Exmark Quest 4500-450, QST22BE482, QST24BE522, Quest 790, 000 Operator's Manual

Download

QUEST®

ForSerialNos. 790,000&Higher

PartNo.4500-450Rev.A

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct containschemicalsknowntotheStateof Californiatocausecancer,birthdefects,or otherreproductiveharm.

Important:Thisengineisnotequippedwith asparkarrestermufer.Itisaviolationof CaliforniaPublicResourceCodeSection4442to useoroperatetheengineonanyforest-covered, brush-covered,orgrass-coveredland.Other statesorfederalareasmayhavesimilarlaws.

ThissparkignitionsystemcomplieswithCanadian ICES-002,ISO14982,EN55012.

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 .

YoumaycontactExmarkdirectlyat www.Exmark.comforproductandaccessory informationorhelpndingadealer.

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

Figure1

Behindtheseat

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contents

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

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

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

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

SafetyandInstructionalDecals.......................8

Specications.......................................................13

ModelNumbers............................................13

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

Dimensions...................................................14

TorqueRequirements....................................15

ProductOverview................................................15

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

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

OperatingInstructions..................................17

RecommendedGasoline................................18

CheckingtheEngineOilLevel.......................19

StartingtheEngine........................................19

OperatingtheBlades.....................................20

StoppingtheEngine......................................20

TheSafetyInterlockSystem...........................21

DrivingForwardorBackward........................21

StoppingtheMachine....................................22

AdjustingtheHeightofCut...........................22

AdjustingtheAnti-ScalpRollers.....................23

PositioningtheSeat.......................................23

ChangingtheSeatRideSuspension................24

AdjustingtheMotionControlLevers.............24

PushingtheMachinebyHand........................24

SideDischarge...............................................25

Transporting.................................................25

OperatingTips.............................................26

Maintenance.........................................................28

RecommendedMaintenanceSchedule(s)...........28

PremaintenanceProcedures..............................29

RaisingtheSeat.............................................29

AccessingtheBattery....................................29

PeriodicMaintenance.......................................29

Lubrication....................................................29

EngineMaintenance......................................30

ServicingtheEngineOil................................31

CheckingtheHydraulicOilLevel...................32

ChangetheHydraulicSystemFilter................33

ServicingtheSparkPlug................................33

CleaningtheBlowerHousing.........................34

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

ElectricalSystemMaintenance.......................35

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

ServicingtheFusesandRelay.........................37

DriveSystemMaintenance............................38

CheckingtheTirePressure............................38

MowerMaintenance......................................38

ServicingtheCuttingBlades..........................38

MowerBeltMaintenance...............................40

LevelingtheMowerDeck..............................41

AdjustingtheBladeSlope..............................42

ReplacingtheDischargeDeector.................44

Adjustments.....................................................45

TrackingAdjustment.....................................45

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

WashingtheUndersideoftheMower.............45

Storage.................................................................47

CleaningandStorage.....................................47

Troubleshooting...................................................48

Schematics...........................................................50

Safety

SafetyAlertSymbol

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

Figure2

1.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.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.1-2003.

Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

GeneralOperation

•Read,understand,andfollowallinstructionsin theoperator’ smanualandonthemachinebefore starting.

•DoNotplacehandsorfeetnearrotatingpartsor underthemachine.Keepclearofthedischarge openingatalltimes.

•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,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

•Neverleavearunningmachineunattended. Alwaysturnoffblades,engageparkingbrake, stopengine,andremovekeybeforedismounting.

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

•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.Ifyoucannotbackuptheslopeorifyou feeluneasyonit,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.

•Engineexhaustcontainscarbonmonoxide,which isanodorless,deadlypoisonthatcankillyou.Do Notrunengineindoorsorinanenclosedarea.

•Stoptheengine,waitforallmovingpartstostop, engageparkingbrake,disconnectsparkplug wire(s)andremovekeybeforeperformingany service,repairs,maintenanceoradjustments.

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

•DoNottouchequipmentorattachmentparts whichmaybehotfromoperation.Allowtocool beforeattemptingtomaintain,adjustorservice.

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

•Batterygasescanexplode.Keepcigarettes,sparks andamesawayfrombattery.

•UseonlyExmarkapprovedattachments. Warrantymaybevoidedifusedwithunapproved attachments.

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

Note:Theleftandrightsidesofthemachineare determinedwhilesittingintheseatinthenormal operatingposition

Safety

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedorlost.

93-7009

1.Warning–DoNotoperate themowerwiththe dischargedeectorup orremoved;keepthe dischargedeectorin place.

2.Cutting/dismemberment hazardofhandorfoot, mowerblade–stayaway frommovingparts.

103-6327

AllUnitsExceptQST20BE422

1.Choke–on

2.Throttle–fast

3.Continuousvariablesetting

4.Throttle–slow

106-5517

1.Warning–DoNottouchthehotsurface.

109-6008

1.ReadtheOperator’s Manual.

3.Pushthemachine.

2.Rotatethedriverelease knobtoloosen,slidethe knob,andtighten.

109-6014

TractionDriveBeltRouting

Safety

109-6035

DeckDriveBeltRouting

109-6036

1.ReadtheOperator’sManual.

2.Removetheignitionkeyandreadtheinstructionsbefore servicingorperformingmaintenance.

3.Heightofcut.

109-6210

1.ReadtheOperator’sManual.

2.Cutting/dismembermenthazard,fanandentanglement hazard,belt–stayawayfrommovingparts.

109-6459

1.Entanglementhazard,belt—DoNotopenorremove safetyshieldswhileengineisrunning,keepshieldsin place.

109-9120

1.Fuse2.Diode

109-9173

1.Parkingbrake4.Neutral

2.Fast5.Reverse

3.Slow6.MachineSpeed

109-9182

1.Machinespeed4.Neutral

2.Fast5.Reverse

3.Slow

Safety

110-6691

1.Thrownobjects hazard–keepbystanders asafedistancefromthe machine.

3.Cutting/dismemberment ofhandorfoot–stay awayfrommovingparts.

2.Thrownobjectshazard, mower–keepthe dischargedeector orcollectionsystemin place.

116-0531

116-0532

QST20BE422Unit

1.Choke–on

2.Throttle–fast

3.Continuousvariablesetting

4.Throttle–slow

116-0533

116-0551

116-0581

Safety

PTOSymbols

1.PTO—Off2.PTO—On

109-6016

1.Readtheinstructionsbeforeservicingorperforming maintenance.

4.RefertotheOperator’smanualforgreaseinstructions.

2.Timeinterval

5.CheckhydraulicoillevelandrefertotheOperator’s Manualforfurtherinstructions.

3.Checkoillevel.6.Checktirepressure.

Safety

109-8965

1.Warning–readtheOperator’sManual.

5.Tippinghazard–avoidsuddenandsharpturnswhileon slopes,onlymowacrossslopeslessthan15degrees, keepasafedistancefromwater,andonlymowupand downslopeslessthan15degrees.

2.Readtheinstructionsbeforeservicingorperforming maintenance;applyparkingbrake,removetheignitionkey anddisconnectthesparkplugwire.

6.Cutting/dismembermenthazardofhandorfoot,mower blade–stayawayfrommovingparts.

3.Thrownobjecthazard—keepbystandersasafedistance fromthemachine,pickupdebrisbeforeoperating,keep thedischargedeectorinplace.

7.Crushing/dismembermenthazardofbystanders, reversing–DoNotcarrypassengers,lookbehindand downwhenreversing.

4.Lossoftraction/controlhazard,slopes–lossof traction/controlonslope,disengagethebladecontrol switch(PTO),proceedofftheslopeslowly.

BatterySymbols

Someorallofthesesymbolsareonyourbattery.

1.Explosionhazard

5.ReadtheOperator’sManual.

9.Flusheyesimmediatelywithwater andgetmedicalhelpfast.

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

10.Containslead;donotdiscard.

3.Causticliquid/chemicalburnhazard

7.Weareyeprotection;explosive gasescancauseblindnessand otherinjuries.

4.Weareyeprotection8.Batteryacidcancauseblindnessor severeburns.

Specications

ModelNumbers

SerialNos:790,000andHigher

QST20BE422;QST22BE482;QST24BE522

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•RPM:

–20HP

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

–22HP&24HP

FullSpeed:3650±100(max)RPM(NoLoad) Idle:1650(min)RPM

FuelSystem

•Capacity:4.0gal.(15.1L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher.

•FuelFilter:

Briggs&StrattonP/N695666

•FuelShut-OffValve:1/4turnincrements(“ON”, “OFF”)

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:16amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:One25amp,one20amp;one15amp bladetype

•Diode:TVS

SafetyInterlockSystem

•PTOmustbedisengaged,brakeengaged,and motioncontrolleversout(neutrallock)tostart engine.(Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.)

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•DeckHeightAdjustmentPin:Setscuttingheight todesiredposition.

•DeckLiftAssistLever:Footpedalthatassists inraisingthedeck.

Seat

•Type:Standardseatwithhighback,foampadded withspringsuspensionandarmrests(armrests areoptionalonthe42inchunit).

•Mounting:Hingedtotiltupforaccessto hydraulicpumps,batteryandothercomponents. Heldintiltedpositionwithlanyard.Adjustable foreandaft.

Specications

•Armrests:Standard–foampaddedip-up adjustableheightarmrests(optionalonthe42 inchunit).

•SeatSafetySwitch:IncorporatedintotheSafety InterlockSystem.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearZT2800 Integrateddrivesystems.

•HydraulicOilType:ExmarkPremiumHydrooil.

•Speeds:

–42inchunit

◊0-6.0mph(9.7km/hr)forward.

◊0-4.0mph(6.4km/hr)reverse.

–48inchand52inchunits

◊0-7.0mph(11.3km/hr)forward.

◊0-5.0mph(8.0km/hr)reverse.

•Drivewheelreleases,locatedonleftandright sidesofenginedeck,allowmachinetobemoved whentheengineisnotrunningandbrakeisoff.

Tires&Wheels

DriveFrontCaster

Pneumatic

(Air-Filled)

Pneumatic

(Air-Filled)

Deck Size

42&48524248&52

Quantity

2222

Tread

TurfTecTurfTecSawtoothSmooth

Size20x

8.00-8

20x

10.00-8

10x410x4

Ply Rating

Pressure

13psi (90kPa)

20psi (138kPa)

13psi (90kPa)

CuttingDeck

•CuttingWidth:

–42inchDeck:42inches(107cm)

–48inchDeck:48inches(122cm)

–52inchDeck:52inches(132cm)

•Discharge:Side

•BladeSize:(3ea.)

–42inchDeck:21.25inches(53.9cm)

–48inchDeck:16.25inches(41.3cm)

–52inchDeck:18.00inches(45.7cm)

•BladeSpindles:Solidsteelspindleswithno maintenancebearings.

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

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

Deckdesignallowsforbagging,mulchingorside discharge.

•DeckDepth:

–42inchDeck:5.0inches(12.7cm)

–48inchDeck:5.0inches(12.7cm)

–52inchDeck:5.0inches(12.7cm)

•CuttingHeightAdjustment:Afootdeckliftlever isusedtoadjustthecuttingheightfrom11/2 inch(3.8cm)to41/2inches(11.4cm)in1/2 inch(1.3cm)increments.

•MulchingKit:Optional.

Dimensions

OverallWidth:

42inch Deck

48inch Deck

52inch Deck

Without Deck

45.5inches (116cm)

47.0inches (119cm)

Deector Up

43.1inches (109cm)

48.3inches (122cm)

53.0inches (135cm)

Deector Down

54.2inches (138cm)

59.4inches (151cm)

64.2inches (163cm)

OverallLength:

AllUnits

73.4inches(186cm)

ProductOverview

OverallHeight:

AllUnits

41.8inches(106cm)

TreadWidth:(CentertoCenterof Tires,Widthwise)

42inch Deck

48inch Deck

52inch Deck

Drive Wheels

36.0inches (91cm)

36.8inches (93cm)

Caster Wheels

27.9inches (71cm)

33.5inches (85cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

AllUnits

48.9inches(124cm)

CurbWeight:

42inchDeck48inchDeck52inchDeck

630lb(286kg)645lb(293kg)660lb(299kg)

TorqueRequirements

BoltLocation

Torque

SpindlePulleyNut75-85ft-lb(102-115N-m)

BladeMountingBolt (lubricatewithanti-seize)

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

EngineMountingBolts

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

Anti-ScalpRollerNyloc Nut

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

WheelLugNuts

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

ClutchMountingBolt (securedwiththreadlocker)

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

SparkPlug

15ft-lb(20N-m)

ProductOverview

Figure3

1.Frontcasterwheel8.Engine

2.Anti-scalproller

9.Seat

3.Heightofcutfootlever

10.Armrest

4.Dischargedeector

11.Motioncontrollevers

5.Heightofcutadjustment

12.Parkbrake

6.Reardrivewheel13.Footrest

7.Controlpanel14.Washouttting

Operation

Controls

Note:Becomefamiliarwithallofthecontrolsin

Figure3andFigure4beforeyoustarttheengineand operatethemachine.

IgnitionSwitch

Locatedoncontrolpanel.

Theignitionswitchisusedtostartandstopthe engine.Theswitchhasthreepositions“OFF”, “RUN”and“START”(Figure4).Insertkeyinto switchandrotateclockwisetothe“ON”position. Rotateclockwisetothenextpositiontoengagethe starter(keymustbeheldagainstspringpressurein thisposition).

Figure4

1.Throttle/Chokelever

3.Bladecontrolswitch (powertake-off)

2.Hourmeter4.Ignitionswitch

Note:Brakemustbeengaged,motioncontrollevers out(neutrallockposition)andPTOswitch“OFF”to startengine.(Itisnotnecessaryfortheoperatorto beintheseattostarttheengine.)

TurningthekeytotheOffpositionwillstopthe engine;however,alwaysremovethekeywhenleaving themachinetopreventsomeonefromaccidentally startingtheengine

BladeControlSwitch(Power Take-Off)

Locatedonthecontrolpanel.

Thebladecontrolswitch,representedbyapower take-off(PTO)symbol,engagesanddisengages powertothemowerblades(seeFigure4).

Pulloutonthebladecontrolswitchto“On”to engagetheblades.

Pushthebladecontrolswitchto“Off”todisengage theblades.

Throttle/ChokeLever

Locatedoncontrolpanel.

Thethrottleisusedtocontrolenginespeed.Moving throttleleverforwardwillincreaseenginespeedand movingthrottlelevertotherearwilldecreaseengine speed.Movingthethrottleforwardintothedetentis fullthrottle(seeFigure4).

Thechokeisusedtoaidinstartingacoldengine. DoNotrunawarmenginewiththechokeinthe “ON”position.Movingtheleverforwardbeyond thedetentwillputthechokeinthe“ON”position andmovingthelevertothedetentwillputthechoke inthe“OFF”position.

MotionControlLevers

Themotioncontrolleverslocatedoneachsideof theseat(Figure3).

Themotioncontrolleversarespeedsensitivecontrols ofindependentwheelmotors.Movingalever forwardorbackwardturnsthewheelonthesameside forwardorinreverse;wheelspeedisproportionalto theamounttheleverismoved.Movingthecontrol leversoutwardfromthecenterpositionlocksthem intheneutralposition.Alwayspositionthemotion controlleversintotheneutralpositionandengage theparkbrakeleverwhenyoustopthemachineor leaveitunattended.Theunitmustbetieddownand brakeengagedwhentransporting.

Operation

ParkingBrakeLever

Locatedonleftsideoftheconsole(Figure3).

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe brake.

Height-of-CutFootLever

Theheightofcutleverallowstheoperatortolower andraisethedeckfromtheseatedposition(Figure3). Whentheleverismovedforward,awayfromthe operatorthedeckisraisedfromthegroundand whenmovedback,towardstheoperatoritislowered towardtheground.Onlyadjusttheheightofcut whilemachineisnotmoving.

HourMeter

Locatedonthecontrolpanel.

Thehourmeterisconnectedtoapressureswitch installedintheengineblockanditrecordsthenumber ofhoursthattheenginehasrun(Figure4).Ifthe ignitionswitchisleftonwithoutenginerunning,hour meterwillnotrun.Thehourmeterisstandardonthe 48and52inchunitsandoptionalforthe42inchunit.

Note:Thisswitchisnotalowoilsensorandwillnot alerttheoperatoriftheengineoilislow .

OperatingInstructions

ThinkSafetyFirst

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Pleasecarefullyreadallofthesafetyinstructions anddecalsinthesafetysection.Knowingthis informationcouldhelpyou,yourfamily,petsor bystandersavoidinjury.

DANGER

Mowingonwetgrassorsteepslopescan causeslidingandlossofcontrol.Wheels droppingoveredgescancauserollovers, whichmayresultinseriousinjury,death ordrowning.Alossoftractionisalossof steeringcontrol.

Toavoidlossofcontrolandpossibilityof rollover:

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15 degrees.

•Reducespeedanduseextremecaution onslopes.

•Whenmowingslopes,graduallywork fromlowertohigherareasontheincline.

•Avoidsuddenturnsorrapidspeed changes.

•Turnup,intoaninclinewhenchanging directionsonslopes.Turningdownthe slopereducestraction.

•Attachmentschangethehandling characteristicsofthemachine.Useextra cautionwhenusingattachmentswiththe machine.

Figure5

1.Water

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

3.SafeZone–usetheQuesthere.

Operation

Seeinsidebackcovertodeterminetheapproximate slopeangletobemowed.

RecommendedGasoline

UseUNLEADEDRegularGasolinesuitablefor automotiveuse(87pumpoctaneminimum).

Important:Neverusemethanol,gasoline containingmethanol,orgasoholcontaining morethan10%ethanolbecausethefuelsystem couldbedamaged.DoNotmixoilwithgasoline.

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsinanopen area,whentheengineiscold.Wipeup anygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Addgasolinetothefueltankuntilthe bodyofthetankisfullbutfueldoesnot lltheneckofthetank.Thisemptyspace inthetankallowsgasolinetoexpand.

•Neversmokewhenhandlinggasoline, andstayawayfromanopenameor wheregasolinefumesmaybeignitedby spark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren. Neverbuymorethana30-daysupplyof gasoline.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitegasolinevapors.Areor explosionfromgasolinecanburnyouand othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

Operation

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof30daysor less.Forlongerstorageitisrecommendedthat thefueltankbedrained.

•Cleanstheenginewhileitruns.

•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstartingAddthe correctamountofgasstabilizer/conditionerto thegas.

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

Gasoline/Alcoholblends

Gasohol(upto10percentethylalcohol,90percent unleadedgasolinebyvolume)isapprovedforfueluse bytheenginemanufacturer.Othergasoline/alcohol blendsarenotapproved.

FillingtheFuelTank

1.Shuttheengineoffandsetthemotioncontrols totheneutralpositionandengageparkingbrake.

2.Cleanaroundthefueltankcapandremovethe cap.

3.Addunleadedregulargasolineuntilthebodyof thetankisfullbutfueldoesnotlltheneckof thetank(Figure6).Thisspaceintheneckofthe tankallowsgasolinetoexpand.DoNotllthe fueltankcompletelyfull.

Figure6

1.Gastankopening3.Gastankbody

2.Filltohere, approximately

4.Installthefueltankcapsecurely.Wipeupany gasolinethatmayhavespilled.

CheckingtheEngineOil Level

Beforeyoustarttheengineandusethemachine, checktheoillevelintheenginecrankcase;referto CheckingtheOilLevelinEngineMaintenance.

StartingtheEngine

1.Sitdownontheseatandmovethemotion controlsoutwardtotheneutralpositionand engagetheparkingbrake.

2.Disengagethebladesbymovingthebladecontrol switchtoOff(Figure7).

Operation

Figure7

1.Throttle/Chokelever

5.Run

2.Bladecontrol switch—Offposition

6.Start

3.Ignitionkey

7.Choke

4.Off8.Throttle–fast(detent

position)

3.Movetheleverforward,beyondthedetent,to engagethechokebeforestartingacoldengine (Figure7).

Note:Awarmorhotenginemaynotrequire choking.

4.TurntheignitionkeytoStarttoenergizethe starter.Whentheenginestarts,releasethekey (Figure7).

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

5.Oncetheenginestarts,movethelevertothe detentposition.Iftheenginestallsorhesitates, movetheleverpartiallyforwardforafewseconds.

OperatingtheBlades

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

EngagingtheBlades

1.Releasepressureonthemotioncontrolleversand placethemachineinneutral.

2.MovethethrottlemidwaytotheFastposition.

Note:Alwaysengagethebladeswiththethrottle inthemidwayposition.

3.Pulloutonthebladecontrolswitch,totheOn position,toengagetheblades(Figure8).

Figure8

1.Throttle–Midway position

2.Bladecontrol switch—Onposition

4.Movethrottletofullforwardpositionbefore mowing.

DisengagingtheBlades

Setthrottletomidwayposition.Pushtheblade controlswitchtoOfftodisengagetheblades (Figure7).

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movethemotioncontrolleversouttotheneutral lockposition.

4.Engagetheparkingbrake.

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

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalvewhenthemachine willnotbeinuseforafewdays,when transporting,orwhentheunitisparkedinside abuilding.

Operation

TheSafetyInterlockSystem

CAUTION

Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•DoNottamperwiththeinterlock switches.

•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:

•Thebladesaredisengaged.

•Themotioncontrolleversareintheneutral position.

•Theparkingbrakeisengaged.

Thesafetyinterlocksystemisdesignedtoinitiate engineshutdownwhen:

•Theparkingbrakeisdisengagedandtheoperator getsoffmachine.

•ThePTOisengagedandtheoperatorgetsoff machine.

•Theparkingbrakeisdisengagedandleversarein andtheoperatorgetsoffmachine.

•Theparkingbrakeisengagedandmotioncontrol leversarein.

TestingtheSafetyInterlockSystem

Testthesafetyinterlocksystembeforeyouusethe machineeachtime

1.Checkstartingcircuit.Startershouldcrankwith parkingbrakeengaged,PTOdisengagedand motioncontrolleversmovedoutintheneutral lockposition.Theoperatordoesnotneedtobe intheseattostarttheengine.

Trytostartwithoperatorinseat,parkingbrake disengaged,PTOdisengagedandmotioncontrol leversintheneutrallockposition-startermust

notcrank.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOdisengaged,andtheleftmotion controlleverin,startermustnotcrank,repeat againwiththerightleverin,thenwithboth leversin-startermustnotcrank.

2.Checkkillcircuits.Runengineatone-third throttle,disengageparkingbrakeandraiseoff ofseat(butdonotgetoffofmachine)engine

mustinitiateshutdown.

Runengineatone-thirdthrottle,engagePTO andraiseoffofseat(butdonotgetoffof machine)enginemustinitiateshutdown.

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

Again,runengineatone-thirdthrottle,brake engaged,andmoveleftmotioncontrolleverin

-enginemustinitiateshutdown.

Repeatagainmovingtherightleverin,then movingbothleversin-enginemustinitiate shutdownwhetheroperatorisonseatornot.

Note:Ifmachinedoesnotpassanyofthesetests, DoNotoperate.ContactyourauthorizedEXMARK

SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

DrivingForwardorBackward

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

Operation

CAUTION

Machinecanspinveryrapidlybypositioning onelevertoomuchaheadoftheother. Operatormaylosecontrolofthemachine, whichmaycausedamagetothemachine orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

Forward

1.Movetheleverstothecenter,unlockedposition.

2.Togoforward,slowlypushthemotioncontrol leversforward(Figure9).

Figure9

1.Neutralposition3.Backward

2.Centerunlockposition

4.Forward

Togostraight,applyequalpressuretoboth motioncontrollevers(Figure9).

Toturn,pullbackonthemotioncontrollever towardthedirectionyouwanttoturn(Figure9).

Thefartheryoumovethemotioncontrollevers ineitherdirection,thefasterthemachinewill moveinthatdirection.

Tostop,pullthemotioncontrolleverstoneutral.

Backward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotioncontrol leversrearward(Figure9).

Togostraight,applyequalpressuretoboth motioncontrollevers(Figure9).

Toturn,releasethepressureonthemotion controllevertowardthedirectionyouwantto turn(Figure9).

Tostop,pushthemotioncontrolleverstoneutral.

StoppingtheMachine

Tostopthemachine,movethemotioncontrol leverstoneutralandoutwardtotheneutralposition, disengagethebladecontrolswitch,movethethrottle levertobetweenFastandhalfthrottle,andturnthe ignitionkeytooff.Remembertoremovethekey fromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemowerwhile itisunattended.

Alwaysremovetheignitionkeyandmovethe motioncontrolleversoutwardtotheneutral positionandapplytheparkingbrakewhen leavingthemachineunattended,evenifjust forafewminutes.

AdjustingtheHeightofCut

1.Raisethedecktothetransportposition(4.5inch (114mm)cutheight)bypushingthefootactuated leverforward(Figure10).Thetransportleverwill automaticallyengageandwilldropintoplace.

Operation

Figure10

1.Transportreleasehandle3.Heightadjusterpin

2.Height-of-cutpositions

4.Footactuated height-of-cutlever

2.Movethedeckheightadjusterpintothedesired cutheight.

3.Pushthefootleverforward,pullthetransport releasehandleupandletthedecklowerdownto thepredeterminedcutheightbyslowlydecreasing footpressureallowingthefootlevertotravel rearward.

AdjustingtheAnti-Scalp Rollers

Itisrecommendedtochangetheanti-scalproller positionwhentheheightofcuthaschanged.

1.Stopthemachineandmovethedriveleversto theneutrallockposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingthenylocnut.

6.Adjusttheanti-scalprollersforthenormal operatingconditions.Placerollersinoneof thepositionsshowninFigure11.Rollerswill maintain3/4inches(19mm)clearancetothe groundtominimizegougingandrollerwearor damage.

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

ground.DoNotadjustrollerstosupportthe deck.

Figure11

Forcuttingheightsabove31/2inches(38mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

2.Cuttingheight

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

PositioningtheSeat

Theseatcanmoveforwardandbackward.Position theseatwhereyouhavethebestcontrolofthe machineandaremostcomfortable.

•48and52InchUnits:

1.Pushtheadjustmentlevertowardsthecenter

ofthemachinetoreleasetheseatadjuster track(Figure12).

Figure12

1.Adjustmentlever

2.Movetheseattothedesiredpositionand

releasethelevertolockinthatposition.

•42InchUnit:

Operation

1.Tiptheseatforward.

2.Loosentheknob.

3.Movetheseattothedesiredposition.

4.Tightentheknob.

5.Tiptheseatbacktotheclosedposition.

ChangingtheSeatRide Suspension

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

Figure13

1.Bolt3.Nut

2.Spring

4.Additionalmounting holes

Uptovespringscanbesecuredtotheseatboxwith anutandbolt,seeFigure13.

RefertoyourPartsManualforspringandhardware partnumbers.

AdjustingtheMotionControl Levers

AdjustingtheHeight

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethetwoboltsholdingthecontrolleverto thecontrolarmshaft(Figure14).

Figure14

1.Bolt

4.Controlarmshaft

2.Washer5.Nut

3.Controllever

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththetwobolts.

3.Repeattheadjustmentfortheoppositecontrol lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraft(Figure14).Tightenboth boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

PushingtheMachineby Hand

Important:Alwayspushthemachinebyhand.

Nevertowthemachinebecausedamagemay occur.

ToPushtheMachine

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardto neutralposition,engageparkingbrake,stopthe

Operation

engine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Locatethebypassreleaseknobsoneithersideof theenginedeck(Figure15).

Figure15

1.Frontofthemachine.5.Leverpositionfor pushingthemachine

2.Rotatebypassrelease

knobcounterclockwise

6.Rotatebypassrelease knobclockwise

3.Leverpositionfor operatingthemachine.

7.Releaselever

4.Pullleverinthisdirection

4.Loosentheknobbyturningcounterclockwise. Thenpullthereleaseleverontheundersideof machine(Figure15)towardsthebackofthe machineandretightentheknobtoholdthe releaseleverbackinthereleasedstate.Repeatthis oneachsideofthemachine.

5.Releasetheparkingbrake.Themachineisnow abletobepushedbyhand.

ToOperatetheMachine

Loosenthebypassknob,pushthereleaselevers forward,andretightentheknobtoengagethedrive system(Figure15).

SideDischarge

Themowerhasahingeddischargedeectorthat dispersesclippingstothesideanddowntowardthe turf.

DANGER

Withoutthedischargedeector,mulchkit, orentiregrasscollectionsystemmountedin place,youandothersareexposedtoblade contactandthrowndebris.Contactwith rotatingmowerblade(s)andthrowndebris willcauseinjuryordeath.

•Neverremovethedischargedeector fromthemowerbecausethedischarge deectorroutesmaterialdowntoward theturf.Ifthedischargedeectorisever damaged,replaceitimmediately.

•Neverputyourhandsorfeetunderthe mower.

•Nevertrytocleardischargeareaor mowerbladesunlessyoumovethemove thebladecontrolswitchtoOffandrotate theignitionkeytoOff.Alsoremovethe keyandpullthewireoffthesparkplug(s).

Transporting

TransportingaUnit

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

CAUTION

Thisunitdoesnothaveproperturn signals,lights,reectivemarkings,ora slowmovingvehicleemblem.Drivingona streetorroadwaywithoutsuchequipment isdangerousandcanleadtoaccidents causingpersonalinjury.Drivingonastreet orroadwaywithoutsuchequipmentmayalso beaviolationofStatelawsandtheoperator maybesubjecttotrafcticketsand/ornes.

DoNotdriveaunitonapublicstreetor roadway.

Operation

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over. Backwardtip-overcouldcauseseriousinjury ordeath.

•Useextremecautionwhenoperatinga unitonaramp.

•Useonlyasingle,fullwidthramp;Do Notuseindividualrampsforeachside oftheunit.

•Ifindividualrampsmustbeused,use enoughrampstocreateanunbroken rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp andgroundorbetweenrampandtrailer ortruck.

•Avoidsuddenaccelerationwhiledriving unituparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking unitdownaramptoavoidtipping backward.

LoadingaUnit

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

Rampshouldbelongenoughsothattheangles betweentherampandthegroundandtherampand thetrailerortruckdonotexceed15°.Asteeperangle maycausemowerdeckcomponentstogetcaughtas theunitmovesfromramptotrailerortruck.Steeper anglesmayalsocausetheunittotipbackward.If loadingonornearaslope,positionthetraileror trucksoitisonthedownsideoftheslopeandthe rampextendsuptheslope.Thiswillminimizethe rampangle.Thetrailerortruckshouldbeaslevel aspossible.

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

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.Soto maintainthesamecuttingheight,whichisagood practice,mowmoreofteninearlyspring.Asthe grassgrowthrateslowsinmidsummer,mowless frequently.Ifyoucannotmowforanextended period,rstmowatahighcuttingheight;thenmow againtwodayslateratalowerheightsetting.

Operation

CuttingSpeed

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.

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

Whilemaintenanceoradjustmentsarebeingmade,someonecouldstarttheengine.Accidental startingoftheenginecouldseriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch,engageparkingbrake,andpullthewire(s)offthespark plug(s)beforeyoudoanymaintenance.Alsopushthewire(s)asidesoitdoesnotaccidentally contactthesparkplug(s).

WARNING

Theenginecanbecomeveryhot.T ouchingahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybeforeserviceormakingrepairsaroundtheenginearea.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst5hours

•Changetheengineoil.

Aftertherst250hours

•Changethehydrauliclter.

Beforeeachuseordaily

•Checkthesafetyinterlocksystem.

•Checktheairintakeandcoolingareas,cleanasnecessary.

•Checktheoillevelbeforestartingorafterevery8hours.

•Checkthehydraulicoillevelintheexpansiontank.

•Checkthemowerblades.

•Cleanthemowerhousing.

Every25hours

•Greasealllubricationpoints.

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

•Servicetheaircleaner.(Mayneedmoreoftenunderextremelydustyordirtyconditions.)

•Checkthetirepressure.

•Checkthebelts.

Every100hours

•Replacethepaperelement.(Moreoftenunderextremelydusty,dirtyconditions.)

•Replacetheaircleanerelement.

•Changetheengineoilandlter.

•Cleantheblowerhousing.Moreoftenunderdirtyconditions.

•Replacethefuellter.

Every200hours

•Servicethesparkplug.

Every500hours

•Changethehydrauliclter(Every250hoursifusingMobil115W50)

•Replacethesparkplug.

Maintenance

MaintenanceService

Interval

MaintenanceProcedure

Beforestorage

•Chargethebatteryanddisconnectthebatterycables.

•Performallmaintenanceproceduresbeforestorage.

•Paintanychippedsurfaces.

Monthly

•Checkthebatterycharge.

Important:RefertoyourEngineOperator’sManualforadditionalmaintenanceprocedures.

Premaintenance Procedures

RaisingtheSeat

Makesurethemotioncontrolleversarelockedin theneutralposition.Lifttheseatforwarduntilthe lanyardistight.Thefollowingcomponentscanbe accessedbyraisingtheseat:

•Auxiliary12VPlug(12Vaccessoryupto15amp)

•Fuses

•Batterycables

AccessingtheBattery

Thebatteryislocatedundertheseat.Toaccess,raise theseat(Figure16).

Figure16

1.Auxiliary12VPlug

3.Seat

2.Battery

PeriodicMaintenance

Lubrication

GreasingtheBearings

ServiceInterval:Every25hours/Monthly

(whichevercomesrst)

GreaseType:NGLIgrade#2multi-purposegun grease.

Greasethefrontcasterwheels(Figure17).

G007184

Figure17

1.Frontcastertire

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe neutralposition,engageparkingbrake,stopthe engine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Cleanthegreasettings(Figure17andFigure18) witharag.Makesuretoscrapeanypaintoffof thefrontofthetting(s).

Maintenance

Figure18

Locatedonthebackoftheseat.

1.Readtheinstructions beforeservicingor performingmaintenance

5.Checkhydraulicoillevel andrefertoOperator’s manualforfurther instructions.

2.Greaseidlerpivot—All units.

6.Checktirepressure.

3.Timeinterval(hours).7.Greaseidlerpivot—48

and52inchonly.

4.Checkoillevel.

4.Connectagreaseguntoeachtting(Figure17 andFigure18).Pumpgreaseintothettingsuntil greasebeginstooozeoutofthebearings.

5.Wipeupanyexcessgrease.

EngineMaintenance

ServicingtheAirCleaner

ServiceInterval:Every25hours/Monthly

(whichevercomesrst) (Mayneedmoreoften underextremelydustyor dirtyconditions.)

Every100hours/Yearly (whichevercomes rst)—Replacethepaper

element.(Moreoften underextremelydusty, dirtyconditions.)

Thisengineisequippedwithareplaceable,high densitypaperaircleanerelement.Checktheair cleanerdailyorbeforestartingtheengine.Checkfor abuildupofdirtanddebrisaroundtheaircleaner system.Keepthisareaclean.Alsocheckforlooseor damagedcomponents.Replaceallbentordamaged aircleanercomponents.

Note:Operatingtheenginewithlooseordamaged aircleanercomponentscouldallowunlteredairinto theenginecausingprematurewearandfailure.

Note:Servicetheaircleanermoreoftenunder extremelydusty,dirtyconditions.

Figure19

1.Aircleaner3.Aircleanercover

2.Knobs

ServicingPaperElement

ServiceInterval:Every25hours/Monthly

(whichevercomesrst) (Mayneedmoreoften underextremelydustyor dirtyconditions.)

Every100hours/Yearly (whichevercomes rst)—Replacetheair cleanerelement.

1.Removetheaircleanercover(Figure19).

2.Removetheaircleanerelementwiththeintegral rubberseal.

Maintenance

3.Removethefoamsleevefromtheelement.

4.Gentlytapthepleatedsideofthepaperelement todislodgedirt.DoNotwashthepaperelement orusepressurizedair,asthiswilldamagethe element.Replaceadirty,bent,ordamaged element.Handlenewelementscarefully;DoNot useiftherubbersealorfoamsleeveisdamaged.

5.Washthefoamsleeveinwarmwaterandallowto dry.Reinstalloverthepaperelement.

6.Cleanallaircleanercomponentsofany accumulateddirtorforeignmaterial.Preventany dirtfromenteringthecarburetor.

7.Installtheaircleanerelementwiththepleated side“out”andseattherubbersealontotheedges oftheaircleanerbase.

8.Reinstalltheaircleanercoverandsecurewith theknobs.

ServicingtheEngineOil

CheckingtheOilLevel

ServiceInterval:Beforeeachuseordaily

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

2.Makesuretheengineisstopped,level,andiscool sotheoilhashadtimetodrainintothesump.

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

4.Pullandremovetheoilllcap/dipstick;wipeoil off.Reinsertthedipstickandpushrmlyinto place(Figure20).

Figure20

1.Oildipstick3.Oillevel

2.Fillertube

5.Removethedipstickandchecktheoillevel.

Theoillevelshouldbeupto,butnotover,the “F”markonthedipstick.

6.Ifthelevelislow,addoilofthepropertype,upto the“F”markonthedipstick.Alwayscheckthe levelwiththedipstickbeforeaddingmoreoil.

Note:Topreventextensiveenginewearor damage,alwaysmaintaintheproperoillevelin thecrankcase.Neveroperatetheenginewiththe oillevelbelowthe“L”markoroverthe“F”mark onthedipstick.

ChangingtheOilandFilter

ServiceInterval:Aftertherst5hours

Every100hours/Yearly (whichevercomesrst) thereafter.

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

1.Starttheengineandletitrununtilwarm.This warmstheoilsoitdrainsbetter.

2.Disengagethebladecontrolswitchandmovethe motioncontrolsoutwardtotheneutralposition andengageparkingbrake.

Maintenance

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Cleantheareaaroundthedrainplugandonthe machineframe.Placeapanunderneathmachine directlybelowthedrainholeintheframeas showninFigure21.

Figure21

1.Oildrain

3.Pan

2.Oildrainplug

5.Removetheoildrainplug(Figure21).Remove theoilllcap/dipstick(Figure20).

Figure22

1.Oillter2.Gasket

6.Besuretoallowampletimeforcomplete drainage.

7.Removetheoldlterandwipeoffthemounting pad(Figure22).

8.Whentheoilhasdrainedcompletely,installthe oildrainplug.Tightentheplugto14N-m(125

in-lb)torque.Wipeupanyexcessoilontheframe (Figure21).

Note:Disposeoftheusedoilatarecycling center.

9.Applyathinlmofcleanoiltotherubbergasket onthenewlter.

10.Installthereplacementoilltertothemounting pad.Turntheoillterclockwiseuntiltherubber gasketcontactsthepad,thentightenthelteran additional1/2to3/4turn(Figure22).

11.Slowlypourapproximately80%ofthespecied oilintothellertube—useoilrecommendedin theEngineOwner’sManual.

12.Installtheoilllcap/dipstickandpushrmly intoplace.

13.Checktheoillevel(Figure20);refertoChecking

theOilLevel.

14.Slowlyaddadditionaloiltobringittothefull mark.DoNotoverll.

15.Installtheoilllcap/dipstickandpushrmly intoplace.

16.Starttheengineandcheckforleaks.

CheckingtheHydraulicOil Level

ServiceInterval:Beforeeachuseordaily

CheckexpansiontankandifnecessaryaddExmark PremiumHydrooiltotheFULLCOLDline.

Figure23

1.Engine2.Expansiontank

Maintenance

ChangetheHydraulic SystemFilter

ServiceInterval:Aftertherst250hours

Every500hoursthereafter (Every250hoursifusing Mobil115W50)

1.Stopengine,waitforallmovingpartstostop,and allowenginetocool.Removekeyandengage parkingbrake.

2.Locatethetwoltersunderthetransmissions. Removelterguards.

3.Carefullycleanareaaroundlters.Itisimportant thatnodirtorcontaminationenterhydraulic system.

4.Unscrewlterstoremoveandallowoiltodrain fromdrivesystem.

Important:Beforereinstallingnewlters, applyathincoatofExmarkPremiumHydro oilonthesurfaceoftheltersrubberseal.

Turntheltersclockwiseuntilrubberseal contactsthelteradapterthentightenthelter anadditional3/4to1fullturn.

5.Removetheventplugoneachtransmissionand llthroughexpansionreservoir,whenoilcomes outofventreinstallplug.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ChangeInterval

ExmarkPremiumHydro Oil(Preferred)

500Hours

Mobil115W50

250Hours

Torqueplugsto180in-lb(244N-m).Continueto addoiluntilitreachestheFULLCOLDlineon theexpansionreservoir.

Figure24

1.Oillter3.Leftreartire

2.Ventplug

6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

7.Startengineandmovethrottlecontrolaheadto 1/2throttleposition.Disengageparkingbrake.

A.Withthebypassvalveopenandtheengine

running,slowlymovethedirectionalcontrol inbothforwardandreverse(5or6times).

B.Withthebypassvalveclosedandtheengine

running,slowlymovethedirectionalcontrol inbothforwardandreversedirections(5to 6times).Checktheoillevel,andaddoilas requiredafterstoppingtheengine.

C.ItmaybenecessarytorepeatstepsAand

Buntilalltheairiscompletelypurgedfrom thesystem.Whenthetransaxleoperatesat normalnoiselevelsandmovessmoothly forwardandreverseatnormalspeeds,then thetransaxleisconsideredpurged.

DoNotchangehydraulicsystemoil(exceptforwhat canbedrainedwhenchanginglter),unlessitisfelt theoilhasbeencontaminatedorbeenextremelyhot.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

ServicingtheSparkPlug

ServiceInterval:Every200hours/Every2

years(whichevercomes rst)

Every500hours—Replace thesparkplug.

Maintenance

Asstatedinthemaintenanceintervals,removethe sparkplug,checkcondition,andresetthegapor replacewithanewplugasnecessary.

ThesparkplugisRFIcompliant.Equivalentalternate brandplugscanalsobeused.

Type:ChampionXC92YC

ChampionRC12YCorQC12Cmaybeusedifyour areadoesnotrequirecompliancewithCanadian ICES-002,ISO14982,orEN55012.

AirGap:0.030inch(0.76mm)

RemovingtheSparkPlug

1.Disengagethebladecontrolswitch,movethe motioncontrolsoutwardtotheparkposition, stoptheengine,andremovethekey.

2.Pullthewireoffofthesparkplug(Figure25). Cleanaroundthesparkplugtopreventdirtfrom fallingintotheengineandpotentiallycausing damage.

Note:Duetothedeeprecessaroundthespark plug,blowingoutthecavitywithcompressedair isusuallythemosteffectivemethodforcleaning. Thesparkplugismostaccessiblewhenthe blowerhousingisremovedforcleaning.

3.Removethesparkplugandmetalwasher.

Figure25

1.Sparkplugandwirelocation

CheckingtheSparkPlug

1.Lookatthecenterofthesparkplug(Figure26). Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingon theinsulatorusuallymeanstheaircleanerisdirty.

Important:Nevercleanthesparkplug. Alwaysreplacethesparkplugwhenithasa

blackcoating,wornelectrodes,anoilylm, orcracks.

2.Checkthegapbetweenthecenterandside electrodes(Figure26).Bendthesideelectrodeif thegapisnotcorrect.

Figure26

1.Sideelectrode3.Airgap(nottoscale)

2.Centerelectrode insulator

InstallingtheSparkPlug

1.Installthesparkplug.Makesurethattheairgap issetcorrectly.

2.Tightenthesparkplugto15ft-lb(20N-m).

3.Pushthewireontothesparkplug(Figure25).

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 .

Maintenance

FuelSystemMaintenance

ReplacingtheFuelFilter

ServiceInterval:Every100hours/Yearly

(whichevercomesrst)

DANGER

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areor explosionfromgasolinecanburnyouand othersandcandamageproperty.

•Performanyfuelrelatedmaintenance whentheengineiscold.Dothisoutdoors inanopenarea.Wipeupanygasoline thatspills.

•Neversmokewhendraininggasoline,and stayawayfromanopenameorwherea sparkmayignitethegasolinefumes.

Neverinstalladirtylterifitisremovedfromthe fuelline.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe neutralposition,engageparkingbrake,stopthe engine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Thefuellterisinthefuellinebetweenthetank andengine.

Figure27

1.Fueltank6.Hoseclamps

2.Fuelshutoffvalve—off

7.Fuellinetoengine

3.Fuelshutoffvalve

8.Filter

4.Fuelshutoffvalve—on

9.Flowdirectionarrow

5.Fuellinefromtank

4.Turnfuelshutoffvalve90°to“off”position.

5.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure27).

6.Removethelterfromthefuellines.

7.Installanewlterwiththeowdirectionarrow comingfromthefueltankandpointingtothe engine.Movethehoseclampsclosetothelter (Figure27)tosecureitinplace.

8.Turnfuelshutoffvalvebackto“on”position.

ElectricalSystem Maintenance

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Maintenance

ChargingtheBattery

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygasses toexplode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery, DoNotallowthebatteryterminalsto touchanymetalpartsofthemachine.

•DoNotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsof themachine.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe neutralposition,engageparkingbrakestopthe engine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Raisetheseat.

4.Disconnectthenegative(black)groundcable fromthebatterypost(Figure28).Retainall fasteners.

Figure28

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(Figure28)andliftthe batteryfromthebatterytray.

ChargingtheBattery

1.Removethebatteryfromthechassis;referto RemovingtheBattery.

2.Allowingbatteriestostandforanextendedperiod withoutrechargingthemwillresultinreduced performanceandservicelife.Topreserve optimumbatteryperformanceandlife,recharge batteriesinstoragewhentheopencircuitvoltage dropsto12.4volts.

Note:Topreventdamageduetofreezing, batteryshouldbefullychargedbeforeputting awayforwinterstorage.

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

Important:Makesurethenegativebattery cablesaredisconnectedandthebattery chargerusedforchargingthebatteryhasan outputof16voltsand7ampsorlesstoavoid damagingthebattery(seechartbelowfor recommendedchargersettings).

Maintenance

Voltage Reading

Percent Charge

Maximum Charger Settings

Charging Interval

12.6or greater

100%

16volts/7 amps

No Charging Required

12.4–12.675–100%

16volts/7 amps

30Minutes

12.2–12.450–75%

16volts/7 amps

1Hour

12.0–12.225–50%

14.4volts/4 amps

2Hours

11.7–12.00–25%

14.4volts/4 amps

3Hours

11.7orless

14.4volts/2 amps

6Hoursor More

4.Whenthebatteryisfullycharged,unplug thechargerfromtheelectricaloutlet,then disconnectthechargerleadsfromthebattery posts(Figure29).

Figure29

1.Negativebatterypost

3.Red(+)chargerlead

2.Black(-)chargerlead

4.Positivebatterypost

Note:DoNotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.

InstallingtheBattery

1.Positionthebatteryinthetraywiththeterminal poststowardtheoperatingposition(Figure28).

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

3.Installthenegativebatterycabletothenegative (-)batteryterminalusingthefastenersremoved previously.

4.Slidetheredterminalbootontothepositive(red) batterypost.

5.Securethebatterywiththestrap(Figure28).

ServicingtheFusesand Relay

Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance;however,ifafuseblows,check thecomponent/circuitforamalfunctionorshort. Thereisalsoareplaceablerelay/snexttothefuse. RefertoyourPartsmanualforcorrectreplacement components.

FuseBlock:

•Mainfuse:25ampfuse,blade-type

•ChargeCircuit:20ampfuse,blade-type

•Auxiliarycircuit:15ampfuse,blade-type

•Diode:TVS

1.Raisetheseattogainaccesstothefuseholder (Figure30).

Figure30

1.Cover4.Charge–20amp

2.Relay5.Main–25amp

3.Auxilliary–15amp6.Diode

2.RemovecoverasshowninFigure30.

3.Toreplaceafuse,pulloutonthefusetoremoveit

Maintenance

DriveSystemMaintenance

CheckingtheTirePressure

ServiceInterval:Every25hours/Monthly

(whichevercomesrst)

Maintaintheairpressureinthefrontandreartiresas specied.Uneventirepressurecancauseunevencut. Checkthepressureatthevalvestem(Figure31).

Checkthetireswhentheyarecoldtogetthemost accuratepressurereading.

RearTires:13psi(90kPa)

FrontTires(casterwheels):

•Smooth:13psi(90kPa)

•Sawtooth:20psi(138kPa)

Figure31

1.Valvestem

MowerMaintenance

ServicingtheCuttingBlades

ServiceInterval:Beforeeachuseordaily

Maintainsharpbladesthroughoutthecuttingseason becausesharpbladescutcleanlywithouttearingor shreddingthegrassblades.Tearingandshredding turnsgrassbrownattheedges,whichslowsgrowth andincreasesthechanceofdisease.

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

WARNING

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

•Inspectthebladeperiodicallyforwearor damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

Parkthemachineonalevelsurface,disengagethe bladecontrolswitch,andmovethemotioncontrol leversoutwardtotheneutralpositionandengage parkingbrake.Stoptheengine,removethekey,and disconnectthesparkplugwire(s)fromthespark plug(s).

InspectingtheBlades

1.Inspectthecuttingedges(Figure32).Iftheedges arenotsharporhavenicks,removeandsharpen theblades;refertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea.If younoticeanydamage,wear,oraslotformingin thisarea(item3inFigure32),immediatelyinstall anewblade.

Figure32

1.Cuttingedge3.Wear/slotforming

2.Curvedarea

CheckingforBentBlades

1.Rotatethebladesuntiltheendsfaceforwardand backward(Figure33andFigure34).Measure fromalevelsurfacetothecuttingedge,ofthe blades.Notethisdimension.

Maintenance

Figure33

48and52InchDeck

1.Bladesfronttorear

2.Measurehere

Figure34

42InchDeck

1.Bladesfronttorear

2.Measurehere

2.Rotatetheoppositeendsofthebladesforward.

3.Measurefromalevelsurfacetothecuttingedge ofthebladesatthesamepositionasinstep1. Thedifferencebetweenthedimensionsobtained insteps1and3mustnotexceed1/8inch(3 mm).Ifthisdimensionexceeds1/8inch(3mm), thebladeisbentandmustbereplaced.Refer toRemovingtheBladesandInstallingthe Blades.

WARNING

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyou orbystanders.

•Alwaysreplacebentordamagedblade withanewblade.

•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.

CheckingforLooseBladesor DamagedSpringDiscWashers

1.Placeawrenchonthebladeboltandtorqueto 32-42ftlb(43-57N-m).

2.Withthewrenchstillonthebladebolt,holdthe bladespindlestationaryandusingaragorthickly paddedglove,trytorotatetheblade.Iftheblade rotatesrelativetothespindleguardwithout furthertighteningthebladebolt,thespring discwasherhasbeenattenedordamagedand theboltandwasherassemblymustbereplaced (Figure35).RefertoRemovingtheBladesand InstallingtheBlades.

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

RemovingtheBlades

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

Holdthebladeendusingaragorthickly-padded glove(orplaceawrenchonthetopsheavenut). Removethebladeboltandwasherassembly,washer, andbladefromthespindleshaft(Figure35).

Maintenance

Figure35

1.Blade

2.Washer

3.Boltandwasherassembly.Applylubricantto threads—torqueto32-42ft-lb(43-57N-m).

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure36).Maintaintheoriginal angle.Thebladeretainsitsbalanceifthesame amountofmaterialisremovedfrombothcutting edges.

Figure36

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure37).Ifthebladestaysina horizontalposition,thebladeisbalancedandcan beused.Ifthebladeisnotbalanced,lesome metalofftheendofthesailareaonly(Figure37). Repeatthisprocedureuntilthebladeisbalanced.

Figure37

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure35).

Important:Thecurvedpartoftheblade mustbepointingupwardtowardtheinsideof themowertoensurepropercutting.

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

3.Torquethebladeboltto32-42ft-lb(43-57N-m).

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecause thebladetocomelooseandcouldseriously injureorkillyouorbystanders.

AlwaysinstalltheoriginalExmarkblades, washersandbladeboltsasshown.

MowerBeltMaintenance

InspectingtheBelts

ServiceInterval:Every25hours/Monthly

(whichevercomesrst)

Checkthebeltsforcracks,frayededges,burnmarks, oranyotherdamage.Replacedamagedbelts.

ReplacingtheMowerBelt

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

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe neutralposition,engageparkingbrake,stopthe engine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Settheheight-of-cutat1-1/2inch(38mm).

4.For48and52inchdecksonly ,removethebelt coversovertheoutsidespindles.

5.Graspbothbeltstrandsgoingtotheclutch.Pull themtotherearofthemachineandslipthebelt

Maintenance

offtheclutchpulleyasshowninFigure38and Figure39.

WARNING

Thespringisundertensionwheninstalled andcancausepersonalinjury.

Becarefulwhenremovingthebelt.

Figure38

48and52InchDecks

1.Outsidepuley

4.Mowerbelt

2.Spring

5.Enginepulley

3.Idlerpulley6.Pullbeltstrandsinthis direction.

Figure39

42InchDeck

1.Outsidepuley

4.Mowerbelt

2.Spring

5.Enginepulley

3.Idlerpulley6.Pullbeltstrandsinthis direction.

6.Routethenewbeltaroundthemowerpulleys.

7.Graspbothbeltstrandsgoingtotheclutch.Pull themtotherearofthemachineandslipthebelt ontotheclutchpulley .

8.For48and52inchdecksonly,installthebelt coversovertheoutsidespindles.

LevelingtheMowerDeck

Themowerbladesmustbelevelfromsidetoside. Checktheside-to-sidelevelanytimeyouinstallthe mowerorwhenyouseeanunevencutonyourlawn.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe neutralposition,engageparkingbrake,stopthe engine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Checktheairpressureofallfourtires.Ifneeded, adjusttotherecommendedination;referto CheckingtheTirePressureinDriveSystem Maintenancesection.Ifeitheroneisoutofrange thenfollowadjustmentprocedure.

4.Carefullyrotatethebladessidetoside.

5.Measurebetweentheoutsidecuttingedgesand theatsurface(Figure40andFigure41).Ifboth measurementsarenotwithin3/16inch(5mm), anadjustmentisrequired;continuewiththis procedure.

Figure40

48and52InchDecks

1.Bladessidetoside2.Measurehere

Maintenance

Figure41

42InchDeck

1.Bladessidetoside2.Measurehere

6.Setanti-scalprollerstotopholesorremove completelyforthisadjustment.

7.Settheheight-of-cutlevertothe3inch(76mm) position.Placetwo“B”thickblocks(seeBlock HeightandRakeTable)undertherearedgeofthe cuttingdeckskirt;oneoneachsideofthecutting deck.Placetwo“ A ”thickblocksundereachside ofthefrontedgeofthedeck,butnotunderthe anti-scalprollerbrackets.

BlockHeightandRakeTable

Deck Size

FrontBlock Height“A”

RearBlock Height“B”

Rake“R”

2.19inches (5.6cm)

2.44inches (6.2cm)

1/8–3/8inch (3.2–9.5mm)

48& 52

2.31inches (5.9cm)

2.50inches (6.4cm)

1/16–5/16inch (1.6–7.9mm)

8.Carefullyrotatethebladessidetoside(Figure40 andFigure41).

9.Loosenthelevelingadjustlockingnuts(item4) onallfourcornerssothatthedeckissitting securelyonallfourblocks.Makesurethatthe deckhangersareallthewaydown(atthetopof theslot)andthedeckliftfootleverispushedback againstthestop,thentightenthefourleveling adjustlockingnuts

10.Recheckthatblockstjustsnuglyunderthedeck skirt.Makesureallattachmentboltsaretight

11.Continuelevelingthedeckbycheckingthe front-to-rearbladeslope;refertoAdjustingthe

Front-to-RearBladeSlope.

12.Recheckbladesforlevelnessandrepeatdeck levelingprocedureifnecessary.

Figure42

1.Deckliftarm

3.Deckhanger

2.Floatretainingnut4.Levelingadjustlocking nut

AdjustingtheBladeSlope

1.Checkthefront-to-rearbladelevelanytimeyou installthemower.Ifthefrontbladetipisnot“R” (seeBlockHeightandRakeTableinLevelingthe MowerDeck)lowerthantherearbladetip,adjust thebladelevelusingthefollowinginstructions:

2.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

3.Movethemotioncontrolleversoutwardto theneutralposition,engagetheparkingbrake, stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Checktheairpressureofallfourtires.Ifneeded, adjusttotherecommendedination;referto CheckingtheTirePressureinDriveSystem Maintenancesection.

5.Checkandadjusttheside-to-sidebladelevelifyou havenotcheckedthesetting;refertoLeveling theMower.

6.Settheheight-of-cutlevertothe3inch(76mm) position.Placetwo“B”thickblocks(seeBlock HeightandRakeTableinLevelingtheMower Deck)undertherearedgeofthecuttingdeck skirt;oneoneachsideofthecuttingdeck.Place

Maintenance

two“ A ”thickblocks(seeBlockHeightandRake TableinLevelingtheMowerDeck)undereach sideofthefrontedgeofthedeck,butnotunder theanti-scalprollerbrackets.

7.Loosenthelevelingadjustlockingnuts(item4) onallfourcornerssothatthedeckissitting securelyonallfourblocks.Makesurethatthe deckhangersareallthewaydown(atthetopof theslot)andthedeckliftfootleverispushedback againstthestop,thentightenthefourleveling adjustlockingnuts(Figure43).

Figure43

1.Deckliftarm

3.Deckhanger

2.Floatretainingnut4.Levelingadjustlocking nut

8.Carefullyrotatethebladessotheyarefacingfront torear(Figure44andFigure45).

9.Measurefromthetipofthefrontbladetothe atsurfaceandthetipoftherearbladetothe atsurface(Figure44andFigure45).Ifthefront bladetipisnot“R”(seeBlockHeightandRake TableinLevelingtheMowerDeck)lowerthan therearbladetip,adjustthefrontdeckhanger.

Figure44

48and52InchDecks

1.Bladesfronttorear

2.Measurehere

Figure45

42InchDeck

1.Bladesfronttorear

2.Measurehere

10.Whenthefront-to-rearbladeslopeiscorrect checktheside-to-sidelevelofthemoweragain; refertoLevelingtheMower.

Maintenance

ReplacingtheDischarge Deector

DANGER

Anuncovereddischargeopeningcouldallow thelawnmowertothrowobjectsinthe operator’sorbystander’sdirectionandresult inseriousinjury.Also,contactwiththeblade couldoccur.

Neveroperatethelawnmowerunlessyou installamulchplate,dischargedeector,or grasscollectionsystem.

1.LocateitemsshowninFigure46.

Figure46

1.Rod4.Mowerdeck

2.Spring5.Dischargedeector bracket

3.Dischargedeector

6.Assembledview

2.Slidetherodoutoftheshortstand-off,spring, anddischargedeector.Removethedamagedor worndischargedeector.

3.Installnewdischargedeector.

4.Orientthespringsothattheshortlegpoints towardsthedischargedeectorandthelongerleg pointstowardsthedeckasshowninFigure46. Placespringonrodandsliderod,straightend,

throughthefrontdischargedeectorbracket, dischargedeector,andreardeectorbracket.

5.Makesurethatthespringandrodareinstalled sothattherodisretainedfromslidingout bythefrontbracketandthespringholdsthe dischargedeectorinthedownposition.Referto (Figure46)forproperorientation.

Important:Thedischargedeectormustbe springloadedinthedownposition.Liftthe deectoruptotestthatitsnapstothefull downposition.

Maintenance

Adjustments

TrackingAdjustment

Ifthemachineturnsrightorleftwhenhandlesare pushedforwardtogether,adjustthetrackingplateon thesideoppositethedirectionofturn(seeFigure47). Loosenthehardwarethatholdsthetrackingplate. Movetheplatebackuntiltheunitdrivesstraight. Tightenthehardwaretolockthetrackingplatein place.Readjusthandlesifnecessary.

Figure47

1.Controlarmshaft

3.Trackingplate

2.Trackingplatenut

Cleaning

WashingtheUndersideof theMower

ServiceInterval:Beforeeachuseordaily

Aftereachuse,washtheundersideofthemowerto preventgrassbuildupforimprovedmulchactionand clippingdispersal.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardtothe neutralposition,engageparkingbrake,stopthe engine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Attachthehosecouplingtotheendofthemower washouttting,andturnthewateronhigh (Figure48).

Note:Spreadpetroleumjellyonthewashout ttingO-ringtomakethecouplingslideoneasier andprotecttheO-ring.

Figure48

4.Lowerthemowertothelowestheight-of-cut.

5.Sitontheseatandstarttheengine.Engagethe bladecontrolswitchandletthemowerrunfor onetothreeminutes.

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

7.Turnthewateroffandremovethecouplingfrom thewashouttting.

Maintenance

Note:Ifthemowerisnotcleanafterone

washing,soakitandletitstandfor30minutes. Thenrepeattheprocess.

8.Runthemoweragainforonetothreeminutes toremoveexcesswater.

WARNING

Abrokenormissingwashoutttingcould exposeyouandotherstothrownobjectsor bladecontact.Contactwithbladeorthrown debriscancauseinjuryordeath.

•Replacebrokenormissingwashout ttingimmediately,beforeusingmower again.

•Pluganyhole(s)inmowerwithboltsand locknuts.

•Neverputyourhandsorfeetunderthe mowerorthroughopeningsinthemower.

Storage

CleaningandStorage

1.Disengagethebladecontrolswitch,movethe motioncontrolsoutwardtotheneutralposition, engageparkingbrake,stoptheengine,and removethekey.

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

Important:Youcanwashthemachinewith milddetergentandwater.DoNotpressure washthemachine.Avoidexcessiveuseof water,especiallynearthecontrolpanel, engine,hydraulicpumps,andmotors.

3.Servicetheaircleaner;refertoServicingtheAir CleanerinEngineMaintenancesection.

4.Greaseandoilthemachine;refertoLubrication section.

5.Changethecrankcaseoilandlter;refer toServicingtheEngineOilinEngine Maintenancesection.

6.Checkthetirepressure;refertoCheckingthe TirePressureinDriveSystemMaintenance section.

7.Chargethebattery;refertoServicingthe BatteryinElectricalSystemMaintenancesection.

8.Checktheconditionoftheblades;referto ServicingtheCuttingBladesinMower Maintenancesection.

9.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachinefor storageasfollows.

A.Addapetroleumbasedstabilizer/conditioner

tothefuelinthetank.Followthemixing instructionsfromthestabilizermanufacturer. DoNotuseanalcoholbasedstabilizer (ethanolormethanol).

Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshgasolineand usedatalltimes.

B.Runtheenginetodistributetheconditioned

fuelthroughthefuelsystem(5minutes).

C.Stoptheengineandturnthefuelshutoff

valve90°tothe“off”position.

D.Restarttheengineandrunituntilitstops.

E.Choketheengine.Startandruntheengine

untilitwillnotstart.

10.Removethesparkplug(s)andcheckitscondition; refertoServicingtheSparkPluginEngine Maintenancesection.Withthesparkplug(s) removedfromtheengine,pourtwotablespoons ofengineoilintothesparkplughole.Usethe startertocranktheengineanddistributetheoil insidethecylinder.Installthesparkplug(s).Do Notinstallthewireonthesparkplug(s).

11.Cleananydirtandchafffromthetopofthe mower.

12.Scrapeanyheavybuildupofgrassanddirtfrom theundersideofthemower,thenwashthemower withagardenhose.

13.Checktheconditionofthedriveandmowerbelts.

14.Checkandtightenallbolts,nuts,andscrews. Repairorreplaceanypartthatiswornor damaged.

15.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

16.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitch andkeepitinamemorableplace.Coverthe machinetoprotectitandkeepitclean.

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,DoNotoverlookthesimplecauses.Forexample:startingproblemscouldbe causedbyanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.Theengineloadisexcessive.1.Reducegroundspeed.

2.Theoillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

3.Thecoolingnsandairpassagesunder theengineblowerhousingareplugged.

3.Removetheobstructionfromthecooling nsandairpassages.

4.Theaircleanerisdirty.

4.Cleanorreplacetheaircleanerelement.

Theengineoverheats.

5.Dirt,water,orstalefuelisinfuelsystem.

5.ContactanAuthorizedServiceDealer.

1.Thebladecontrolswitchisengaged.1.Movethebladecontrolswitchto Disengaged.

2.Themotioncontrolleversarenotinthe

parkposition.

2.Movethemotioncontrolleversoutward totheparkposition.

3.Theoperatorisnotseated.

3.Sitontheseat.

4.Thebatteryisdead.4.Chargethebattery.

5.Theelectricalconnectionsarecorroded orloose.

5.Checktheelectricalconnectionsforgood contact.

6.Afuseisblown.

6.Replacethefuse.

Thestarterdoesnotcrank

7.Arelayorswitchisdamaged.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Thechokeisnoton.2.MovethechokelevertoOn.

3.Theaircleanerisdirty.

3.Cleanorreplacetheaircleanerelement.

4.Thesparkplugwire(s)islooseor disconnected.

4.Installthewire(s)onthesparkplug.

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

5.Installanew,correctlygappedspark plug(s).

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

7.Dirt,water,orstalefuelisinthefuel system.

7.ContactanAuthorizedServiceDealer.

8.Thereisincorrectfuelinthefueltank.

8.Drainthetankandreplacethefuelwith thepropertype.

Enginewillnotstart,startshard,orfailsto keeprunning

9.Theoillevelinthecrankcaseislow .

9.Addoiltothecrankcase.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

2.Cleanorreplacetheaircleanerelement.

3.Oillevelinthecrankcaseislow .

3.Addoiltothecrankcase.

4.Coolingnsandairpassagesforthe engineareplugged.

4.Removetheobstructionsfromthecooling nsandairpassages.

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

5.Installanew,correctlygappedspark plug(s).

6.Ventholeinthefuelcapisclosed.

6.Opentheventinthefuelcap.

7.Dirtinfuellter.7.Replacethefuellter.

8.Dirt,water,orstalefuelisinthefuel system.

8.ContactanAuthorizedServiceDealer.

Enginelosespower

9.Thereisincorrectfuelinthefueltank.

9.Drainthetankandreplacethefuelwith thepropertype.

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

2.Thedrivebeltsareoffofthepulleys.2.ContactanAuthorizedServiceDealer.

Themachinedoesnotdrive.

3.Thedriveisinbypassmode.3.Takemachineoutofbypassmode.Refer toPushingtheMachinebyHand section.

1.Enginemountingboltsareloose.1.Tightentheenginemountingbolts.

2.Looseenginepulley,idlerpulley ,orblade

pulley.

2.Tightentheappropriatepulley .

3.Enginepulleyisdamaged.3.ContactanAuthorizedServiceDealer.

4.Cuttingblade(s)is/arebentorunbalanced.

4.Installnewcuttingblade(s).

5.Bladeisloose.5.Tightentheblademountingboltand inspectthebladespringdiscwasherfor damage(SeeServicingtheCutting Bladessection).

Abnormalvibration

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

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

2.Cuttingblade(s)is/arebent.

2.Installnewcuttingblade(s).

3.Abladeisloose.3.Tightentheblademountingboltand inspectthebladespringdiscwasherfor damage(SeeServicingtheCutting Bladessection).

4.Mowerdeckisnotlevel.4.Levelmowerdeckfromside-to-sideand front-to-rear.

5.Ananti-scalpwheelisnotsetcorrectly5.Adjusttheanti-scalpwheelheight.

6.Undersideofmowerisdirty.6.Cleantheundersideofthemower.

7.Tirepressureindrivetiresnotcorrect.7.Adjusttirepressure.

Unevencuttingheight.

8.Bladespindlebent.8.ContactanAuthorizedServiceDealer.

1.Drivebeltisworn,looseorbroken.1.Installnewdrivebelt.

2.Drivebeltisoffpulley.2.Installdrivebeltandcheckadjusting shaftsandbeltguidesforcorrectposition.

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler pulley,idlerarmandspringforcorrect positionandfunction.

Bladesdonotrotate.

5.Themowerbeltisworn,loose,orbroken.5.Installanewmowerbelt.

Schematics

ElectricalDiagram

FUEL SOLENOID

BRAKE

SWITCH

MOTION

CONTROL

MOTION

CONTROL

STARTER LOCKOUT

& KILL RELAY

START

SOLENOID

GROUND

START

SOLENOID

SIGNAL

START

SOLENOID

B+

PTO

CLUTCH

GROUND

ALTERNATOR

OIL SWITCH

HOUR METER

ACCESSORIES

FUSE BLOCK

IGNITION SWITCH

SEAT SWITCH

PTO SWITCH

ORANGE

Y S X A B

ORANGE

PINK

VIOLET

RED

DK BLUE

LT BLUE

RED

VIOLET

BLACK

DK GREEN

BROWN

WHITE

YELLOW

GREEN

YELLOW

VIOLET

GRAY

VIOLET

MAGNETO

ENGINE

BROWN

DK GREEN

5 3 1 2 4

1 1 1

B A

123

3 5 7 4 6 8 1 2

5 1 4 3 2

2 1

9 8 7 6 5 4 3 2 1

51463

2 1

B A

8 6 4 2

7 5 3 1

G009785

POSITION

CIRCUIT “MAKE”

NONE

B + R + I + A

B + R + I + S

1. OFF

2. RUN

3. START

IGNITION SWITCH

TERMINAL CONNECTIONS

TERMINAL B

TERMINAL A

ACCESSORY

BATTERY

IGNITION

START

RECTIFIER

TERMINAL I

TERMINAL S

TERMINAL R

TERMINAL I

TERMINAL A

TERMINAL R

TERMINAL B

TERMINAL S

CONNECTORS VIEWED FROM WIRE END

NOTE:

Schematics

ElectricalLogicSchematic

START

SOLENOID

B+

START

SOLENOID

GROUND

SHOWN WITH CONTROL

LEVERS IN NEUTRAL

LOCK POSITION

(HANDLES OUT)

SHOWN WITH

BRAKE DISENGAGED

TERMINAL I

TERMINAL A

TERMINAL R

TERMINAL B

TERMINAL S

GROUND

HOUR

METER

START

RUN

OFF

B + R + I + A

NONE

CIRCUIT "MAKE"

S + B + R + I

2. RUN

1. OFF

POSITION

3. START

PINK

RED

VIOLET

ORANGE

VIOLET

ORANGE

RED

VIOLET

ORANGE ORANGE

PINK

GRAY

BROWN

PINK

VIOLET

ORANGE

YELLOW

PTO SWITCH

(DISENGAGED)

SEAT SWITCH

(OPERATOR IN SEAT)

IGNITION SWITCH

FUSE BLOCK

ACCESSORIES

OIL SWITCH

PTO

CLUTCH

START

SOLENOID

SIGNAL

STARTER LOCKOUT

& KILL RELAY

MOTION

CONTROL

MOTION

CONTROL

BRAKE

SWITCH

YELLOW

GREEN

VIOLET

YELLOW

VIOLET

GRAY

VIOLET

BLACK

WHITE

YELLOW

VIOLET

PINK

BLACK

ORANGE

LT. BLUE

DK. GREEN

DK. BLUE

RED

DK. GREEN

BROWN

DK. GREEN

BLACK

WHITE

YELLOW

DK. BLUE

FUEL SOLENOID

MAGNETO

ALTERNATOR

STARTER

BROWN

RED

DK. GREEN

G009777

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* 3-Year, 3rd Year Covered by Exmark

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

This warranty only includes the cost of parts and labor. For the first warrantable service repair, Exmark will cover up to $45 for associated pick-up and delivery charges to and from any authorized Exmark Service Dealer. Additional transportation charges may apply, contact your Dealer for details.

Limited Warranty for Commercial Use

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

 Warranty Exception Warranty Period

• Air Cooled Gas Engines  90 days

Items and Conditions Not Covered

This warranty does not cover the following:

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

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

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

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

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

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

All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts.

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

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

General Conditions

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

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

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

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

Exmark Quest Turf Equipment

3-Year Limited Consumer Warranty

(30-Day Limited Commercial Warranty)

G4500-428

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF 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

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-F RONT RIDING AC CESSORIES 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

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

ModelNo.EngineSerialNo.(E/No)

SerialNo.

PartNo.4500-450Rev .A (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark Quest 4500-450, QST22BE482, QST24BE522, Quest 790, 000 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual