofthedistancebetweenthecutting edgeandthelevelsurfacethemachineison.

Figure40

1.Deck3.Blade

2.Spindlehousing

3.Measurefromthetipofthebladetotheat surfacehere.

Figure42

1.Blade,sidepreviouslymeasured

2.Measurementpositionusedpreviously

3.Opposingsideofbladebeingmovedintomeasurement position

5.Measurefromthetipofthebladetotheat surfacehere.Thevarianceshouldbenomore than1/8inch(3mm).

Maintenance

G014973

G014975

Figure43

1.Opposingbladeedge,inpositionformeasuring

2.Levelsurface

3.Secondmeasureddistancebetweenbladeandsurface (B)

WARNING

Awornordamagedbladecanbreak,anda pieceofthebladecouldbethrownintothe operator'sorbystander'sarea,resultingin seriouspersonalinjuryordeath.

•Inspectthebladeperiodicallyforwearor damage.

thicklypaddedglove,trytorotatetheblade.Ifthe bladerotatesrelativetothespindleguardwithout furthertighteningthebladebolt,thespring discwasherhasbeenattenedordamagedand theboltandwasherassemblymustbereplaced (Figure44).RefertoRemovingtheBladesand InstallingtheBlades.

3.Oncethebladehasbeenremoved,inspectthe springdiscwasher.Ifthewasherappearstobe damaged(thewashersurfacehasbeenmarred) orattened,theboltandwasherassemblymust bereplaced.

RemovingtheBlades

Thebladesmustbereplacedifasolidobjectishit,if thebladeisoutofbalance,orthebladeisbent.To ensureoptimumperformanceandcontinuedsafety conformanceofthemachine,usegenuineExmark replacementblades.Replacementbladesmadeby othermanufacturersmayresultinanunsafemachine.

Holdthebladeendusingaragorthickly-padded glove.Removethebladebolt,curvedwasher,and bladefromthespindleshaft(

Figure44).

•Replaceawornordamagedblade.

A.IfthedifferencebetweenAandBisgreater

than1/8inch(3mm)replacethebladewitha newblade.RefertoRemovingtheBladesand InstallingtheBlades.

Note:Ifabentbladeisreplacedwithanew oneandthedimensionobtainedcontinues toexceed1/8inch(3mm),thebladespindle couldbebent.ContactanAuthorizedExmark Dealerforservice.

B.Ifthevarianceiswithinconstraints,moveto

thenextblade.

Repeatthisprocedureoneachblade.

CheckingforLooseBladesor DamagedSpringDiscWashers

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

2.Withthewrenchstillonthebladebolt,hold thebladespindlestationaryandusingaragor

Figure44

1.Sailareaofblade3.Curvedwasher

2.Blade4.Bladebolt

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure45).Maintaintheoriginal angle.Thebladeretainsitsbalanceifthesame amountofmaterialisremovedfrombothcutting edges.

Maintenance

G009682

LevelingtheMowerDeck

Checktoensurethemowerdeckislevelanytime youinstallthemowerorwhenyouseeanunevencut onyourlawn.

Figure45

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure46).Ifthebladestaysina horizontalposition,thebladeisbalancedandcan beused.Ifthebladeisnotbalanced,lesome metalofftheendofthesailareaonly(Figure46). Repeatthisprocedureuntilthebladeisbalanced.

Figure46

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure44).

Important:Thecurvedpartoftheblade mustbepointingupwardtowardtheinsideof themowertoensurepropercutting.

Themowerdeckmustbecheckedforbentblades priortoleveling;anybentbladesmustberemoved andreplaced.RefertotheCheckingforBent Bladesprocedurebeforecontinuing.

Themowerdeckmustbeleveledside-to-siderst thenthefronttorearslopecanbeadjusted.

Requirements:

•Themachinemustbeonalevelsurface.

•Allfourtiremustbeproperlyinated.Referto CheckingtheTirePressureintheDriveSystem Maintenancesection.

Side-to-SideLeveling

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe parkposition,stoptheengine,removethekey, andwaitforallmovingpartstostopbefore leavingtheoperatingposition.

3.Settheheight-of-cutlevertomiddleposition.

4.Carefullyrotatethebladessothattheyareallside toside(

Figure47andFigure48).

2.Holdthebladeendusingaragorthickly-padded glove(orplaceawrenchonthetopsheavenut). Applylubricanttothethreadsofthebladebolt asneededtopreventseizing.Copperbased anti-seizeispreferable.Greaseisanacceptable substitute.Installthewasherandbladeboltand washerassembly.

3.Torquethebladeboltto35-65ft-lb(47-88N-m).

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecause thebladetocomelooseandcouldseriously injureorkillyouorbystanders.

AlwaysinstalltheoriginalExmarkblades, washersandbladeboltsasshown.

Figure47

42InchDecks

1.Bladessidetoside

2.Sailareaofblade4.Measurefromthetip

3.Outsidecuttingedges

ofthebladetotheat surfacehere

Maintenance

G005278

G015323

G014633

Figure48

50InchDecks

Figure49

1.Bladessidetoside

2.Sailareaofblade4.Measurefromthetip

3.Outsidecuttingedges

ofthebladetotheat surfacehere

5.Measurebetweentheoutsidecuttingedgesand theatsurface(Figure47andFigure48).Ifboth measurementsarenotwithin3/16inch(5mm), anadjustmentisrequired;continuewiththis procedure.

6.Supporttheweightofmowerdeckbyplacing woodblocksundertheedgesofthedeck.

Note:Avoidplacingthesupportsunderany anti-scalprollersifpresentonthedeck.

7.Movetotheleftsideofthemachine.Remove thesidecarriageboltandlockingnutfromthe xedpositionandinstallitintotherear,slotted positionandleaveitslightlyloose(

Figure49).

1.Hangerbracket

2.Slottedadjustment position

3.Fixedposition

4.Sidelockingnut

5.Sidecarriagebolt

8.Loosenthesidelockingnutonthehangerbracket justenoughtoallowthehangertobeadjusted (Figure50).Usethenotchesonthewelded brackettomeasuretheamountofadjustment. Eachnotchsurfaceisequivalentto1/16ofan inch.Adjusttheheightofthemowerdecktothe desiredheight.

Figure50

1.Hangerbracket

2.Rearlockingnut4.Adjustmentnotches

3.Sidelockingnut

9.Stopthedeckattheadjustedpositionandtighten thesidelockingnutonthehangerbrackettohold

thenewposition(Figure50).Tightentherear

G009658

G009659

G014634

lockingnutonthehangerbracket.

10.Continuelevelingthedeckbycheckingthe front-to-rearbladeslope;refertoAdjustingthe Front-to-RearBladeSlope.

AdjustingtheFront-to-RearBlade Slope

Checkthefront-to-rearbladelevelanytimeyouinstall themower.Ifthefrontofthemowerismorethan 5/16inch(7.9mm)lowerthantherearofthemower, adjustthebladelevelusingthefollowinginstructions:

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

Maintenance

Figure52

50InchDecks

1.Bladesfronttorear

2.Outsidecuttingedges

3.Measurefromthetipofthebladetotheatsurfacehere

2.Movethemotioncontrolleversoutwardtothe parkposition,stoptheengine,removethekey, andwaitforallmovingpartstostopbefore leavingtheoperatingposition.

3.Settheheight-of-cutlevertomiddleposition.

Note:Checkandadjusttheside-to-sideblade levelifyouhavenotcheckedthesetting;referto Side-to-SideLeveling.

4.Carefullyrotatethebladessotheyarefacingfront torear(

Figure51andFigure52).

Figure51

42InchDecks

5.Measurefromthetipofthefrontbladetotheat surfaceandthetipoftherearbladetotheat surface(

Figure51andFigure52).Ifthefront bladetipisnot1/16-5/16inch(1.6-7.9mm)lower thantherearbladetip,adjustthefrontlocknut.

6.Toadjustthefront-to-rearbladeslope,rotate theadjustmentnutinthefrontofthemower

Figure53).

(

1.Bladesfronttorear

2.Measurefromthetipofthebladetotheatsurfacehere

1.Adjustingrod3.Locknut

2.Adjustingblock

Figure53

7.Toraisethefrontofthemower,tightenthe

adjustmentnut.Tolowerthefrontofthemower, loosentheadjustmentnut.

8.Afteradjustment,checkthefront-to-rearslope again.Continueadjustingthenutuntilthefront

Maintenance

G014635

G005077

bladetipis1/16-5/16inch(1.6-7.9mm)lower thantherearbladetip(Figure51andFigure52).

9.Whenthefront-to-rearbladeslopeiscorrect checktheside-to-sidelevelofthemoweragain; refertoLevelingtheMowerfromSide-to-Side.

RemovingtheMower

ServiceInterval:Asrequired

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe parkposition,stoptheengine,removethekey, andwaitforallmovingpartstostopbefore leavingtheoperatingposition.

3.Lowertheheight-of-cutlevertothelowest position.

4.Removethehairpincotterfromthefrontsupport rodandremovetherodfromthedeckbracket

Figure54).Carefullylowerthefrontofthe

( mowerdecktotheground.

Figure55

1.Mowerdeck

2.Hangerbracket

3.Rearliftrod

6.Slidethemowerdeckrearwardtoremovethe mowerbeltfromtheenginepulley.

7.Slidethemowerdeckoutfromunderneaththe machine.

Note:Retainallpartsforfutureinstallation.

MowerBeltMaintenance

InspectingtheBelts

ServiceInterval:Every25hours/Monthly

(whichevercomesrst)

Checkthebeltsforcracks,frayededges,burnmarks, oranyotherdamage.Replacedamagedbelts.

ReplacingtheMowerBelt

Squealingwhenthebeltisrotating,bladesslipping whencuttinggrass,frayedbeltedges,burnmarks, andcracksaresignsofawornmowerbelt.Replace themowerbeltifanyoftheseconditionsareevident.

Figure54

1.Frontsupportrod3.Deckbracket

2.Lockingnut

5.Liftthemowerdeckandhangerbracketsclearof therearliftrodandlowerthemowercarefullyto theground(Figure55).

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe parkposition,stoptheengine,removethekey, andwaitforallmovingpartstostopbefore leavingtheoperatingposition.

3.Settheheight-of-cutatthelowestcuttingposition

G014930

G014931

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

4.Usingaspringremovaltool,(P/N.92-5771), removetheidlerspringfromthedeckhookto removetensionontheidlerpulleyandrollthe beltoffofthepulleys(

Figure56andFigure57).

WARNING

Thespringisundertensionwheninstalled andcancausepersonalinjury.

Becarefulwhenremovingthebelt.

Maintenance

Figure57

50InchDeck

1.Idlerpulley

2.Mowerbelt5.Enginepulley

3.Outsidepulley6.Springremovaltool

4.Spring

5.Routethenewbeltaroundtheenginepulleyand mowerpulleys(Figure57).

6.Usingaspringremovaltool,(P/N92-5771), installtheidlerspringoverthedeckhookand placingtensionontheidlerpulleyandmowerbelt (Figure56andFigure57).

Figure56

42InchDeck

1.Idlerpulley

2.Mowerbelt5.Enginepulley

3.Outsidepulley6.Springremovaltool

4.Spring

InstallingtheMower

ServiceInterval:Asrequired

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe parkposition,stoptheengine,removethekey, andwaitforallmovingpartstostopbefore leavingtheoperatingposition.

3.Slidethemowerunderthemachine.

4.Lowertheheight-of-cutlevertothelowest position.

5.Lifttherearofthemowerdeckandguidethe hangerbracketsovertherearliftrod(

Figure55).

Maintenance

G005192

6.Attachthefrontsupportrodtothemowerdeck withtheclevispinandhairpincotter(Figure54).

7.Installthemowerbeltontotheenginepulley; refertoReplacingtheMowerBelt.

ReplacingtheDischarge Deector

DANGER

Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator’sor bystander’sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.

Neveroperatethelawnmowerunlessyouinstall amulchplate,dischargedeector,orgrass collectionsystem.

Inspectthedischargedeectorfordamagebefore eachuse.Replaceanydamagedpartsbeforeuse.

•42inchand50inchE-SeriesDeck

1.LocateitemsshowninFigure58.

4.Replacethedischargedeector.

5.Sliderod,straightend,throughtherear dischargedeectorbracket.

6.Placethespringontherod,withendwires down,andbetweenthedischargedeector brackets.Sliderodthroughseconddischarge deectorbracket.

7.Insertrodatfrontofdischargedeectorinto shortstand-offondeck.Securerearendof rodintothemowerwithanut(3/8inch).

Important:Thedischargedeectormust bespringloadedinthedownposition. Liftthedeectoruptotestthatitsnapsto thefulldownposition.

•50inchS-SeriesDeck

1.Disengagethespringfromthenotchinthe deectorbracketandslidetherodoutofthe weldeddeckbrackets,spring,anddischarge deector(

Figure59).Removethedamagedor

worndischargedeector.

1.Mowerdeck

2.Dischargedeector6.Nut(3/8inch)

3.Dischargedeector bracket

4.Rod

2.Removethenut(3/8inch)fromtherodunder themower.

3.Slidetherodoutoftheshortstand-off, spring,anddischargedeector.Removethe damagedorworndischargedeector.

Figure58

5.Spring

7.Shortstand-off

Maintenance

g017617

g017618

Figure60

1.Rodandspring assemblyinstalled

2.Loopendofthespring installedintothenotchin thedeectorbracket

3.Rod,shortend,moved behindmowerbracket

4.Shortend,retainedby mowerbracket.

5.Securetherodandspringassemblybytwisting itsotheshortendoftherodcanbeplaced behindthefrontbracketweldedtothedeck

1.Rod4.Deckbrackets

2.Spring5.Springinstalledoverthe

3.Deectorassembly

Figure59

rod

(Figure60).

Important:Thegrassdeectormustbe springloadedinthedownposition.Lift thedeectoruptotestthatitsnapstothe fulldownposition.

2.Positionthenewdischargedeectorassembly withthebracketendsbetweenthewelded bracketsonthedeckasshowninFigure59.

3.Installthespringontothestraightendofthe rod.Positionthespringontherodasshown insotheshorterspringendiscomingfrom undertherodbeforethebendandgoingover therodasitreturnsfromthebend.

4.Lifttheloopendofthespringandplace itintothenotchonthedeectorassembly bracket(

Figure60).

Maintenance

Cleaning

WashingtheUndersideof theMower

ServiceInterval:Beforeeachuseor

daily—Cleanthemower housing.

Washtheundersideofthemoweraftereachuseto preventgrassbuildupforimprovedmulchactionand clippingdispersal.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe parkposition,stoptheengine,removethekey, andwaitforallmovingpartstostopbefore leavingtheoperatingposition.

3.Attachthehosecouplingtotheendofthemower washouttting,andturnthewateronhigh

Figure61).

(

6.Disengagethebladecontrolswitch,stopthe engine,andremovetheignitionkey.Waitforall movingpartstostop.

7.Turnthewateroffandremovethecouplingfrom thewashouttting.

Note:Ifthemowerisnotcleanafterone washing,soakitandletitstandfor30minutes. Thenrepeattheprocess.

8.Runthemoweragainforonetothreeminutes toremoveexcesswater.

WARNING

Abrokenormissingwashoutttingcould exposeyouandotherstothrownobjectsor bladecontact.Contactwithbladeorthrown debriscancauseinjuryordeath.

•Replacebrokenormissingwashouttting immediately,beforeusingmoweragain.

•Neverputyourhandsorfeetunderthe mowerorthroughopeningsinthemower.

Note:Spreadpetroleumjellyonthewashout ttingO-ringtomakethecouplingslideoneasier andprotecttheO-ring.

Figure61

1.Washouttting3.O-ring

2.Hose

4.Lowerthemowertothelowestheight-of-cut.

5.Sitontheseatandstarttheengine.Engagethe bladecontrolswitchandletthemowerrunfor onetothreeminutes.

4.Coupling

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancauseengine, exhaustarea,andhydraulicsystemtooverheat whichcancreatearehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea.

Storage

CleaningandStorage

1.Disengagethebladecontrolswitch,movethe motioncontrolsoutwardtotheparkposition, stoptheengine,andremovethekey.

2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engine.Cleandirtandchafffromtheoutsideof theenginecylinderheadnsandblowerhousing.

Important:Youcanwashthemachinewith milddetergentandwater.Donotpressure washthemachine.Avoidexcessiveuseof water,especiallynearthecontrolpanel,under theseat,aroundtheengine,hydraulicpumps, andmotors.

3.Servicetheaircleaner;refertoServicingtheAir CleanerintheEngineMaintenancesection.

4.Greaseandoilthemachine;refertothe Lubricationsection.

5.Changethecrankcaseoilandlter;refer toServicingtheEngineOilintheEngine Maintenancesection.

6.Checkthetirepressure;refertoCheckingthe TirePressureintheDriveSystemMaintenance section.

7.Chargethebattery;refertoServicingtheBattery intheElectricalSystemMaintenancesection.

8.Checktheconditionoftheblades;referto ServicingtheCuttingBladesintheMower Maintenancesection.

9.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachinefor storageasfollows.

Stoptheengine,allowittocool,anddrainthe fueltank;refertoDrainingtheFuelTankinthe FuelSystemMaintenancesection.

Restarttheengineandrunituntilitstops.

Choketheengine.Startandruntheengineuntil itwillnotstart.

Disposeoffuelproperly.Recyclepursuantto localcodes.

Important:Donotstore stabilizer/conditionedgasolineover 30days.

11.Removethesparkplug(s)andcheckitscondition; refertoServicingtheSparkPlugintheEngine Maintenancesection.Withthesparkplug(s) removedfromtheengine,pourtwotablespoons ofengineoilintothesparkplughole.Usethe startertocranktheengineanddistributetheoil insidethecylinder.Installthesparkplug(s).Do notinstallthewireonthesparkplug(s).

12.Cleananydirtandchafffromthetopofthe mower.

13.Scrapeanyheavybuildupofgrassanddirtfrom theundersideofthemower,thenwashthemower withagardenhose.

14.Checktheconditionofthedriveandmowerbelts.

15.Checkandtightenallbolts,nuts,andscrews. Repairorreplaceanypartthatiswornor damaged.

16.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

17.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitchand keepitinamemorableplace.Coverthemachine toprotectitandkeepitclean.

10.Addapetroleumbasedstabilizer/conditioner tothefuelinthetank.Followthemixing instructionsfromthestabilizermanufacturer.Do notuseanalcoholbasedstabilizer(ethanolor methanol).

Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshgasolineandused atalltimes.

Runtheenginetodistributetheconditionedfuel throughthefuelsystem(5minutes).

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,DoNotoverlookthesimplecauses.Forexample:startingproblemscouldbe causedbyanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDONotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Theengineoverheats.

Thestarterdoesnotcrank

Enginewillnotstart,startshard,orfailsto keeprunning

1.Theengineloadisexcessive.1.Reducegroundspeed.

2.Theoillevelinthecrankcaseislow.

3.Thecoolingnsandairpassagesunder theengineblowerhousingareplugged.

4.Theaircleanerisdirty.

5.Dirt,water,orstalefuelisinfuelsystem.

1.Thebladecontrolswitchisengaged.1.Movethebladecontrolswitchto

2.Themotioncontrolleversarenotinthe parkposition.

3.Theoperatorisnotseated.

4.Batterydoesnothaveafullcharge.

5.Theelectricalconnectionsarecorroded orloose.

6.Afuseisblown.

7.Arelayorswitchisdamaged.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .1.Fillthefueltank.

2.Thechokeisnoton.2.MovethechokelevertoOn.

3.Theaircleanerisdirty.

4.Thesparkplugwire(s)islooseor disconnected.

5.Thesparkplug(s)ispitted,fouled,orthe gapisincorrect.

6.Thereisdirtinfuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel system.

8.Thereisincorrectfuelinthefueltank.

9.Theoillevelinthecrankcaseislow.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthecooling nsandairpassages.

4.Cleanorreplacetheaircleanerelement.

5.ContactanAuthorizedServiceDealer.

Disengaged.

2.Movethemotioncontrolleversoutward totheparkposition.

3.Sitontheseat.

Chargethebattery.SeeCheck

BatteryChargeandRecommended JumpStartingProceduresectionsin

Maintenance.

5.Checktheelectricalconnectionsforgood contact.

6.Replacethefuse.

3.Cleanorreplacetheaircleanerelement.

4.Installthewire(s)onthesparkplug.

5.Installanew,correctlygappedspark plug(s).

7.ContactanAuthorizedServiceDealer.

8.Drainthetankandreplacethefuelwith thepropertype.

9.Addoiltothecrankcase.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Enginelosespower

Themachinedoesnotdrive.

Abnormalvibration

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

5.Thesparkplug(s)ispitted,fouled,orthe gapisincorrect.

6.Dirtinfuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel system.

8.Thereisincorrectfuelinthefueltank.

1.Thedrivebeltsareworn,loose,orbroken.1.ContactanAuthorizedServiceDealer.

2.Thedrivebeltsareoffofthepulleys.2.ContactanAuthorizedServiceDealer.

3.Thedriveisinbypassmode.3.Takemachineoutofbypassmode.Refer

1.Enginemountingboltsareloose.1.Tightentheenginemountingbolts.

2.Looseenginepulley,idlerpulley,orblade pulley.

3.Enginepulleyisdamaged.3.ContactanAuthorizedServiceDealer.

4.Cuttingblade(s)is/arebentorunbalanced.

5.Bladeisloose.5.Tightentheblademountingboltand

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.Installanew,correctlygappedspark plug(s).

7.ContactanAuthorizedServiceDealer.

8.Drainthetankandreplacethefuelwith thepropertype.

toPushingtheMachinebyHand section.

2.Tightentheappropriatepulley.

4.Installnewcuttingblade(s).

inspectthebladespringdiscwasherfor damage(SeeServicingtheCutting Bladessection).

Unevencuttingheight.

Bladesdonotrotate.

1.Blade(s)notsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.

3.Abladeisloose.3.Tightentheblademountingboltand

4.Mowerdeckisnotlevel.4.Levelmowerdeckfromside-to-sideand

5.Ananti-scalpwheelisnotsetcorrectly5.Adjusttheanti-scalpwheelheight.

6.Undersideofmowerisdirty.6.Cleantheundersideofthemower.

7.Tirepressureindrivetiresnotcorrect.7.Adjusttirepressure.

8.Bladespindlebent.8.ContactanAuthorizedServiceDealer.

1.Drivebeltisworn,looseorbroken.1.Installnewdrivebelt.

2.Drivebeltisoffpulley.2.Installdrivebeltandcheckadjusting

3.Themowerbeltisworn,loose,orbroken.3.Installanewmowerbelt.

2.Installnewcuttingblade(s).

inspectthebladespringdiscwasherfor damage(SeeServicingtheCutting Bladessection).

front-to-rear.

shaftsandbeltguidesforcorrectposition.

Schematics

ElectricalDiagram

ElectricalLogicSchematic

G014644

Schematics

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 Warranty Period

• Bags, Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine *

* Please refer to the manufacturer’s warranty statement that is included in the literature packet.

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 Warranty Period

• Engines  *

* Please refer to the manufacturer’s warranty statement that is included in the literature packet.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized Exmark   Service Dealer beyond first warrantable service.

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

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

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

• 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.

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  service@exmark.com

Owner’s Responsibilities

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

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.

Exmark Quest Turf Equipment

3-Year Limited Consumer Warranty

(30-Day Limited Commercial Warranty)

G4500-750_A

Notes:

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

G011841

Figure62

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopeindicatortodeterminethe degreeofslopeofhillsbeforeoperating.DoNotoperatethismachineonaslopegreaterthan15degrees.Fold alongtheappropriatelinetomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

EXMARK ACCESSORIES AND OPTIONS*

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT R IDING ACCESSORIES A ND 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

*Some accessories and options not available for some models.

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

www.exmark.com

PartNo.4501-191Rev.A PrintedintheUSA

Exmark 4501-191 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual