Exmark QUEST 850000 AND HIGHER User Manual

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QUEST®

ForSerialNos. 850,000&Higher

PartNo.4500-523Rev.B

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

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

Toacquireasparkarresterforyourunit,seeyour EngineServiceDealer.

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 .

Exmarkpartsmanualsareavailableonlineat http://www.exmark.com/manuals.htm.Youmay contactExmarkdirectlyatwww.Exmark.comfor productandaccessoryinformationorhelpnding adealer.

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.......................9

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

StoppingtheMachine....................................23

AdjustingtheHeightofCut...........................23

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

PositioningtheSeat.......................................24

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

AdjustingtheMotionControlLevers.............25

PushingtheMachinebyHand........................25

SideDischarge...............................................26

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

OperatingTips.............................................27

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

RecommendedMaintenanceSchedule(s)...........29

PremaintenanceProcedures..............................30

RaisingtheSeat.............................................30

AccessingtheBattery....................................30

PeriodicMaintenance.......................................30

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

EngineMaintenance......................................31

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

CheckingtheHydraulicOilLevel...................33

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

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

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

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

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

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

ServicingtheFusesandRelay.........................39

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

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

MowerMaintenance......................................40

ServicingtheCuttingBlades..........................40

MowerBeltMaintenance...............................42

LevelingtheMowerDeck..............................43

AdjustingtheBladeSlope..............................44

ReplacingtheDischargeDeector.................45

Adjustments.....................................................46

TrackingAdjustment.....................................46

BrakeLinkageAdjustment.............................46

Cleaning...........................................................47

WashingtheUndersideoftheMower.............47

Storage.................................................................49

CleaningandStorage.....................................49

Troubleshooting...................................................50

Schematics...........................................................52

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.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator’s

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

•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.

Safety

•UseonlyExmarkapprovedattachments. Warrantymaybevoidedifusedwithunapproved attachments.

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

Note:Theleftandrightsidesofthemachineare determinedwhilesittingintheseatinthenormal operatingposition

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedorlost.

93-7009

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

2.Cutting/dismemberment

Safety

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.

Safety

109-9120

109-6035

DeckDriveBeltRouting

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

1.Thrownobjects hazard–keepbystanders asafedistancefromthe machine.

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

Safety

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

Safety

117–2718

PTOSymbols

1.PTO—Off2.PTO—On

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.

116-2321

1.Readtheinstructionsbeforeservicingorperforming maintenance.

2.Timeinterval

3.Checkoillevel.6.RefertotheOperator’smanualforgreaseinstructions.

4.CheckhydraulicoillevelandrefertotheOperator’s Manualforfurtherinstructions.

5.Checktirepressure.

Safety

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:850,000andHigher

QST20BE422;QST22BE482;QST24BE522;QST22BE482C;QST24BE522C

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;containingnomorethan10% methanolorethanol.

•FuelFilter:

Briggs&StrattonP/N695666

engine.(Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.)

•OperatormustbeinseatwhenPTOisengaged, brakeisdisengaged,ormotioncontrolleversare movedinorenginewillstop.

•Enginewillstopifeithertheleft,theright,or bothleversaremovedfromneutrallockposition whilebrakeisengaged.

OperatorControls

•SteeringandMotionControl:

Note:Motioncontrolleversareadjustableto twoheights.

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

–Movingmotioncontrolleversoutward(in

slots)locksthedrivesysteminneutral.

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

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:16amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:One25amp,one20amp;one15amp bladetype

•Diode:TVS

SafetyInterlockSystem

•PTOmustbedisengaged,brakeengaged,and motioncontrolleversout(neutrallock)tostart

•PTOEngagementSwitch:Engageselectricclutch (todrivebelt)whichengagesmowerblades.

•ParkingBrakeLever:Engagesparkingbrake.

•DeckHeightAdjustmentPin:Setscuttingheight todesiredposition.

•DeckLiftAssistLever:Footpedalthatassists inraisingthedeck.

Seat

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

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

Specications

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

•SeatSafetySwitch:IncorporatedintotheSafety InterlockSystem.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearZT2800 Integrateddrivesystems.

•HydraulicOilType:ExmarkPremiumHydrooil.

•Speeds:

–42inchunit

◊0-6.0mph(9.7km/hr)forward.

◊0-4.0mph(6.4km/hr)reverse.

–48inchand52inchunits

◊0-7.0mph(11.3km/hr)forward.

◊0-5.0mph(8.0km/hr)reverse.

•Drivewheelreleases,locatedonleftandright sidesofenginedeck,allowmachinetobemoved whentheengineisnotrunningandbrakeisoff.

Tires&Wheels

DriveFrontCaster

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(see

Figure4).

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(

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

Figure3).

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

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

Toavoidlossofcontrolandpossibilityofrollover:

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon slopes.

•Whenmowingslopes,graduallyworkfrom lowertohigherareasontheincline.

•Avoidsuddenturnsorrapidspeedchanges.

•Turnup,intoaninclinewhenchanging directionsonslopes.Turningdowntheslope reducestraction.

•Attachmentschangethehandling characteristicsofthemachine.Useextra cautionwhenusingattachmentswiththe machine.

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.

Seeinsidebackcovertodeterminetheapproximate slopeangletobemowed.

RecommendedGasoline

UseUNLEADEDRegularGasolinesuitablefor automotiveuse(87pumpoctaneminimum).

Operation

Important:Neverusemethanol,gasoline

containingmethanol,gasoholcontainingmore than10%ethanol,premiumgasoline,orwhite gasbecausethefuelsystemcouldbedamaged. DoNotmixoilwithgasoline.

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburnyou, others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground,in anopenarea,whentheengineiscold.Wipe upanygasolinethatspills.

•Neverrellthefueltankordrainthemachine indoorsorinsideanenclosedtrailer.

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

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.

DANGER

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

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebeforelling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowtheloss ofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimes untilfuelingiscomplete.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Never buymorethana30-daysupplyofgasoline.

•DoNotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascausedcancer inlaboratoryanimals.Failuretousecautionmay causeseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

Operation

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof30daysor less.Forlongerstorageitisrecommendedthat thefueltankbedrained.

•Cleanstheenginewhileitruns.

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

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

Gasoline/Alcoholblends

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

FillingtheFuelTank

1.Shuttheengineoffandsetthemotioncontrols totheneutralpositionandengageparkingbrake.

2.Cleanaroundthefueltankcapandremovethe cap.

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

Figure6).Thisspaceintheneckofthe

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).

Figure7

1.Throttle/Chokelever

2.Bladecontrol switch—Offposition

3.Ignitionkey

4.Off8.Throttle–fast(detent

5.Run

6.Start

7.Choke

position)

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

Note:Awarmorhotenginemaynotrequire choking.

4.TurntheignitionkeytoStarttoenergizethe starter.Whentheenginestarts,releasethekey

Figure7).

(

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

5.Oncetheenginestarts,movethelevertothe detentposition.Iftheenginestallsorhesitates, movetheleverpartiallyforwardforafewseconds.

Operation

2.MovethethrottlemidwaytotheFastposition.

Note:Alwaysengagethebladeswiththethrottle inthemidwayposition.

3.Pulloutonthebladecontrolswitch,totheOn position,toengagetheblades(

Figure8

1.Throttle–Midway position

2.Bladecontrol

Figure8).

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

Ifthesafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitches beforeoperatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:

•Thebladesaredisengaged.

•Themotioncontrolleversareintheneutral position.

•Theparkingbrakeisengaged.

Thesafetyinterlocksystemisdesignedtoinitiate engineshutdownwhen:

•Theparkingbrakeisdisengagedandtheoperator getsoffmachine.

•ThePTOisengagedandtheoperatorgetsoff machine.

•Theparkingbrakeisdisengagedandleversarein andtheoperatorgetsoffmachine.

•Theparkingbrakeisengagedandmotioncontrol leversarein.

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.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOengagedandmotioncontrol leversintheneutrallockposition-startermust notcrank.

DrivingForwardorBackward

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

CAUTION

Machinecanspinveryrapidlybypositioningone levertoomuchaheadoftheother.Operatormay losecontrolofthemachine,whichmaycause damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

Operation

Forward

1.Movetheleverstothecenter,unlockedposition.

2.Togoforward,slowlypushthemotioncontrol leversforward(

1.Neutralposition3.Backward

2.Centerunlockposition

Figure9).

Figure9

4.Forward

StoppingtheMachine

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

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemowerwhileit isunattended.

Alwaysremovetheignitionkeyandmovethe motioncontrolleversoutwardtotheneutral positionandapplytheparkingbrakewhen leavingthemachineunattended,evenifjustfora fewminutes.

AdjustingtheHeightofCut

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

Figure10).Thetransportleverwill

Togostraight,applyequalpressuretoboth motioncontrollevers(Figure9).

Toturn,pullbackonthemotioncontrollever towardthedirectionyouwanttoturn(Figure9).

Thefartheryoumovethemotioncontrollevers ineitherdirection,thefasterthemachinewill moveinthatdirection.

Tostop,pullthemotioncontrolleverstoneutral.

Backward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotioncontrol leversrearward(

Togostraight,applyequalpressuretoboth motioncontrollevers(Figure9).

Toturn,releasethepressureonthemotion controllevertowardthedirectionyouwantto

Figure9).

turn(

Tostop,pushthemotioncontrolleverstoneutral.

Figure9).

Figure10

1.Transportreleasehandle3.Heightadjusterpin

2.Height-of-cutpositions

4.Footactuated height-of-cutlever

2.Movethedeckheightadjusterpintothedesired cutheight.

3.Pushthefootleverforward,pullthetransport releasehandleupandletthedecklowerdownto thepredeterminedcutheightbyslowlydecreasing footpressureallowingthefootlevertotravel rearward.

Operation

AdjustingtheAnti-Scalp Rollers

Itisrecommendedtochangetheanti-scalproller positionwhentheheightofcuthaschanged.

1.Stopthemachineandmovethedriveleversto theneutrallockposition.

2.DisengagethePTO.

3.Engagetheparkbrake.

4.Stoptheengine,removethekeyandwaitforall movingpartstostop.

5.Afteradjustingtheheightofcut,adjustthe anti-scalprollersbyremovingthenylocnut.

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

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

Figure11.Rollerswill

•48and52InchUnits:

1.Pushtheadjustmentlevertowardsthecenter ofthemachinetoreleasetheseatadjuster track(

1.Adjustmentlever

2.Movetheseattothedesiredpositionand releasethelevertolockinthatposition.

•42InchUnit:

1.Tiptheseatforward.

2.Loosentheknob.

Figure12).

Figure12

Figure11

Forcuttingheightsabove31/2inches(90mm)usethe

bottomhole.Therollerswillstillbeeffectiveagainst

scalping.

1.Anti-scalproller mountingbracket

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

2.Cuttingheight

PositioningtheSeat

Theseatcanmoveforwardandbackward.Position theseatwhereyouhavethebestcontrolofthe machineandaremostcomfortable.

3.Movetheseattothedesiredposition.

4.Tightentheknob.

5.Tiptheseatbacktotheclosedposition.

ChangingtheSeatRide Suspension

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

Operation

2.Movethecontrollevertothenextsetofholes. Securetheleverwiththehardware.

3.Repeattheadjustmentfortheoppositecontrol lever.

AdjustingtheTilt

Themotioncontrolleverscanbetiltedforeoraftfor maximumoperatorcomfort.

1.Loosentheupperboltholdingthecontrollever tothecontrolarmshaft.

Figure13

1.Bolt3.Nut

2.Spring

Uptovespringscanbesecuredtotheseatboxwith anutandbolt,see

RefertoyourPartsManualforspringandhardware partnumbers.

Figure13.

4.Additionalmounting holes

AdjustingtheMotionControl Levers

AdjustingtheHeight

Themotioncontrolleverscanbeadjustedhigheror lowerformaximumoperatorcomfort.

1.Removethehardwareholdingthecontrolleverto thecontrolarmshaft(Figure14).

2.Loosenthelowerboltjustenoughtopivotthe controlleverforeoraft(Figure14).Tightenboth boltstosecurethecontrolinthenewposition.

3.Repeattheadjustmentfortheoppositecontrol lever.

PushingtheMachineby Hand

Important:Alwayspushthemachinebyhand.

Nevertowthemachinebecausedamagemay occur.

ToPushtheMachine

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

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

Figure14

1.Nut4.Washer

2.Controllever

3.Controlarmshaft

3.Locatethebypassreleaseknobsoneithersideof theenginedeck(

5.Bolt

Figure15).

Operation

Figure15

1.Frontofthemachine.5.Leverpositionfor

2.Rotatebypassrelease knobcounterclockwise

3.Leverpositionfor operatingthemachine.

4.Pullleverinthisdirection

pushingthemachine

6.Rotatebypassrelease knobclockwise

7.Releaselever

DANGER

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

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

•Neverputyourhandsorfeetunderthe mower.

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

Transporting

TransportingaUnit

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

5.Releasetheparkingbrake.Themachineisnow abletobepushedbyhand.

ToOperatetheMachine

Loosenthebypassknob,pushthereleaselevers forward,andretightentheknobtoengagethedrive system(Figure15).

SideDischarge

Themowerhasahingeddischargedeectorthat dispersesclippingstothesideanddowntowardthe turf.

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

CAUTION

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

DoNotdriveaunitonapublicstreetorroadway .

Operation

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityofbackwardtip-over.Backward tip-overcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit onaramp.

•Useonlyasingle,fullwidthramp;DoNot useindividualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.

•DoNotexceeda15°anglebetweenrampand groundorbetweenrampandtrailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

LoadingaUnit

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

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

OperatingTips

FastThrottleSetting

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

CuttingaLawnfortheFirstTime

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

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrowsmore slowly.

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhich enhancesdecompositionandfertilization.

MowatCorrectIntervals

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

CuttingSpeed

Important:DoNotattempttoturntheunit

whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdownaramp. Bothmaneuverscancausetheunittotipbackward.

Toimprovecutquality ,useaslowergroundspeed.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthe moweryoupreviouslyused,raisethecuttingheight toensurethatuneventurfisnotcuttooshort.

Operation

LongGrass

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

WhenStopping

Ifthemachine’sforwardmotionmustbestopped whilemowing,aclumpofgrassclippingsmaydrop ontoyourlawn.Toavoidthis,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.

Maintenance

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

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

WARNING

Theenginecanbecomeveryhot.T ouchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

RecommendedMaintenanceSchedule(s)

WARNING

Removingstandardoriginalequipmentparts, orusingnon-Exmarkreplacementpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.

Replaceallpartsincluding,butnotlimitedto tires,belts,andbladeswithoriginalExmark parts.

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

Beforeeachuseordaily

Every25hours

Every100hours

Every200hours

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.

•Servicethesparkplug.

Every500hours

•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(Figure17)witharag. Makesuretoscrapeanypaintoffofthefrontof thetting(s).

4.Wipeupanyexcessgrease.

Maintenance

EngineMaintenance

ServicingtheAirCleaner

ServiceInterval:Every25hours/Monthly

(whichevercomesrst) (Mayneedmoreoften underextremelydustyor dirtyconditions.)

Every100hours/Yearly (whichevercomes rst)—Replacethepaper element.(Moreoften underextremelydusty, dirtyconditions.)

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

Note:Operatingtheenginewithlooseordamaged aircleanercomponentscouldallowunlteredairinto theenginecausingprematurewearandfailure.

Note:Servicetheaircleanermoreoftenunder extremelydusty,dirtyconditions.

ServicingPaperElement

ServiceInterval:Every25hours/Monthly

(whichevercomesrst) (Mayneedmoreoften underextremelydustyor dirtyconditions.)

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

1.Removetheaircleanercover(

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.

Figure18).

Figure18

1.Aircleaner3.Aircleanercover

2.Knobs

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(Figure19).

Maintenance

Figure19

1.Oildipstick3.Oillevel

2.Fillertube

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Cleantheareaaroundthedrainplugandonthe machineframe.Placeapanunderneathmachine directlybelowthedrainholeintheframeas shownin

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.

Figure20

1.Oildrain

2.Oildrainplug

3.Pan

5.Removetheoildrainplug(Figure20).Remove theoilllcap/dipstick(Figure19).

Figure21

1.Oillter2.Gasket

6.Besuretoallowampletimeforcomplete drainage.

7.Removetheoldlterandwipeoffthemounting pad(Figure21).

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

Maintenance

in-lb)torque.Wipeupanyexcessoilontheframe (Figure20).

Note:Disposeoftheusedoilatarecycling center.

9.Applyathinlmofcleanoiltotherubbergasket onthenewlter.

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

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

12.Installtheoilllcap/dipstickandpushrmly intoplace.

13.Checktheoillevel(Figure19);refertoChecking

theOilLevel.

14.Slowlyaddadditionaloiltobringittothefull mark.DoNotoverll.

15.Installtheoilllcap/dipstickandpushrmly intoplace.

16.Starttheengineandcheckforleaks.

Figure21).

ChangetheHydraulic SystemFilter

ServiceInterval:Aftertherst100hours

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.

CheckingtheHydraulicOil Level

ServiceInterval:Beforeeachuseordaily

CheckexpansiontankandifnecessaryaddExmark PremiumHydrooiltotheFULLCOLDline.

Figure22

1.Engine2.Expansiontank

5.Removetheventplugoneachtransmissionand llthroughexpansionreservoir,whenoilcomes outofventreinstallplug.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

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

ChangeInterval

500Hours

250Hours

Maintenance

6times).Checktheoillevel,andaddoilas requiredafterstoppingtheengine.

C.ItmaybenecessarytorepeatstepsAand

Buntilalltheairiscompletelypurgedfrom thesystem.Whenthetransaxleoperatesat normalnoiselevelsandmovessmoothly forwardandreverseatnormalspeeds,then thetransaxleisconsideredpurged.

DoNotchangehydraulicsystemoil(exceptforwhat canbedrainedwhenchanginglter),unlessitisfelt theoilhasbeencontaminatedorbeenextremelyhot.

Figure23

1.Oillter3.Leftreartire

2.Ventplug

6.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely .

CAUTION

Raisingthemowerforserviceormaintenance relyingsolelyonmechanicalorhydraulic jackscouldbedangerous.Themechanicalor hydraulicjacksmaynotbeenoughsupport ormaymalfunctionallowingtheunittofall, whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

7.Startengineandmovethrottlecontrolaheadto 1/2throttleposition.Disengageparkingbrake.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

ServicingtheSparkPlug

ServiceInterval:Every200hours/Every2

years(whichevercomes rst)

Every500hours—Replace thesparkplug.

Asstatedinthemaintenanceintervals,removethe sparkplug,checkcondition,andresetthegapor replacewithanewplugasnecessary.

ThesparkplugisRFIcompliant.Equivalentalternate brandplugscanalsobeused.

Type:ChampionXC92YC

ChampionRC12YCorQC12Cmaybeusedifyour areadoesnotrequirecompliancewithCanadian ICES-002,ISO14982,orEN55012.

AirGap:0.030inch(0.76mm)

WARNING

Enginemustberunninganddrivewheels mustbeturningsoadjustmentscanbe performed.Contactwithmovingpartsorhot surfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

A.Withthebypassvalveopenandtheengine

running,slowlymovethedirectionalcontrol inbothforwardandreverse(5or6times).

B.Withthebypassvalveclosedandtheengine

running,slowlymovethedirectionalcontrol inbothforwardandreversedirections(5to

RemovingtheSparkPlug

1.Disengagethebladecontrolswitch,movethe motioncontrolsoutwardtotheparkposition, stoptheengine,andremovethekey.

2.Pullthewireoffofthesparkplug(Figure24). Cleanaroundthesparkplugtopreventdirtfrom fallingintotheengineandpotentiallycausing damage.

Note:Duetothedeeprecessaroundthespark plug,blowingoutthecavitywithcompressedair isusuallythemosteffectivemethodforcleaning. Thesparkplugismostaccessiblewhenthe blowerhousingisremovedforcleaning.

3.Removethesparkplugandmetalwasher.

Figure24

1.Sparkplugandwirelocation

CheckingtheSparkPlug

1.Lookatthecenterofthesparkplug(Figure25). Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly .Ablackcoatingon theinsulatorusuallymeanstheaircleanerisdirty.

Maintenance

CleaningtheBlowerHousing

ServiceInterval:Every100hours/Yearly

(whichevercomesrst) Moreoftenunderdirty conditions.

Toensurepropercooling,makesurethegrassscreen, coolingns,andotherexternalsurfacesoftheengine arekeptcleanatalltimes.

1.Removetheblowerhousingandanyothercooling shrouds.

2.Cleanthecoolingnsandexternalsurfacesas necessary.

3.Makesurethecoolingshroudsarereinstalled

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

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

2.Checkthegapbetweenthecenterandside electrodes( thegapisnotcorrect.

1.Sideelectrode3.Airgap(nottoscale)

2.Centerelectrode insulator

Figure25).Bendthesideelectrodeif

Figure25

InstallingtheSparkPlug

FuelSystemMaintenance

ReplacingtheFuelFilter

ServiceInterval:Every100hours/Yearly

(whichevercomesrst)

DANGER

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

•Performanyfuelrelatedmaintenancewhen theengineiscold.Dothisoutdoorsinan openarea.Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,and stayawayfromanopenameorwherea sparkmayignitethegasolinefumes.

Neverinstalladirtylterifitisremovedfromthe fuelline.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

1.Installthesparkplug.Makesurethattheairgap issetcorrectly.

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

3.Pushthewireontothesparkplug(

Figure24).

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

3.Thefuellterisinthefuellinebetweenthetank andengine.

Maintenance

Figure26

1.Fueltank6.Hoseclamps

2.Fuelshutoffvalve—off

3.Fuelshutoffvalve

4.Fuelshutoffvalve—on

5.Fuellinefromtank

4.Turnfuelshutoffvalve90°to“off”position.

7.Fuellinetoengine

8.Filter

9.Flowdirectionarrow

ChargingtheBattery

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,Do Notallowthebatteryterminalstotouchany metalpartsofthemachine.

•DoNotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

5.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure26).

6.Removethelterfromthefuellines.

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

Figure26)tosecureitinplace.

(

8.Turnfuelshutoffvalvebackto“on”position.

ElectricalSystem Maintenance

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

•Keepsparks,ames,orcigarettesawayfrom battery.

•Ventilatewhenchargingorusingbatteryin anenclosedspace.

•Makesureventingpathofbatteryisalways openoncebatteryislledwithacid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid,which ispoisonousandcancausesevereburns. Swallowingelectrolytecanbefatalorifittouches skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber glovestoprotectskinandclothingwhen handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately.

Maintenance

CAUTION

Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagementof components.Sparkscouldcauseanexplosionor movingpartscouldaccidentallyengagecausing personalinjury

Besureignitionswitchisinthe“OFF”position beforechargingthebattery.

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

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

3.Raisetheseat.

4.Disconnectthenegative(black)groundcable fromthebatterypost( fasteners.

Figure27).Retainall

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(

Figure27)andliftthe

batteryfromthebatterytray.

CheckingtheBatteryCharge

1.Removethebatteryfromthechassis;referto RemovingtheBattery.

Figure27

1.Negativebatterypost4.Positivebatterypost

2.Bolt,washer,andnut5.Batterystrap

3.Terminalboot6.Battery

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

Note:Topreventdamageduetofreezing, batteryshouldbefullychargedbeforeputting awayforwinterstorage.

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

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

Voltage Reading

12.6or greater

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

Charging Interval

No Charging Required

Maintenance

Voltage Reading

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

14.4volts/2 amps

RecommendedJumpStarting Procedure

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

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe enginemayoccur.

Charging Interval

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricalsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

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

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

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

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure28.

DANGER

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

DoNotjumpstartaweakbatteryifthese conditionsexist.

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

Figure28

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

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

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

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

InstallingtheBattery

1.Positionthebatteryinthetraywiththeterminal poststowardtheoperatingposition(Figure27).

Maintenance

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

3.Installthenegativebatterycabletothenegative (-)batteryterminalusingthefastenersremoved previously.

4.Slidetheredterminalbootontothepositive(red) batterypost.

5.Securethebatterywiththestrap(

Figure27).

ServicingtheFusesand Relay

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

FuseBlock:

Figure29

1.Cover4.Charge–20amp

2.Relay5.Main–25amp

3.Auxilliary–15amp6.Diode

2.RemovecoverasshowninFigure29.

3.Toreplaceafuse,pulloutonthefusetoremoveit

DriveSystemMaintenance

CheckingtheTirePressure

ServiceInterval:Every25hours/Monthly

(whichevercomesrst)

Maintaintheairpressureinthefrontandreartiresas specied.Uneventirepressurecancauseunevencut. Checkthepressureatthevalvestem(Figure30).

Checkthetireswhentheyarecoldtogetthemost accuratepressurereading.

•Mainfuse:25ampfuse,blade-type

•ChargeCircuit:20ampfuse,blade-type

•Auxiliarycircuit:15ampfuse,blade-type

•Diode:TVS

1.Raisetheseattogainaccesstothefuseholder

Figure29).

(

RearTires:13psi(90kPa)

FrontTires(casterwheels):

•Smooth:13psi(90kPa)

•Sawtooth:20psi(138kPa)

Maintenance

Figure30

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(Figure31).Iftheedges arenotsharporhavenicks,removeandsharpen theblades;refertoSharpeningtheBlades.

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

1.Cuttingedge3.Wear/slotforming

2.Curvedarea

Figure31),immediatelyinstall

Figure31

CheckingforBentBlades

1.Rotatethebladesuntiltheendsfaceforwardand backward(Figure32andFigure33).Measure fromalevelsurfacetothecuttingedge,ofthe blades.Notethisdimension.

WARNING

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

•Inspectthebladeperiodicallyforwearor damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

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

1.Bladesfronttorear

Figure32

48and52InchDeck

2.Measurehere

1.Bladesfronttorear

42InchDeck

Figure33

2.Measurehere

Maintenance

(

Figure34).RefertoRemovingtheBladesand

InstallingtheBlades.

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

RemovingtheBlades

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

2.Rotatetheoppositeendsofthebladesforward.

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

WARNING

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.

•Alwaysreplacebentordamagedbladewith anewblade.

•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

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

Figure34

1.Blade

2.Washer

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

Figure34).

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure35).Maintaintheoriginal angle.Thebladeretainsitsbalanceifthesame amountofmaterialisremovedfrombothcutting edges.

Maintenance

Figure35

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona bladebalancer( horizontalposition,thebladeisbalancedandcan beused.Ifthebladeisnotbalanced,lesome metalofftheendofthesailareaonly(Figure36). Repeatthisprocedureuntilthebladeisbalanced.

1.Blade2.Balancer

Figure36).Ifthebladestaysina

Figure36

MowerBeltMaintenance

InspectingtheBelts

ServiceInterval:Every25hours/Monthly

(whichevercomesrst)

Checkthebeltsforcracks,frayededges,burnmarks, oranyotherdamage.Replacedamagedbelts.

ReplacingtheMowerBelt

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

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

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

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure34).

Important:Thecurvedpartoftheblade mustbepointingupwardtowardtheinsideof themowertoensurepropercutting .

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

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

WARNING

Incorrectinstallationofthebladeor componentsusedtoretainthebladecause thebladetocomelooseandcouldseriously injureorkillyouorbystanders.

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

4.For48and52inchdecksonly,removethebelt coversovertheoutsidespindles.

5.Graspbothbeltstrandsgoingtotheclutch.Pull themtotherearofthemachineandslipthebelt offtheclutchpulleyasshownin Figure38.

Figure37and

WARNING

Thespringisundertensionwheninstalled andcancausepersonalinjury.

Becarefulwhenremovingthebelt.

AlwaysinstalltheoriginalExmarkblades, washersandbladeboltsasshown.

Figure37

48and52InchDecks

Maintenance

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

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

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

4.Carefullyrotatethebladessidetoside.

1.Outsidepuley

2.Spring

3.Idlerpulley6.Pullbeltstrandsinthis

42InchDeck

1.Outsidepuley

2.Spring

3.Idlerpulley6.Pullbeltstrandsinthis

4.Mowerbelt

5.Enginepulley

direction.

Figure38

4.Mowerbelt

5.Enginepulley

direction.

5.Measurebetweentheoutsidecuttingedgesand theatsurface(

Figure39andFigure40).Ifboth measurementsarenotwithin3/16inch(5mm), anadjustmentisrequired;continuewiththis procedure.

Figure39

48and52InchDecks

1.Bladessidetoside2.Measurehere

6.Routethenewbeltaroundthemowerpulleys.

7.Graspbothbeltstrandsgoingtotheclutch.Pull themtotherearofthemachineandslipthebelt ontotheclutchpulley.

8.For48and52inchdecksonly ,installthebelt coversovertheoutsidespindles.

LevelingtheMowerDeck

Themowerbladesmustbelevelfromsidetoside. Checktheside-to-sidelevelanytimeyouinstallthe mowerorwhenyouseeanunevencutonyourlawn.

Figure40

42InchDeck

1.Bladessidetoside2.Measurehere

Maintenance

6.Setanti-scalprollerstotopholesorremove completelyforthisadjustment.

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

BlockHeightandRakeTable

Deck Size

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(Figure39 andFigure40).

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

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(

Figure41).

10.Recheckthatblockstjustsnuglyunderthedeck skirt.Makesureallattachmentboltsaretight

11.Continuelevelingthedeckbycheckingthe front-to-rearbladeslope;refertoAdjustingthe

Front-to-RearBladeSlope.

12.Recheckbladesforlevelnessandrepeatdeck levelingprocedureifnecessary.

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.

Figure41

1.Deckliftarm

2.Floatretainingnut4.Levelingadjustlocking

3.Deckhanger

nut

8.Carefullyrotatethebladessotheyarefacingfront torear(

Figure42andFigure43).

Maintenance

9.Measurefromthetipofthefrontbladetothe atsurfaceandthetipoftherearbladetothe atsurface(Figure42andFigure43).Ifthefront bladetipisnot“R”(seeBlockHeightandRake TableinLevelingtheMowerDeck)lowerthan therearbladetip,adjustthefrontdeckhanger.

Figure42

48and52InchDecks

1.Bladesfronttorear

2.Measurehere

ReplacingtheDischarge Deector

DANGER

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

Neveroperatethelawnmowerunlessyouinstall amulchplate,dischargedeector,orgrass collectionsystem.

1.LocateitemsshowninFigure44.

Figure43

42InchDeck

1.Bladesfronttorear

2.Measurehere

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

Figure44

1.Rod4.Mowerdeck

2.Spring5.Dischargedeector

3.Dischargedeector

6.Assembledview

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

3.Installnewdischargedeector.

4.Orientthespringsothattheshortlegpoints towardsthedischargedeectorandthelongerleg pointstowardsthedeckasshowninFigure44. Placespringonrodandsliderod,straightend,

bracket

Maintenance

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

5.Makesurethatthespringandrodareinstalled sothattherodisretainedfromslidingout bythefrontbracketandthespringholdsthe dischargedeectorinthedownposition.Referto

Figure44)forproperorientation.

(

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

Adjustments

TrackingAdjustment

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

Figure45).

Figure45

1.Controlarmshaft

2.Trackingplatenut

3.Trackingplate

BrakeLinkageAdjustment

1.Parkthemachineonalevelsurfaceanddisengage thebladecontrolswitch.

2.Movethemotioncontrolleversoutwardto neutralposition,engageparkingbrake,stopthe engine,removethekeyandwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Setupthemachinetobepushedbyhand (seePushingtheMachinebyHandinthe Operationsection).

4.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely .

5.Engage/disengagethebrakeandcheckeachdrive tiretomakesureeachbrakeengages/disengages.

Maintenance

6.Ifadjustmentisnecessary,loosenthejamnut fromtheyokeonthesidethatneedsadjustment. Removethehairpinandclevispin(seeFigure46).

Figure46

1.Hairpin3.Y oke

2.Clevispin

•AdjustingtheBraketoEngage:Shortenthe linkagebyturningtheyokeclockwise.

•AdjustingtheBraketoDisengage: Lengthenthelinkagebyturningtheyoke counterclockwise.

7.Reinstalltheclevispinandhairpinandtighten downthejamnut.Repeatstep necessary.

4.Jamnut

5andreadjustif

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

Figure47).

(

Note:Spreadpetroleumjellyonthewashout ttingO-ringtomakethecouplingslideoneasier andprotecttheO-ring.

8.Whenadjustmentiscomplete,removethejack standsorequivalentsupportandlowerthe machine.

9.Placethemachineintooperatingposition (seePushingtheMachinebyHandinthe Operationsection).

Figure47

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tting immediately,beforeusingmoweragain.

•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.Batterydoesnothaveafullcharge.

5.Theelectricalconnectionsarecorroded orloose.

6.Afuseisblown.

7.Arelayorswitchisdamaged.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Thechokeisnoton.2.MovethechokelevertoOn.

3.Theaircleanerisdirty .

4.Thesparkplugwire(s)islooseor disconnected.

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

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

7.Dirt,water,orstalefuelisinthefuel system.

8.Thereisincorrectfuelinthefueltank.

9.Theoillevelinthecrankcaseislow .

2.Addoiltothecrankcase.

3.Removetheobstructionfromthecooling nsandairpassages.

4.Cleanorreplacetheaircleanerelement.

5.ContactanAuthorizedServiceDealer.

Disengaged.

2.Movethemotioncontrolleversoutward totheparkposition.

3.Sitontheseat.

Chargethebattery.SeeCheck

BatteryChargeandRecommended JumpStartingProceduresectionsin

Maintenance.

5.Checktheelectricalconnectionsforgood contact.

6.Replacethefuse.

3.Cleanorreplacetheaircleanerelement.

4.Installthewire(s)onthesparkplug.

5.Installanew ,correctlygappedspark plug(s).

7.ContactanAuthorizedServiceDealer.

8.Drainthetankandreplacethefuelwith thepropertype.

9.Addoiltothecrankcase.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Enginelosespower

Themachinedoesnotdrive.

Abnormalvibration

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesforthe engineareplugged.

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

6.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

GRAYVIOLET

VIOLET

BLACK

WHITE

YELL

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

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

General Conditions

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

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

Such damages include but are not limited to:

• Expenses related to gasoline, oil or lubricants.

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

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

• Any telephone or telegram charges or travel charges.

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

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

• Attorney's fees.

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

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

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

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

Exmark Quest Turf Equipment

3-Year Limited Consumer Warranty

(30-Day Limited Commercial Warranty)

G4500-428_B

Notes:

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

575859

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.4500-523Rev .B (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark QUEST 850000 AND HIGHER User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual