Exmark Quest User Manual

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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.

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Figure1

Behindtheseat

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.

•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.

GeneralOperation

•Read,understand,andfollowallinstructionsin theoperator’ smanualandonthemachinebefore starting.

•DoNotplacehandsorfeetnearrotatingpartsor underthemachine.Keepclearofthedischarge openingatalltimes.

•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.

AllUnitsExceptQST20BE422

1.Choke–on

2.Throttle–fast

3.Continuousvariablesetting

4.Throttle–slow

109-6008

1.ReadtheOperator’s Manual.

2.Rotatethedriverelease knobtoloosen,slidethe knob,andtighten.

3.Pushthemachine.

103-6327

109-6014

TractionDriveBeltRouting

106-5517

1.Warning–DoNottouchthehotsurface.

DeckDriveBeltRouting

Safety

109-9120

109-6035

1.Fuse2.Diode

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.

109-9173

1.Parkingbrake4.Neutral

2.Fast5.Reverse

3.Slow6.MachineSpeed

109-9182

1.Machinespeed4.Neutral

2.Fast5.Reverse

3.Slow

Safety

1.Thrownobjects hazard–keepbystanders asafedistancefromthe machine.

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

110-6691

3.Cutting/dismemberment ofhandorfoot–stay awayfrommovingparts.

116-0532

QST20BE422Unit

1.Choke–on

2.Throttle–fast

3.Continuousvariablesetting

4.Throttle–slow

116-0531

116-0533

116-0551

116-0581

PTOSymbols

1.PTO—Off2.PTO—On

Safety

109-6016

1.Readtheinstructionsbeforeservicingorperforming maintenance.

2.Timeinterval

3.Checkoillevel.6.Checktirepressure.

4.RefertotheOperator’smanualforgreaseinstructions.

5.CheckhydraulicoillevelandrefertotheOperator’s Manualforfurtherinstructions.

Safety

1.Warning–readtheOperator’sManual.

2.Readtheinstructionsbeforeservicingorperforming maintenance;applyparkingbrake,removetheignitionkey anddisconnectthesparkplugwire.

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

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

109-8965

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

6.Cutting/dismembermenthazardofhandorfoot,mower blade–stayawayfrommovingparts.

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

BatterySymbols

Someorallofthesesymbolsareonyourbattery.

1.Explosionhazard

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

3.Causticliquid/chemicalburnhazard

4.Weareyeprotection8.Batteryacidcancauseblindnessor

5.ReadtheOperator’sManual.

fromthebattery.

7.Weareyeprotection;explosive gasescancauseblindnessand otherinjuries.

severeburns.

9.Flusheyesimmediatelywithwater andgetmedicalhelpfast.

10.Containslead;donotdiscard.

Specications

ModelNumbers

SerialNos:790,000andHigher

QST20BE422;QST22BE482;QST24BE522

Specications

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”)

•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.

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.)

•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

Deck Size

Quantity

Tread

Size20x

Ply Rating

Pressure

42&48524248&52

2222

TurfTecTurfTecSawtoothSmooth

8.00-8

13psi (90kPa)

Pneumatic

(Air-Filled)

20x

10.00-8

13psi (90kPa)

Pneumatic

(Air-Filled)

10x410x4

20psi (138kPa)

13psi (90kPa)

•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:

Without Deck

Deector Up

Deector Down

42inch Deck

45.5inches (116cm)

43.1inches (109cm)

54.2inches (138cm)

48inch Deck

45.5inches (116cm)

48.3inches (122cm)

59.4inches (151cm)

52inch Deck

47.0inches (119cm)

53.0inches (135cm)

64.2inches (163cm)

CuttingDeck

•CuttingWidth:

–42inchDeck:42inches(107cm)

–48inchDeck:48inches(122cm)

–52inchDeck:52inches(132cm)

•Discharge:Side

OverallLength:

AllUnits

73.4inches(186cm)

ProductOverview

OverallHeight:

AllUnits

41.8inches(106cm)

TreadWidth:(CentertoCenterof Tires,Widthwise)

Drive Wheels

Caster Wheels

42inch Deck

36.0inches (91cm)

27.9inches (71cm)

48inch Deck

36.0inches (91cm)

33.5inches (85cm)

52inch Deck

36.8inches (93cm)

33.5inches (85cm)

WheelBase:(CenterofCasterTireto CenterofDriveTire)

AllUnits

48.9inches(124cm)

CurbWeight:

42inchDeck48inchDeck52inchDeck

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

ProductOverview

Figure3

1.Frontcasterwheel8.Engine

2.Anti-scalproller

3.Heightofcutfootlever

4.Dischargedeector

5.Heightofcutadjustment

6.Reardrivewheel13.Footrest

7.Controlpanel14.Washouttting

9.Seat

10.Armrest

11.Motioncontrollevers

12.Parkbrake

TorqueRequirements

BoltLocation

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

BladeMountingBolt (lubricatewithanti-seize)

EngineMountingBolts

Anti-ScalpRollerNyloc Nut

WheelLugNuts

ClutchMountingBolt (securedwiththreadlocker)

SparkPlug

Torque

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

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

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

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

15ft-lb(20N-m)

Operation

Controls

Note:Becomefamiliarwithallofthecontrolsin

Figure3andFigure4beforeyoustarttheengineand operatethemachine.

IgnitionSwitch

Locatedoncontrolpanel.

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

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).

Figure4

1.Throttle/Chokelever

2.Hourmeter4.Ignitionswitch

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

TurningthekeytotheOffpositionwillstopthe engine;however,alwaysremovethekeywhenleaving themachinetopreventsomeonefromaccidentally startingtheengine

3.Bladecontrolswitch (powertake-off)

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.

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.

Note:Thisswitchisnotalowoilsensorandwillnot alerttheoperatoriftheengineoilislow .

OperatingInstructions

ThinkSafetyFirst

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Pleasecarefullyreadallofthesafetyinstructions anddecalsinthesafetysection.Knowingthis informationcouldhelpyou,yourfamily,petsor bystandersavoidinjury.

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.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof30daysor less.Forlongerstorageitisrecommendedthat thefueltankbedrained.

•Cleanstheenginewhileitruns.

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

Operation

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

2.Bladecontrol switch—Offposition

3.Ignitionkey

4.Off8.Throttle–fast(detent

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.

5.Run

6.Start

7.Choke

position)

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.

OperatingtheBlades

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

EngagingtheBlades

1.Releasepressureonthemotioncontrolleversand placethemachineinneutral.

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.

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.

TestingtheSafetyInterlockSystem

Testthesafetyinterlocksystembeforeyouusethe machineeachtime

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

Trytostartwithoperatorinseat,parkingbrake disengaged,PTOdisengagedandmotioncontrol leversintheneutrallockposition-startermust

notcrank.

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).

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.

Figure9

1.Neutralposition3.Backward

2.Centerunlockposition

Togostraight,applyequalpressuretoboth motioncontrollevers(Figure9).

Toturn,pullbackonthemotioncontrollever towardthedirectionyouwanttoturn(Figure9).

4.Forward

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemowerwhile itisunattended.

Alwaysremovetheignitionkeyandmovethe motioncontrolleversoutwardtotheneutral positionandapplytheparkingbrakewhen leavingthemachineunattended,evenifjust forafewminutes.

AdjustingtheHeightofCut

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

Thefartheryoumovethemotioncontrollevers ineitherdirection,thefasterthemachinewill moveinthatdirection.

Tostop,pullthemotioncontrolleverstoneutral.

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.

Operation

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).

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

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.

Figure14

1.Bolt

2.Washer5.Nut

3.Controllever

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththetwobolts.

4.Controlarmshaft

Figure13

1.Bolt3.Nut

2.Spring

Uptovespringscanbesecuredtotheseatboxwith anutandbolt,seeFigure13.

RefertoyourPartsManualforspringandhardware partnumbers.

4.Additionalmounting holes

AdjustingtheMotionControl Levers

3.Repeattheadjustmentfortheoppositecontrol lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraft(Figure14).Tightenboth boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

PushingtheMachineby Hand

Important:Alwayspushthemachinebyhand.

Nevertowthemachinebecausedamagemay occur.

AdjustingtheHeight

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethetwoboltsholdingthecontrolleverto thecontrolarmshaft(Figure14).

ToPushtheMachine

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardto neutralposition,engageparkingbrake,stopthe

Operation

engine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Locatethebypassreleaseknobsoneithersideof theenginedeck(Figure15).

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).

Figure15

1.Frontofthemachine.5.Leverpositionfor

2.Rotatebypassrelease knobcounterclockwise

3.Leverpositionfor operatingthemachine.

4.Pullleverinthisdirection

pushingthemachine

6.Rotatebypassrelease knobclockwise

7.Releaselever

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

5.Releasetheparkingbrake.Themachineisnow abletobepushedbyhand.

ToOperatetheMachine

Loosenthebypassknob,pushthereleaselevers forward,andretightentheknobtoengagethedrive system(Figure15).

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.

SideDischarge

Themowerhasahingeddischargedeectorthat dispersesclippingstothesideanddowntowardthe turf.

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

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.

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.

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.

CuttingSpeed

Toimprovecutquality,useaslowergroundspeed.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthe moweryoupreviouslyused,raisethecuttingheight toensurethatuneventurfisnotcuttooshort.

LongGrass

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

WhenStopping

Operation

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

Aftertherst5hours

Aftertherst250hours

Beforeeachuseordaily

Every25hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Changethehydrauliclter.

•Checkthesafetyinterlocksystem.

•Checktheairintakeandcoolingareas,cleanasnecessary.

•Checktheoillevelbeforestartingorafterevery8hours.

•Checkthehydraulicoillevelintheexpansiontank.

•Checkthemowerblades.

•Cleanthemowerhousing.

•Greasealllubricationpoints.

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

•Servicetheaircleaner.(Mayneedmoreoftenunderextremelydustyordirtyconditions.)

•Checkthetirepressure.

•Checkthebelts.

•Replacethepaperelement.(Moreoftenunderextremelydusty,dirtyconditions.)

•Replacetheaircleanerelement.

•Changetheengineoilandlter.

•Cleantheblowerhousing.Moreoftenunderdirtyconditions.

•Replacethefuellter.

Every200hours

Every500hours

•Servicethesparkplug.

•Changethehydrauliclter(Every250hoursifusingMobil115W50)

•Replacethesparkplug.

Maintenance

G007184

MaintenanceService

Interval

Beforestorage

Monthly

Important:RefertoyourEngineOperator’sManualforadditionalmaintenanceprocedures.

Premaintenance

MaintenanceProcedure

•Chargethebatteryanddisconnectthebatterycables.

•Performallmaintenanceproceduresbeforestorage.

•Paintanychippedsurfaces.

•Checkthebatterycharge.

PeriodicMaintenance

Procedures

Lubrication

RaisingtheSeat

Makesurethemotioncontrolleversarelockedin theneutralposition.Lifttheseatforwarduntilthe lanyardistight.Thefollowingcomponentscanbe accessedbyraisingtheseat:

•Auxiliary12VPlug(12Vaccessoryupto15amp)

GreasingtheBearings

ServiceInterval:Every25hours/Monthly

(whichevercomesrst)

GreaseType:NGLIgrade#2multi-purposegun grease.

•Fuses

•Batterycables

AccessingtheBattery

Thebatteryislocatedundertheseat.Toaccess,raise theseat(Figure16).

Figure16

1.Auxiliary12VPlug

2.Battery

3.Seat

Greasethefrontcasterwheels(Figure17).

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

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.

Figure18

Locatedonthebackoftheseat.

1.Readtheinstructions beforeservicingor performingmaintenance

2.Greaseidlerpivot—All units.

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

4.Checkoillevel.

5.Checkhydraulicoillevel andrefertoOperator’s manualforfurther instructions.

6.Checktirepressure.

and52inchonly.

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

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.

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.

Maintenance

Figure20

1.Oildipstick3.Oillevel

2.Fillertube

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).

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.

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.

Figure21

1.Oildrain

2.Oildrainplug

3.Pan

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

Figure22

1.Oillter2.Gasket

6.Besuretoallowampletimeforcomplete drainage.

15.Installtheoilllcap/dipstickandpushrmly intoplace.

16.Starttheengineandcheckforleaks.

CheckingtheHydraulicOil Level

ServiceInterval:Beforeeachuseordaily

CheckexpansiontankandifnecessaryaddExmark PremiumHydrooiltotheFULLCOLDline.

7.Removetheoldlterandwipeoffthemounting pad(Figure22).

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

Figure23

1.Engine2.Expansiontank

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

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

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

ChangeInterval

500Hours

250Hours

Maintenance

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.

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).

Figure25

1.Sparkplugandwirelocation

CheckingtheSparkPlug

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

Important:Nevercleanthesparkplug. Alwaysreplacethesparkplugwhenithasa

CleaningtheBlowerHousing

ServiceInterval:Every100hours/Yearly

(whichevercomesrst) Moreoftenunderdirty conditions.

Toensurepropercooling,makesurethegrassscreen, coolingns,andotherexternalsurfacesoftheengine arekeptcleanatalltimes.

1.Removetheblowerhousingandanyothercooling shrouds.

2.Cleanthecoolingnsandexternalsurfacesas necessary.

3.Makesurethecoolingshroudsarereinstalled

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

FuelSystemMaintenance

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.

Figure27

1.Fueltank6.Hoseclamps

2.Fuelshutoffvalve—off

3.Fuelshutoffvalve

4.Fuelshutoffvalve—on

5.Fuellinefromtank

7.Fuellinetoengine

8.Filter

9.Flowdirectionarrow

Maintenance

Neverinstalladirtylterifitisremovedfromthe fuelline.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

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

3.Thefuellterisinthefuellinebetweenthetank andengine.

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.

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.

Figure28

1.Negativebatterypost4.Positivebatterypost

2.Bolt,washer,andnut5.Batterystrap

3.Terminalboot6.Battery

Note:Topreventdamageduetofreezing, batteryshouldbefullychargedbeforeputting awayforwinterstorage.

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

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

Maintenance

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

14.4volts/2 amps

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

Charging Interval

No Charging Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

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).

Figure29

1.Negativebatterypost

2.Black(-)chargerlead

3.Red(+)chargerlead

4.Positivebatterypost

Note:DoNotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.

InstallingtheBattery

1.Positionthebatteryinthetraywiththeterminal poststowardtheoperatingposition(Figure28).

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

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)

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).

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.

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.

1.Bladesfronttorear

Figure33

48and52InchDeck

2.Measurehere

Maintenance

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.

Figure34

42InchDeck

1.Bladesfronttorear

2.Measurehere

2.Rotatetheoppositeendsofthebladesforward.

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

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

Important:Thecurvedpartoftheblade

mustbepointingupwardtowardtheinsideof themowertoensurepropercutting.

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

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

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.

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

Figure37

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure35).

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

2.Spring

3.Idlerpulley6.Pullbeltstrandsinthis

4.Mowerbelt

5.Enginepulley

direction.

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.

Figure39

42InchDeck

1.Outsidepuley

2.Spring

3.Idlerpulley6.Pullbeltstrandsinthis

4.Mowerbelt

5.Enginepulley

direction.

6.Routethenewbeltaroundthemowerpulleys.

Figure40

48and52InchDecks

1.Bladessidetoside2.Measurehere

Maintenance

Figure41

42InchDeck

1.Bladessidetoside2.Measurehere

6.Setanti-scalprollerstotopholesorremove completelyforthisadjustment.

11.Continuelevelingthedeckbycheckingthe front-to-rearbladeslope;refertoAdjustingthe

Front-to-RearBladeSlope.

12.Recheckbladesforlevelnessandrepeatdeck levelingprocedureifnecessary.

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

48& 52

FrontBlock Height“A”

2.19inches (5.6cm)

2.31inches (5.9cm)

RearBlock Height“B”

2.44inches (6.2cm)

2.50inches (6.4cm)

Rake“R”

1/8–3/8inch (3.2–9.5mm)

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

Figure42

1.Deckliftarm

2.Floatretainingnut4.Levelingadjustlocking

3.Deckhanger

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

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

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

Maintenance

Figure44

48and52InchDecks

Figure43

1.Deckliftarm

2.Floatretainingnut4.Levelingadjustlocking

3.Deckhanger

nut

8.Carefullyrotatethebladessotheyarefacingfront torear(Figure44andFigure45).

1.Bladesfronttorear

42InchDeck

1.Bladesfronttorear

2.Measurehere

Figure45

2.Measurehere

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

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

Maintenance

ReplacingtheDischarge Deector

DANGER

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

Neveroperatethelawnmowerunlessyou installamulchplate,dischargedeector,or grasscollectionsystem.

1.LocateitemsshowninFigure46.

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

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

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

Figure46

1.Rod4.Mowerdeck

2.Spring5.Dischargedeector

3.Dischargedeector

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

3.Installnewdischargedeector.

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

bracket

6.Assembledview

Maintenance

Adjustments

TrackingAdjustment

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

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.

1.Controlarmshaft

2.Trackingplatenut

Figure47

3.Trackingplate

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.

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.

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.

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,DoNotoverlookthesimplecauses.Forexample:startingproblemscouldbe causedbyanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDONOTpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Theengineoverheats.

Thestarterdoesnotcrank

Enginewillnotstart,startshard,orfailsto keeprunning

1.Theengineloadisexcessive.1.Reducegroundspeed.

2.Theoillevelinthecrankcaseislow .

3.Thecoolingnsandairpassagesunder theengineblowerhousingareplugged.

4.Theaircleanerisdirty.

5.Dirt,water,orstalefuelisinfuelsystem.

1.Thebladecontrolswitchisengaged.1.Movethebladecontrolswitchto

2.Themotioncontrolleversarenotinthe parkposition.

3.Theoperatorisnotseated.

4.Thebatteryisdead.4.Chargethebattery.

5.Theelectricalconnectionsarecorroded orloose.

6.Afuseisblown.

7.Arelayorswitchisdamaged.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Thechokeisnoton.2.MovethechokelevertoOn.

3.Theaircleanerisdirty.

4.Thesparkplugwire(s)islooseor disconnected.

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

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

7.Dirt,water,orstalefuelisinthefuel system.

8.Thereisincorrectfuelinthefueltank.

9.Theoillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

3.Removetheobstructionfromthecooling nsandairpassages.

4.Cleanorreplacetheaircleanerelement.

5.ContactanAuthorizedServiceDealer.

Disengaged.

2.Movethemotioncontrolleversoutward totheparkposition.

3.Sitontheseat.

5.Checktheelectricalconnectionsforgood contact.

6.Replacethefuse.

3.Cleanorreplacetheaircleanerelement.

4.Installthewire(s)onthesparkplug.

5.Installanew,correctlygappedspark plug(s).

7.ContactanAuthorizedServiceDealer.

8.Drainthetankandreplacethefuelwith thepropertype.

9.Addoiltothecrankcase.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Enginelosespower

Themachinedoesnotdrive.

Abnormalvibration

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

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

6.Ventholeinthefuelcapisclosed.

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

8.Dirt,water,orstalefuelisinthefuel system.

9.Thereisincorrectfuelinthefueltank.

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

2.Thedrivebeltsareoffofthepulleys.2.ContactanAuthorizedServiceDealer.

3.Thedriveisinbypassmode.3.Takemachineoutofbypassmode.Refer

1.Enginemountingboltsareloose.1.Tightentheenginemountingbolts.

2.Looseenginepulley,idlerpulley ,orblade pulley.

3.Enginepulleyisdamaged.3.ContactanAuthorizedServiceDealer.

4.Cuttingblade(s)is/arebentorunbalanced.

5.Bladeisloose.5.Tightentheblademountingboltand

6.Bladespindleisbent.6.ContactanAuthorizedServiceDealer.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.Installanew,correctlygappedspark plug(s).

6.Opentheventinthefuelcap.

8.ContactanAuthorizedServiceDealer.

9.Drainthetankandreplacethefuelwith thepropertype.

toPushingtheMachinebyHand section.

2.Tightentheappropriatepulley .

4.Installnewcuttingblade(s).

inspectthebladespringdiscwasherfor damage(SeeServicingtheCutting Bladessection).

Unevencuttingheight.

Bladesdonotrotate.

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

2.Cuttingblade(s)is/arebent.

3.Abladeisloose.3.Tightentheblademountingboltand

4.Mowerdeckisnotlevel.4.Levelmowerdeckfromside-to-sideand

5.Ananti-scalpwheelisnotsetcorrectly5.Adjusttheanti-scalpwheelheight.

6.Undersideofmowerisdirty.6.Cleantheundersideofthemower.

7.Tirepressureindrivetiresnotcorrect.7.Adjusttirepressure.

8.Bladespindlebent.8.ContactanAuthorizedServiceDealer.

1.Drivebeltisworn,looseorbroken.1.Installnewdrivebelt.

2.Drivebeltisoffpulley.2.Installdrivebeltandcheckadjusting

3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.

4.Deckbeltisoffpulley.4.Installdeckpulleyandchecktheidler

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

2.Installnewcuttingblade(s).

inspectthebladespringdiscwasherfor damage(SeeServicingtheCutting Bladessection).

front-to-rear.

shaftsandbeltguidesforcorrectposition.

pulley,idlerarmandspringforcorrect positionandfunction.

Schematics

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

ElectricalDiagram

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

Schematics

ElectricalLogicSchematic

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:

535455

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

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

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

www.exmark.com

Exmark Quest User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual