Exmark Quest QST24BE522, Quest QST22BE482 Operator's Manual

M

TM

For Serial Nos.

670,000 & Higher

®

FG. CO. INC.

on the purchase of your new Exmark equipment. This product has been carefully designed and
manufactured to give you a maximum amount of dependability and years of trouble-free operation. If additional information
is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor.
If you need to order replacement parts from your dealer, always give the model number and serial number of your equipment
as well as the part number, description and quantity of the part needed.

The Serial No. plate is located on the back left side of the seat box. For ease of ordering and reference, we suggest

record the information requested in the following identification table. that you

Place Model No. and Serial No. Label Here

(Included in Literature Pack)

or Fill in Below

Engine Model No. and Spec. No. (Code)

Engine Serial No. (E/No)

Model No.

Date Purchased

Serial No.

Part No. 109-6232 Rev B

Warning

CALIFORNIA

Proposition 65 Warning

The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.

Important: This engine is not equipped
with a spark arrester muffler. It is a
violation of California Public Resource
Code Section 4442 to use or operate the
engine on any forest-covered, brush-
covered, or grass-covered land. Other
states or federal areas may have similar
laws.

This spark ignition system complies with
Canadian ICES-002, ISO 14982, EN 55012.

The enclosed
supplied for information regarding the US
Environmental Protection Agency (EPA)
and the California Emission Control
Regulation of emission systems,
maintenance, and warranty. Replacements
may be ordered through the engine
manufacturer.

For models with stated engine horsepower,
the gross horsepower of the engine was
laboratory rated by the engine manufacturer
in accordance with SAE J1940. As configured
to meet safety, emission, and operating
requirements, the actual engine horsepower
on this class of lawn mower will be
significantly lower.

Engine Owner’s Manual

Introduction

Read this information carefully to learn how to
operate and maintain your product properly
and to avoid injury and product damage. You
are responsible for operating the product
properly and safely.
You may contact Exmark directly at
www.Exmark.com for product and accessory
information or help finding a dealer.

is

Whenever you need service, genuine Exmark
parts, or additional information, contact an
Authorized Service Dealer or Exmark
Customer Service and have the model and
serial numbers of your product ready.

Figure 1 identifies the location of the model

and serial numbers on the product. Write the
numbers on the front cover.

Figure 1

Behind the seat

1. Model and serial number plate

This manual identifies potential hazards and
has safety messages identified by the safety
alert symbol (Figure 2), which signals a
hazard that may cause serious injury or death
if you do not follow the recommended
precautions.

Figure 2

1. Safety alert symbol.

This manual uses two other words to highlight
information.
special mechanical information and
emphasizes general information worthy of
special attention.

Important

calls attention to

Note

2

Specifications

Model Number:

QST22BE482; QST24BE522

Engine Specifications:

See Your Engine Owner’s Manual

RPM:

Full Speed: 3650 ± 100 (max) RPM

(No Load)

Idle: 1650 (min) RPM

Fuel System:

Capacity: 4.0 gal. (15.1L)
Type of Fuel: Regular unleaded gasoline,

87 octane or higher.

Fuel Filter: replaceable in-line

STRATTON

Fuel Shut-Off Valve: in-line, 1/4 turn

P/N 695666

BRIGGS &

Electrical System:

Charging System: Flywheel Alternator
Charging Capacity: 16 amps
Battery Type: BCI Group U1
Battery Voltage: 12 Volt
Polarity: Negative Ground
Fuses: 1-25 amp, 1-20 amp, 1-15amp

blade type

Safety Interlock System:

PTO

must be

and

motion control levers out

lock)

to start engine

for the operator to be in the seat to start the
engine.)

Operator must be in seat

engaged, brake is disengaged
control levers are moved in

stop.
Engine will stop if either the left, the right, or

both levers are

position while brake is engaged

disengaged, brake engaged

(neutral

. (It is not necessary

when PTO is

, or

or engine will

moved from neutral lock

.

motion

Operator Controls

Steering and Motion Control:

Separate levers, on each side of the
console, control speed and direction of
travel of the respective drive wheels.

Steering is controlled by varying the
position of the levers relative to each
other.

Moving motion control levers outward (in
slots) locks the drive system in neutral.

Motion control levers are adjustable to
two heights.

PTO Switch: Engages electric clutch (to

drive belt) which engages mower
blades.

Parking Brake Lever: Engages parking

brake.

Deck Height Adjustment Pin: Sets cutting

height to desired position.

Deck Lift: Foot pedal that raises the deck.

Seat:

Type: Standard seat: high back, foam

padded with spring suspension.

Mounting: Hinged to tilt up for access to

battery and other components. Held in
tilted position with lanyard. Adjustable
fore and aft.

,

Armrests: Standard: foam padded flip-up

adjustable height armrests.

Seat Safety Switch: Incorporated into the

Safety Interlock System.

Hydrostatic Ground Drive System:

Hydrostatic Drive: Two Hydro Gear ZT2800

Integrated drive systems.

Hydraulic Oil: Use Mobil 1 15W-50 Synthetic

Motor Oil.

Speeds: All units:

0 – 7 mph (11.3 km/hr) forward.
0 – 5 mph (8.0 km/hr) reverse.

Drive wheel releases, located on left and
right sides of engine deck, allow machine to
be moved when the engine is not running
and brake is off.

3

Tires and Wheels

Drive Tires:

(48”) 20 x 9-8
(52”) 20 x 10-8
All 4-ply

Front Caster Tires:

Pneumatic, 10 x 4 smooth tread tires.

Cutting Deck

48” Deck: 48” (122 cm)
52” Deck: 52” (132 cm)
Discharge:

Side (Optional Mulch and/or Bag)

Blade Size:

48” Deck: 3 each - 16.25” blades
52” Deck: 3 each - 18” blades

Blade Spindles: solid steel spindles with no
maintenance bearings.

Deck Drive: Electric clutch mounted on
vertical engine shaft. Blades are driven by
one belt (w/self-tensioning idler) direct from
the engine.

Deck: Full floating deck.
Maximum turf protection is provided by

anti-scalp rollers: 3 rollers (48” & 52”)
Deck design allows for bagging, mulching or

side discharge.
Cutting Height Adjustment: a foot deck lift

lever is used to adjust the cutting height
from 1.5” (3.8 cm) to 4.5” (11.4 cm.) in 1/2”
(1.3 cm.) increments.

The cutting height adjustment handle has a
transport position and all adjustments can
be made while the operator remains seated.

Mulching Kit: Optional.

Kit numbers: 48” – P/N 109-5980

52” – P/N 109-5982

Dimensions

Overall Width:

Without deck:

48” Deck: 45.5” (116 cm)
52” Deck: 47.0” (119 cm)

Deflector up:

48” Deck: 48.3” (122 cm)
52” Deck: 53.0” (135 cm)

Deflector down:

48” Deck: 59.4” (151 cm)
52” Deck: 64.2 (163 cm)

Overall Length:

48” Deck: 73.4” (186 cm)
52” Deck: 73.4” (186 cm)

Overall Height:

48” Deck: 42.2” (107 cm)
52” Deck: 42.2” (107 cm)

Tread Width: (center to center of tires,

widthwise)

Drive Wheels:

48” Deck: 42.2” (107 cm)
52” Deck: 42.2” (107 cm)

Front Casters:

48” Deck: 42.2” (107 cm)
52” Deck: 42.2” (107 cm)

Wheel Base: (center of caster tire to center of

drive tire)
48” Deck: 42.2” (107 cm)
52” Deck: 42.2” (107 cm)

Curb Weight:

48” Deck: 645 lbs (292.6 kg)
52” Deck: 660 lbs (299.4 kg)

Torque Requirements

Spindle Pulley Nuts: 45-55 ft-lbs (61-75 N-m)
Blade Mounting Bolt: 45-55 ft-lbs. (61-75N-m)
Anti-Scalp Roller Nuts: 27-33 ft-lbs. (37-45 N-m)
Engine Mounting Bolts: 27-33 ft-lbs. (37-45 N-m)
Wheel Lug Nuts: 70-90 ft-lbs. (95-122 N-m)
Clutch Mounting Bolt (secured with threadlocker):

50-55 ft-lbs. (68-75 N-m)

4

Contents

Introduction ................................................2

Specifications .............................................3

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

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

Exmark Riding Mower Safety................9

Slope Chart ......................................... 10

Safety and Instructional Decals............11

Product Overview .....................................15

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

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

Think Safety First................................. 17

Recommended Gasoline...................... 17

Checking the Engine Oil Level .............19

Starting the Engine...............................19

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

Stopping the Engine............................. 20

The Safety Interlock System ................20

Driving Forward or Backward...............21

Stopping the Machine ..........................22

Tracking Adjustment ............................22

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

Positioning the Seat .............................23

Adjusting the Motion Control Levers.....23

Pushing the Machine by Hand .............24

Side Discharge.....................................25

Operating Tips ..................................... 25

Maintenance

Recommended Maintenance

Schedule(s).......................................... 27

Premaintenance Procedures .....................28

Raising the Seat...................................28

Accessing the Battery .......................... 28

Lubrication ................................................28

Greasing the Bearings..........................28

Engine Maintenance ..................................29

Servicing the Air Cleaner......................29

Servicing the Engine Oil .......................29

Checking the Hydraulic Oil Level..........31

Change the Hydraulic System Filter .....32

Servicing the Spark Plug ......................32

Cleaning the Blower Housing ...............33

Fuel System Maintenance .........................34

Replacing the Fuel Filter.......................34

Electrical System Maintenance .................35

Charging the Battery.............................35

Servicing the Fuses and Relays ...........36

Drive System Maintenance ........................37

Checking the Tire Pressure..................37

Mower Maintenance...................................37

Servicing the Cutting Blades.................37

Leveling the Mower Deck .....................39

Adjusting the Blade Slope ....................40

Removing the Mower Deck...................41

Mower Belt Maintenance ......................42

Installing the Mower Deck ....................42

Replacing the Discharge Deflector ......43

Cleaning.....................................................43

Washing the Underside of the Mower...43

Storage ......................................................44

Cleaning and Storage...........................44

Troubleshooting .........................................46

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

5

Safety

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

Safe Operating Practices

The following instructions are from ANSI
standard B71.1-2003.
This product is capable of amputating hands
and feet and throwing objects. Always follow
all safety instructions to avoid serious injury or
death.

General Operation

•

Read, understand, and follow all

instructions in the operator’s manual and
on the machine before starting.

•

Do not place hands or feet near rotating

parts or under the machine. Keep clear of
the discharge opening at all times.

•

Allow only responsible adults who are

familiar with the instructions to operate the
machine.

•

Clear the area of objects such as rocks,

toys, wire, etc., which could be picked up
and thrown by the blade.

•

Be sure the area is clear of other people

before mowing. Stop the machine if
anyone enters the area.

•

Never carry passengers.

•

Do not mow in reverse unless absolutely

necessary. Always look down and behind
before and while backing up.

•

Be aware of the mower discharge

direction and do not point it at anyone.
Avoid discharging material against a wall
or obstruction. Material may ricochet back
toward the operator. Stop the blades
when crossing gravel surfaces.

•

Do not operate the mower without either

the entire grass collection system or the
discharge deflector in place.

•

Be alert, slow down and use caution when

making turns. Look behind and to the side
before changing directions.

•

Never leave a running machine

unattended. Always turn off blades,
engage parking brake, stop engine, and
remove key before dismounting.

•

Turn off blades when not mowing. Stop

the engine, wait for all parts to come to a
complete stop, engage parking brake, and
remove key before cleaning the machine,
removing the grass or unclogging the
deflector.

•

Operate the machine only in daylight or

good artificial light.

•

Do not operate the machine while under

the influence of alcohol or drugs.

•

Watch for traffic when operatin g near or

crossing roadways.

•

Use extra care when loading or unloading

the machine into a trailer or truck.

•

Always wear eye protection when

operating the mower.

•

Data indicates that operators, age 60

years and above, are involved in a large
percentage of riding mower-related
injuries. These operators should evaluate
their ability to operate the riding mower
safely enough to protect themselves and
others from serious injury.

•

Always follow the recommendations for

wheel weights or counterweights.

6

Slope Operation

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

•

Do not mow slopes greater than

15 degrees.

•

Watch for ditches, holes, rocks, dips, and

rises that change the operating angle, as
rough terrain could overturn the machine.

•

Choose a low ground speed so you will

not have to stop while operating on a
slope.

•

Do not mow slopes when grass is wet.

Slippery conditions reduce traction and
could cause sliding and loss of control.

•

Reduce speed and use extreme caution

on slopes.

•

Do not make sudden turns or rapid speed

changes.

•

Remove or mark obstacles such as rocks,

tree limbs, etc. from the mowing area. Tall
grass can hide obstacles.

•

Avoid sudden starts when mowing uphill

because the mower may tip backwards.

•

Be aware that loss of traction may occur

going downhill. Weight transfer to the front
wheels may cause drive wheels to slip
and cause loss of braking and steering.

•

Always avoid sudden starting or stopping

on a slope. If tires lose traction, disengage
the blades and proceed slowly off the
slope.

•

Use extreme care with grass collection

systems or other attachments. These can
change the stability of the machine and
cause loss of control.

•

Do not try to stabilize the machine by

putting your foot on the ground.

•

Do not mow near drop-offs, ditches, steep

banks or water. Wheels dropping over
edges can cause rollovers, which may
result in serious injury, death or drowning.

•

Use a walk behind mower and/or a hand

trimmer near drop-offs, ditches, steep
banks or water.

Children

Tragic accidents can occur if the operator is
not alert to the presence of children. Children
are often attracted to the machine and the
mowing activity. Never assume that children
will remain where you last saw them.

•

Keep children out of the mowing area and

under the watchful care of another
responsible adult, not the operator.

•

Be alert and turn the machine off if

children enter the area.

•

Before and while backing or changing

direction, look behind, down, and side-to-
side for small children.

•

Never carry children, even with the blades

off. They may fall off and be seriously
injured or interfere with safe machine
operation.

•

Children who have been given rides in the

past may suddenly appear in the mowing
area for another ride and be run over or
backed over by the mower.

•

Never allow children to operate the

machine.

•

Use extra care when approaching blind

corners, shrubs, trees, the end of a fence
or other objects that may obscure vision.

Towing

•

This machine does not make any

provisions for towing.

7

Service

Safe Handling of Gasoline:
To avoid personal injury or property damage,

use extra care when handling gasoline and
other fuels. They are flammable and the
vapors are explosive.

•

Extinguish all cigarettes, cigars, pipes and

•

Use only an approved container.

•

Never remove the gas cap or add fuel

•

Never refuel the machine indoors.

•

Never store the machine or fuel container

•

Never fill containers inside a vehicle or on

•

Remove gas-powered equipment from the

•

Keep the nozzle in contact with the rim of

•

If fuel is spilled on clothing, change

•

Never overfill the fuel tank. Replace gas

other sources of ignition.

when the engine is running. Allow the
engine to cool before refueling.

inside where there is an open flame, such
as near a water heater or furnace.

a truck or trailer with a plastic liner.
Always place containers on the ground
away from your vehicle before filling.

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

the fuel tank or container opening at all
times until the fueling is complete. Do not
use a nozzle lock-open device.

clothing immediately.

cap and tighten securely.

General Service:

•

Never run a machine inside a closed area.

•

Keep nuts and bolts tight, especially the

blade attachment bolts. Keep equipment
in good condition.

•

Never tamper with safety devices. Check

their proper operation regularly.

•

Keep the machine free of grass, leaves, or

other debris build-up. Clean up oil or fuel
spillage and fuel soaked debris. Allow the
machine to cool before storing.

•

Stop and inspect the equipment if you

strike an object. Repair, if necessary,
before restarting.

•

Never make any adjustments or repairs

with the engine running.

•

Grass collection system components are

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

•

Mower blades are sharp and can cut.

Wrap the blades or wear gloves, and use
extra caution when servicing them.

•

Check for proper brake operation

frequently. Adjust and service as
required.

•

Maintain or replace safety and instruction

decals as necessary.

•

Use only genuine Exmark replacement

parts to ensure that original standards are
maintained.

8

Exmark Riding Mower Safety

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

•

Engine exhaust contains carbon

monoxide, which is an odorless, deadly
poison that can kill you. Do not run
engine indoors or in an enclosed area.

•

Stop the engine, wait for all moving

parts to stop, engage parking brake,
disconnect spark plug wire(s) and
remove key before performing any
service, repairs, maintenance or
adjustments.

•

Keep hands, feet, hair, and loose

clothing away from attachment
discharge area, underside of mower and
any moving parts while engine is
running.

•

Do not touch equipment or attachment

parts which may be hot from operation.
Allow to cool before attempting to
maintain, adjust or service.

•

Battery acid is poisonous and can cause

burns. Avoid contact with skin, eyes, and
clothing. Protect your face, eyes, and
clothing when working with a battery.

•

Battery gases can explode. Keep

cigarettes, sparks and flames away from
battery.

•

Use only Exmark approved attachments.

Warranty may be voided if used with
unapproved attachments.

•

If loading the machine onto a trailer or

truck, use a single, full-width ramp only.
The ramp angle should not exceed
15 degrees.

Note:

are determined while sitting in the seat in the
normal operating position.

The left and right sides of the machine

9

Slope Chart

10

Safety and Instructional Decals

Safety decals and instructions are easily visible to the
operator and are located near any area of potential

PART NO. 106-5517
LOCATION: On LH & RH Rear Frame

PART NO. 109-6210
LOCATION: Under Seat Shield

PART NO. 110-6691
LOCATION: On Top Side of Deck, on Front

1

1

1

1 3

Corners of Deck

2

5

Some or all of these symbols are on the battery.

6

1. Warning – do

2

2

Battery Symbols

danger. Replace any decal that is damaged or lost.

not touch the
hot surface.

PART NO. 109-6011
LOCATION: Inside Seat Box by Fuse Box

1. Read the Operator’s manual

2. Cutting/dismemberment hazard, fan
and entanglement hazard, belt– sta y
away from moving parts.

1. Explosion hazard

2. No fire, open flame, or smoking.

3. Caustic liquid/chemical burn hazard.

4. Wear eye protection.

5. Read the Operator’s Manual.

6. Keep bystanders a safe distance from
the battery.

7. Wear eye protection; explosive gases
can cause blindness and other injuries.

8. Battery acid can cause blindness or
severe burns.

9. Flush eyes immediately with wat er and

G1101

get medical help fast.

10. Contains lead; do not discard.

7

3

8

2

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

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

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

4

9

10

1. Unused fuse

1

2

receptacle

2. Fuse

11

1

Control Lever

PART NO. 93-7009
LOCATION: Behind Discharge Deflector on

Deck Side Plate

1

PART NO. 109-6459
LOCATION: Under Belt Shields

2

1. Warning – do not operate the
mower with the discharge
deflector up or removed; keep the
discharge deflector in place.

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

1. Entanglement hazard, belt – do
not open or remove safety
shields while engine is running,
keep shields in place.

1. Parking Brake

2. Machine Speed

3. Fast

1

2

3

4

5

6

PART NO. 109-6009
LOCATION: Near LH Motion

Control Lever

4. Slow

5. Neutral

6. Reverse

2

3

4

5

6

PART NO. 99-8936
LOCATION: Near RH Motion

1. Height of cut

1

PART NO. 109-6010
LOCATION: On Cut

Height Frame

12

PART NO. 109-6016
LOCATION: Near LH Motion Control Lever

A

B

B

D

E

F

C

A. Read the instructions

before servicing or
performing

maintenance.
B. Time interval.
C. Check oil level.
D. Refer to Operator’s

Manual for grease

instructions.
E. Check hydraulic oil level

and refer to Operator’s

manual for further

instructions.
F. Check tire pressure.

1

3

4

5

6

PART NO. 109-6013
LOCATION: Middle of Footrest

7

2

1. Warning—read the Operator’s Manual.

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

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

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

5. Tipping hazard – avoid sudden and sharp
turns while on slopes, only mow across
slopes less than 15 degrees, keep a safe
distance from water, and do not mow up
and down slopes.

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

7. Crushing/dismemberment hazard of
bystanders, reversing;– do not carry
passengers, look behind and down when
reversing.

13

TRACTION DRIVE

BELT ROUTING

1

5

2

3

1. Engine – stop

2. Engine – run

3. Engine – start

4. Power take-off (PTO),
Blade control switch.

5. Read Operator’s Manual

6. Throttle - fast

7. Choke – on

8. Throttle – slow

9. Choke – off

PART NO. 109-6014
LOCATION: RH Side of

Seat Box

109-6029

4

6

7

8

9

PART NO. 109-6029
LOCATION: On Control Panel

DECK DRIVE

BELT ROUTING

PART NO. 109-6035
LOCATION: Left Rear Edge of Deck

1

PART NO. 109-6008
LOCATION: Next to Drive

1

PART NO. 109-6036
LOCATION: Top of Deck Near Washout Port

2

Release

2

3

1. Read the Operator’s

2. Rotate the drive release

3. Push the machine.

3

1. Read Operator’s
Manual.

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

3. Height of cut.

Manual.

knob to loosen, slide the
knob, and tighten.

14

Product Overview

1. Operator seat

2. Front caster wheel

3. Anti-scalp roller

4. Washout fitting

Figure 3

5. Park brake

6. Rear drive wheel

7. Gas tank cap

1. Motion control levers

2. Engine

3. Control panel

4. Discharge deflector

Figure 4

5. Height of cut adjustment

6. Height of cut foot lever

7. Footrest

15

Controls

Become familiar with all of the controls in

Figure 3, Figure 4, and Figure 5 before you

start the engine and operate the machine.

Figure 5

Control Panel

1. Ignition switch 3. Throttle

2. Blade control switch 4. Choke
(power take-off)

Ignition Switch

The ignition switch has three positions, Off,
Run and Start. The key will turn to Start and
move back to Run upon release. Turning the
key to the Off position will stop the engine;
however, always remove the key when
leaving the machine to prevent someone from
accidentally starting the engine (Figure 5).

Blade Control Switch (Power Take-Off)

The blade control switch, represented by a
power take-off (PTO) symbol, engages and
disengages power to the mower blades
(Figure 5).

Throttle Control

The throttle is used to control engine speed.
Moving throttle lever
engine speed and moving throttle lever

rear

will decrease engine speed. Moving the
throttle forward into the detent is full throttle
(Figure 5).

forward

will increase

to the

Motion Control Levers and Parking
Brake

The motion control levers are speed sensitive
controls of independent wheel motors. Moving
a lever forward or backward turns the wheel on
the same side forward or in reverse; wheel
speed is proportional to the amount the lever is
moved. Moving the control levers outward from
the center position locks them in the neutral
position. Engaging the parking brake lever
allows the operator to exit the machine
(Figure 13). Always position the motion control
levers into the neutral position and engage the
park brake lever when you stop the machine or
leave it unattended.

Height-of-Cut Foot Lever

The height of cut lever allows the operator to
lower and raise the deck from the seated
position. When the lever is moved forward,
away from the operator the deck is raised from
the ground and when moved back, towards the
operator it is lowered toward the ground. Only
adjust the height of cut while machine is not
moving (Figure 14).

Choke Control

The choke is used to aid in starting a cold
engine.
choke in the
choke lever forward will put the choke in the

“ON”

the rear will put the choke in the
position (Figure 5).

DO NOT

position and moving the choke lever to

run a warm engine with the

“ON”

position. Moving the

“OFF”

16

Operation

Note:

are determined while sitting in the seat in the
normal operating position.

Think Safety First

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

The left and right sides of the machine

Mowing on wet grass or steep slopes
can cause sliding and loss of control.

Wheels dropping over edges can
cause rollovers, which may result in
serious injury, death or drowning.

To avoid loss of control and possibility
of rollover:

• Do not mow near drop-offs or near

water.

• Do not mow slopes greater than

15 degrees.

• Reduce speed and use extreme

caution on slopes.

• Avoid sudden turns or rapid speed

changes.

Figure 6

1. Safe Zone-use the Quest here.

2. Use walk behind mower and/or hand trimmer near drop-
offs and water.

3. Water

Refer to the Slope Chart on page 10 to
determine the approximate slope angle to be
mowed.

Recommended Gasoline

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

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

In certain conditions, gasoline is
extremely flammable and highly
explosive.

A fire or explosion from gasoline can
burn you and others and can damage
property.

• Fill the fuel tank outdoors, in an

open area, when the engine is cold.
Wipe up any gasoline that spills.

• Never fill the fuel tank inside an

enclosed trailer.

• Do not fill the fuel tank completely

full. Add gasoline to the fuel tank
until the body of the tank is full but
fuel does not fill the neck of the
tank. This empty space in the tank
allows gasoline to expand.

• Never smoke when handling

gasoline, and stay away from an
open flame or where gasoline
fumes may be ignited by a spark.

• Store gasoline in an approved

container and keep it out of the
reach of children. Never buy more
than a 30-day supply of gasoline.

• Do not operate without entire

exhaust system in place and in
proper working condition.

17

In certain conditions during fueling,
static electricity can be released
causing a spark which can ignite the
gasoline vapors.

A fire or explosion from gasoline can
burn you and others and can damage
property.

• Always place gasoline containers

on the ground away from your
vehicle before filling.

• Do not fill gasoline containers

inside a vehicle or on a truck or
trailer bed because interior
carpets or plastic truck bed liners
may insulate the container and
slow the loss of any static charge.

• When practical, remove gas-

powered equipment from the
truck or trailer and refuel the
equipment with its wheels on the
ground.

• If this is not possible, then refuel

such equipment on a truck or
trailer from a portable container,
rather than from a gasoline
dispenser nozzle.

• If a gasoline dispenser nozzle must

be used, keep the nozzle in contact
with the rim of the fuel tank or
container opening at all times until
fueling is complete.

Gasoline is harmful or fatal if
swallowed.

Long-term exposure to vapors can
cause serious injury and illness.

• Avoid prolonged breathing of

vapors.

• Keep face away from nozzle and

gas tank or conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

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

•

Keeps gasoline fresh during storage of 30

days or less. For longer storage it is
recommended that the fuel tank be
drained.

•

Cleans the engine while it runs

•

Eliminates gum-like varnish buildup in the

fuel system, which causes hard starting
Add the correct amount of gas

stabilizer/conditioner to the gas.

Note:

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

Gasoline/Alcohol blends

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

Filling the Fuel Tank

1. Shut the engine off and set the motion

controls to the neutral position and
engage parking brake.

2. Clean around the fuel tank cap and

remove the cap.

3. Add unleaded regular gasoline until the

body of the tank is full but fuel does not fill
the neck of the tank (Figure 7). This

18

space in the neck of the tank allows
gasoline to expand. Do not fill the fuel
tank completely full.

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

1. Gas tank opening

2. Fill to here, approximately

3. Gas tank body

Figure 7

Checking the Engine Oil
Level

Before you start the engine and use the
machine, check the oil level in the engine
crankcase; refer to Checking the Oil Level in

Engine Maintenance.

Starting the Engine

1. Sit down on the seat and move the motion

2. Disengage the blades by moving the

1. Control panel

2. Blade control switch—Off position

controls outward to the neutral position
and engage the parking brake.

blade control switch to Off (Figure 8).

Figure 8

3. Move the throttle lever to midway and the
choke lever forward before starting a cold
engine (Figure 9).

Note:

A warm or hot engine may not require

choking.

Figure 9

1. Control panel 4. Choke – off

2. Throttle – fast 5. Choke – on

3. Throttle – slow

4. Turn the ignition key to Start to energize
the starter. When the engine starts,
release the key (Figure 10).

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

Figure 10

1. Control panel 4. Run

2. Ignition key—start position 5. Start

3. Off 6. Choke

19

5. If the engine stalls or hesitates, move the
choke lever partially forward for a few
seconds. (Figure 10).

Operating the Blades

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

Engaging the Blades

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

2. Move the throttle midway to the Fast
position.

Note:

throttle in the midway position.

3. Pull out on the blade control switch to On
to engage the blades (Figure 11).

4. Move throttle to full forward position
before mowing.

Always engage the blades with the

1. Control panel

2. Blade control switch—On position

Figure 11

Disengaging the Blades

Set throttle to midway position. Push the
blade control switch to Off to disengage the
blades (Figure 12).

1. Control panel

2. Blade control switch—Off

Figure 12

Stopping the Engine

1. Move the throttle lever to between Fast
and half throttle (Figure 10).

2. Disengage the blades by moving the
blade control switch to Off (Figure 12).

3. Turn the ignition key to Off (Figure 10).

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

The Safety Interlock System

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

• Do not tamper with the interlock

switches.

• Check the operation of the interlock

switches daily and replace any
damaged switches before operating
the machine.

20

Understanding the Safety Interlock
System

The safety interlock system is designed to
prevent the engine from starting unless:

•

The blades are disengaged.

•

The motion control levers are in the

•

The parking brake is engaged.

The safety interlock system is designed to
initiate engine shutdown when:

•

The parking brake is disengaged and the

•

The PTO is engaged and the operator

•

The parking brake is disengaged and

•

The parking brake is engaged and motion

Testing the Safety Interlock System

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

1. Check starting circuit. Starter

2. Try to start with

3. Try to start with

4. Try to start with

neutral position.

operator gets off machine.

gets off machine.

levers are in and the operator gets off
machine.

control levers are in.

should

with parking brake

disengaged

moved out in the
operator does not need to be in the seat to
start the engine.

brake
motion control levers in the
position - starter

brake

engaged,

control levers in the
starter

brake

engaged,
left motion control lever in,
not crank,
in

, then with

not crank.

and motion control levers

disengaged,

must not crank.

repeat again with the

engaged

neutral lock

operator in seat

PTO

disengaged

must not crank

operator in seat

PTO

engaged

neutral lock

operator in seat

PTO

disengaged, and the

both levers in

, PTO

position. The

neutral lock

and motion

starter

- starter

crank

, parking

and

.
, parking

position -

, parking

must

right lever

must

5. Check kill circuits. Run engine at one-third
throttle,

off

engine

6. Run engine at one-third throttle,

PTO

of machine) engine

shutdown.

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

must initiate shutdown.

8. Again, run engine at one-third throttle, brake

engaged,
lever in

9. Repeat again moving the
then moving

initiate shutdown
seat or not

NOTE: If machine
of these tests, do not operate. Contact
your authorized EXMARK SERVICE
DEALER.

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

Driving Forward or Backward

The throttle control regulates the engine
speed as measured in rpm (revolutions per
minute). Place the throttle control in the Fast
position for best performance. Always
operate in the Fast (full throttle) position.

The machine can spin very rapidly.
The operator may lose control of the
machine and cause personal injury or
damage to the machine.

• Use caution when making turns.

• Slow the machine down before

making sharp turns.

disengage

of seat (but do not get off of machine)

must initiate shutdown.

and

raise off

and move

- engine

both levers in

.

parking brake and

engage

of seat (but do not get off

must initiate

left motion control

must initiate shutdown.

right lever in

- engine

whether operator is

does not

pass any

raise

,

must

on

21

Forward

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

2. To go forward, slowly push the motion
control levers forward (Figure 13).

Figure 13

1. Neutral position 3. Forward

2. Center unlock position 4. Backward

To go straight, apply equal pressure to both
motion control levers (Figure 13).

To turn, pull back on the motion control lever
toward the direction you want to turn
(Figure 13).

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

To stop, pull the motion control levers to
neutral.

Backward

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

2. To go backward, slowly pull the motion
control levers rearward (Figure 13).

To go straight, apply equal pressure to
both motion control levers (Figure 13).

To turn, release the pressure on the
motion control lever toward the direction
you want to turn (Figure 13).

To stop, push the motion control levers to
neutral.

Stopping the Machine

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

Tracking Adjust ment

If the machine turns right or left when handles
are pushed forward together, adjust the stop
on the side opposite the direction of turn (see
Figure 14). Loosen the screws that hold the
motion control limiter stop. Move the stop
back until the unit drives straight. Tighten the
screws to lock the stop in place. Readjust
handles if necessary.

1. Control Arm Shaft 3. Limiter Stop Screws

2. Adjust Stop

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

• Always remove the ignition key and

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

Figure 14

22

Adjusting the Height of Cut

1. Raise the deck to the transport position
(4.5” cut height) by pushing the foot
actuated lever forward (Figure 15). The
spring loaded transport pin will
automatically engage and will click into
place.

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

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

Figure 15

1. Foot actuated height-of-cut lever

2. Height-of-cut positions

3. Transport release handle

4. Height adjuster pin

Positioning the Seat

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

1. Push the adjustment lever towards the
center of the machine to release the seat
adjuster track (Figure 16).

1. Adjustment lever

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

Figure 16

Adjusting the Motion Control
Levers

Adjusting the Height

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

1. Remove the 2 bolts holding the control
lever to the control arm shaft (Figure 17).

2. Move the control lever to the next set of
holes. Secure the lever with the 2 bolts
(Figure 17).

1. Control arm shaft 4. Washer

2. Control lever 5. Bolt

3. Slotted holes

Figure 17

23

3. Repeat the adjustment for the opposite
control lever.

Adjusting the Tilt

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

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

2. Loosen the lower bolt just enough to pivot
the control lever fore or aft (Figure 17).
Tighten both bolts to secure the control in
the new position.

3. Repeat the adjustment for the opposite
control lever.

Pushing the Machine by
Hand

Important: Always push the machine
by hand. Never tow the machine
because damage may occur.

To Push the Machine

1. Park the machine on a level surface and

2. Move the motion control levers outward to

3. Locate the bypass release knobs on either

4. Loosen the knob by turning

5. Release the parking brake.

disengage the blade control switch.

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

side of the engine deck. (Figure 18)

counterclockwise. Then pull the release
lever on the underside of machine
(Figure 18) towards the back of the
machine and retighten the knob to hold
the release lever back in the released
state. Repeat this on each side of the
machine.

The machine is now able to be pushed by
hand.

Figure 18

1. Bypass release knob location

2. Lever position for pushing the machine

3. Lever position for operating the machine

4. Release lever

To Operate the Machine

1. Loosen the bypass knob, push the release
levers forward, and retighten the knob to
engage the drive system (Figure 18).

24

Side Discharge

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

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

• Never remove the discharge deflector

from the mower because the
discharge deflector routes material
down toward the tur f. If the
discharge deflector is ever damaged,
replace it immediately.

• Never put your hands or feet under

the mower.

• Never try to clear discharge area or

mower blade(s) unless you move the
blade control switch to Off and rotate
the ignition key to Off. Also remove
the key and pull the wire off the
spark plug(s).

Operating Tips

Fast Throttle Setting

For best mowing and maximum air circulation,
operate the engine at the Fast position. Air is
required to thoroughly cut grass clippings, so
do not set the height-of-cut so low as to totally
surround the mower by uncut grass. Always
try to have one side of the mower free from
uncut grass, which allows air to be drawn into
the mower.

cut the lawn twice to ensure an acceptable
quality of cut.

Cut 1/3 of the Grass Blade

It is best to cut only about 1/3 of the grass
blade. Cutting more than that is not
recommended unless grass is sparse, or it is
late fall when grass grows more slowly.

Mowing Direction

Alternate mowing direction to keep the grass
standing straight. This also helps disperse
clippings which enhances decomposition and
fertilization.

Mow at Correct Intervals

Normally, mow every four days. But
remember, grass grows at diff eren t rate s at
different times. So to maintain the same
cutting height, which is a good practice, mow
more often in early spring. As the grass
growth rate slows in mid summer, mow less
frequently. If you cannot mow for an
extended period, first mow at a high cutting
height; then mow again two days later at a
lower height setting.

Cutting Speed

To improve cut quality, use a slower ground
speed.

Avoid Cutting Too Low

If the cutting width of the mower is wider than
the mower you previously used, raise the
cutting height to ensure that uneven turf is not
cut too short.

Long Grass

If the grass is ever allowed to grow slightly
longer than normal, or if it contains a high
degree of moisture, raise the cutting height
higher than usual and cut the grass at this
setting. Then cut the grass again using the
lower, normal setting.

Cutting a Lawn for the First Time

Cut grass slightly longer than normal to
ensure that the cutting height of the mower
does not scalp any uneven ground. However,
the cutting height used in the past is generally
the best one to use. When cutting grass
longer than six inches tall, you may want to

When Stopping

If the machine’s forward motion must be
stopped while mowing, a clump of grass
clippings may drop onto your lawn. To avoid
this, move onto a previously cut area with the
blades engaged.

25

Keep the Underside of the Mower
Clean

Clean clippings and dirt from the underside of
the mower after each use. If grass and dirt
build up inside the mower, cutting quality will
eventually become unsatisfactory.

Blade Maintenance

Maintain a sharp blade throughout the cutting
season because a sharp blade cuts cleanly
without tearing or shredding the grass blades.
Tearing and shredding turns grass brown at
the edges, which slows growth and increases

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

26

Maintenance

Note:

normal operating position.

The left and right sides of the machine are determined while sitting in the seat in the

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

Before each use or daily

Every 25 hours

Every 50 hours

Maintenance Procedure

•

Check the safety interlock system

•

Check the air cleaner for dirty, loose or damaged.

•

Check the engine oil level.

•

Check air intake and cooling areas, clean as necessary.

•

Check the cutting blades.

•

Clean the mower housing.

•

Check hydraulic oil level.

•

Grease all lubrication points.

•

Service the paper element (more often under extremely dusty,

dirty conditions).

•

Check tire pressure.

•

Check the belts for wear/cracks.

•

Change the engine oil and filter.

•

Replace the paper element (more often under extremely

dusty, dirty conditions).

Every 100 hours

Every 200 hours

Every 500 hours

Before storage

•

Clean the blower housing (more often under extremely dusty,

dirty conditions).

•

Replace the fuel filter.

•

Check spark plug condition and gap.

•

Change hydraulic system filter.

•

Replace the spark plug.

•

Charge the battery and disconnect battery cables.

•

Perform all maintenance procedures listed above before

storage.

•

Paint any chipped surfaces.

Important: Refer to your engine operator’s manual for additional maintenance
procedures.

If you leave the key in the ignition switch, someone could accidentally start the engine
and seriously injure you or other bystanders.

• Remove the key from the ignition and disconnect the wire from the spark plug before

you do any maintenance. Set the wire aside so that it does not acc identally contact the
spark plug.

27

Premaintenance
Procedures

Raising the Seat

Make sure the motion control levers are
locked in the neutral position. Lift the seat
forward until the lanyard is tight.

The following components can be accessed
by raising the seat:

•

Auxiliary 12V Plug

(12V accessory up to 15 amp)

•

Fuses

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

3. Clean the grease fittings (Figure 20 and

Figure 21) with a rag. Make sure to

scrape any paint off of the front of the
fitting(s).

•

Battery cables

Accessing the Battery

1. The battery is located under the seat. To
access, raise the seat (Figure 19).

1. Front caster tire

A

1. Seat

2. Battery

3. Auxiliary 12V Plug

Figure 19

D

Figure 20

D

B

C

D

E

F

Lubrication

Greasing the Bearings

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

Grease the front caster pivots and wheels
(Figure 20).

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

Located on the back of the seat

A. Read the instructions before servicing or performing

maintenance.
B. Time interval.
C. Check oil level.
D. Grease idler pivots.
E. Check hydraulic oil level and refer to Operator’s manual

for further instructions.
F. Check tire pressure.

Figure 21

28

4. Connect a grease gun to each fitting
(Figure 20 and Figure 21). Pump grease
into the fittings until grease begins to ooze
out of the bearings.

5. Wipe up any excess grease.

Engine Maintenance

Servicing the A ir Cleaner

This engine is equipped with a replaceable,
high density paper air cleaner element.
Check the air cleaner daily or before starting
the engine. Check for a buildup of dirt and
debris around the air cleaner system. Keep
this area clean. Also check for loose or
damaged components. Replace all bent or
damaged air cleaner components.

Note:

damaged air cleaner components could allow
unfiltered air into the engine causing
premature wear and failure.

Note:

under extremely dusty, dirty conditions.

Operating the engine with loose or

Service the air cleaner more often

Figure 22

1. Air Cleaner

2. Knobs, air cleaner cover

3. Air cleaner cover

Servicing Paper Element

Check the paper element every 25 hours of
operation (more often under extremely dusty
or dirty conditions). Clean or replace the
element as necessary. Replace the air
cleaner element yearly, or every 100 hours.

1. Remove the air cleaner cover (Figure 22).

2. Remove the air cleaner element with the
integral rubber seal (Figure 22).

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

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

5. Install the air cleaner element with the
pleated side “out” and seat the rubber seal
onto the edges of the air cleaner base
(Figure 22).

6. Reinstall the air cleaner cover and secure
with the two knobs (Figure 22).

Servicing the Engine Oil

Check the oil level daily or after every 8
hours.

Change oil after first 5 to 8 hours of use, then
every 50 hours thereafter. Change oil every
25 hours when operating the engine under
heavy load or in high temperatures.

Oil Type: Detergent oil (API service SF, SG,
SH, SJ, or higher)

Crankcase Capacity: 2.0 qt (1.9 l) when the
filter is changed

Choose a viscosity according to the table
below.

Figure 23

29

SAE 30 40°F and higher (5°C and higher)

is
good for all purpose use above 40°F. Use
below 40° will cause hard starting.

10W-30 0 to 100°F (-18 to 38°C)

is better for
varying temperature conditions. This viscosity
improves cold weather starting, but may
increase oil consumption above 80°F

(27°C).

*Check oil level frequently at higher
temperatures.

Synthetic 5W-30 -20 to 120°F (-30 to 40°C)

provides the best protection in all
temperatures, as well as improved starting
with less oil consumption.

5W-30 40°F and below (5°C and below)

is
recommended for winter use and works best
in cold conditions.

Checking the Oil Level

1. Park the machine on a level surface,

disengage the blade control switch, stop
the engine, engage parking brake, and
remove the key.

2. Make sure the engine is stopped, level,

and is cool so the oil has had time to drain
into the sump.

3. To keep dirt, grass clippings, etc., out of

the engine, clean the area around the oil
fill cap/dipstick before removing it.

4. Pull and remove the oil fill cap/dipstick;

wipe oil off. Reinsert the dipstick and
push firmly into place (Figure 24).

1

2

3

1. Oil dipstick

2. Filler tube

3. Oil level

Figure 24

5. Remove the dipstick and check the oil
level. (Figure 24).

The oil level should be up to, but not over,
the F mark on the dipstick.

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

Note:

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

Changing the Oil and the Filter

Change the oil filter annually or every 100
hours of operation. Refill with service class
SF, SG, SH, SJ or higher oil as specified in
the “Viscosity Grades” table.

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

Change the oil and oil filter as follows:

1. Start the engine and let it run until warm.

This warms the oil so it drains better.

2. Park the machine so that the drain side is

slightly lower than the opposite side to
assure the oil drains completely.

3. Disengage the blade control switch and

move the motion controls outward to the
neutral position and engage parking
brake.

4. Stop the engine, remove the key, and wait

for all moving parts to stop before leaving
the operating position.

5. Clean the area around the drain plug and

on the machine frame. Place a pan
underneath machine directly below the
drain hole in the frame as shown in

Figure 24.

30

1. Oil drain 3. Pan

2. Oil drain plug

Figure 25

6. Remove the oil drain plug (Figure 25).
Remove the oil fill cap/dipstick
(Figure 24).

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

8. Remove the old filter and wipe off the
mounting pad (Figure 26).

9. When the oil has drained completely,
install the oil drain plug. Tighten the plug
to 14 N-m (125 in-lb) torque. Wipe up any
excess oil on the frame (Figure 25).

Note:

center.

10. Apply a thin film of clean oil to the rubber

11. Install the replacement oil filter to the

Dispose of the used oil at a recycling

gasket on the new filter.

mounting pad. Turn the oil filter clockwise
until the rubber gasket contacts the pad,
then tighten the filter an additional 1/2 to
3/4 turn (Figure 26).

1. Oil filter

2. Gasket

12. Slowly pour approximately 80% of the

13. Install the oil fill cap/dipstick and push

14. Check the oil level (Figure 24); refer to

15. Slowly add additional oil to bring it to the

16. Install the oil fill cap/dipstick and push

specified oil into the filler tube (Figure 24).

firmly into place (Figure 24).

Checking the Oil Level.

full mark.

firmly into place (Figure 24).

Figure 26

Checking the Hydraulic Oil
Level

Check expansion tank and if necessary add
MOBIL 1 15W-50 synthetic motor oil to the
FULL COLD line.

1. Seat 3. Expansion Tank

2. Engine

Figure 27

31

Change the Hydraulic
System Filter

Service the hydraulic system filter after the
first 200 hours of operation.

NOTE: Use only MOBIL 1 15W-50 Synthetic

motor oil.

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

2. Locate the two (2) filters under the
transmissions. Remove filter guards.

3. Carefully clean area around filters. It is

important

enter hydraulic system.

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

IMPORTANT

apply a thin coat of oil on the surface of the
filters rubber seal.

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

4. Remove the vent plug on each
transmission and fill through expansion
reservoir, when oil comes out of vent
reinstall plug. Torque plugs to 180 in-lbs
(244 N-m). Continue to add oil until it
reaches the FULL COLD line on the
expansion reservoir.

1. Vent Plug

2. Oil filter

3. Left rear tire

: Before reinstalling new filters,

that

no dirt

Figure 28

or

contamination

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

6. Start engine and move throttle control
ahead to 1/2 throttle position. Disengage
parking brake.

a) With the bypass valve open and the

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

b) With the bypass valve closed and the

engine running, slowly move the

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

Changing oil unnecessarily

hydraulic system by introducing contaminates
into the system.

Servicing the Spark Plug

Every 2 years or 200 hours of operation,
remove the spark plug, check condition, and
reset the gap or replace with a new plug as
necessary. The spark plug is RFI compliant.
Equivalent alternate brand plugs can also be
used. Spark plug replacement is
recommended at 500 hours.

Type: Champion XC92YC

Air Gap: 0.030 inch (0.76 mm)

directional control in both forward and
reverse directions (5 to 6 times).
Check the oil level, and add oil as
required after stopping the engine.

c) It may be necessary to repeat Steps a)

and b) until all the air is completely
purged from the system. W h en the
transaxle operates at normal noise
levels and moves smoothly forward
and reverse at normal speeds, then
the transaxle is considered purged.

could

damage

Champion RC1ZYC or QC12C may be
used if your area does not require
compliance with Canadian ICES-002,
ISO 14982, or EN 55012.

32

Removing the Spark Plug

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

2. Pull the wire off of the spark plug
(Figure 29). Clean around the spark plug
to prevent dirt from falling into the engine
and potentially causing damage.

Note:

spark plug, blowing out the cavity with
compressed air is usually the most effective
method for cleaning. The spark plug is most
accessible when the blower housing is
removed for cleaning.

3. Remove the spark plug and metal washer.

Due to the deep recess around the

11

Figure 29

1. Spark plug and wire location

Checking the Spark Plug

1. Look at the center of the spark plug
(Figure 30). If you see light brown or gray
on the insulator, the engine is operating
properly. A black coating on the insulator
usually means the air cleaner is dirty.

Important: Never clean the spark plug.
Always replace the spark plug when it
has a black coating, worn electrodes,
an oily film, or cracks.

2. Check the gap between the center and
side electrodes (Figure 30). Bend the
side electrode (Figure 30) if the gap is not
correct.

Figure 30

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

Installing the Spark Plug

1. Install the spark plug. Make sure that the
air gap is set correctly.

2. Tighten the spark plug to 30 ft-lb(41 N-m).

3. Push the wire onto the spark plug
(Figure 29).

Cleaning the Blower Housing

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

Annually or every 100 hours of operation
(more often under extremely dusty, dirty
conditions), remove the blower housing and
any other cooling shrouds. Clean the cooling
fins and external surfaces as necessary.
Make sure the cooling shrouds are
reinstalled. Torque the blower housing
screws to 80 in-lb (9 N-m).

Important: Operating the engine with a
blocked grass screen, dirty or plugged
cooling fins, and/or cooling shrouds
removed, will cause engine damage
due to overheating.

33

Fuel System
Maintenance

Replacing the Fuel Filter

In certain conditions, gasoline is
extremely flammable and highly
explosive. A fire or explosion from
gasoline can burn you and others and
can damage property.

• Perform any fuel related maintenance

when the engine is cold. Do this
outdoors in an open area. Wipe up
any gasoline that spills.

• Never smoke when draining gasoline,

and stay away from an open flame or
where a spark may ignite the
gasoline fumes.

Replace the fuel filter after every 100
operating hours or yearly, whichever occurs
first.

Never install a dirty filter if it is removed from
the fuel line.

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

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

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

Figure 31

1. Fuel line from tank 6. Fuel tank

2. Hose clamp 7. Fuel shut off valve

3. Filter 8. Fuel shut off valve – On

4. Fuel line to engine 9. Fuel shut off valve – Off

5. Flow direction arrow

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

5. Squeeze the ends of the hose clamps
together and slide them away from the
filter (Figure 31).

6. Remove the filter from the fuel lines.

7. Install a new filter with the flow direction
arrow coming from the fuel tank and
pointing to the engine. Move the hose
clamps close to the filter (Figure 31) to
secure it in place.

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

34

Electrical System
Maintenance

CALIFORNIA

Proposition 65 Warning

Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the
State of California to cause cancer and
reproductive harm. Wash hands after
handling.

Charging the Battery

Removing the Battery

Battery terminals or metal tools could
short against metal machine
components causing sparks. Sparks
can cause the battery gasses to
explode, resulting in personal injury.

• When removing or installing the

battery, do not allow the battery
terminals to touch any metal parts
of the machine.

• Do not allow metal tools to short

between the battery terminals and
metal parts of the machine.

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

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

3. Raise the seat.

4. Disconnect the negative (black) ground
cable from the battery post (Figure 32).
Retain all fasteners.

Incorrect battery cable routing could
damage the machine and cables
causing sparks. Sparks can cause the
battery gasses to explode, resulting in
personal injury.

• Always disconnect the negative

(black) battery cable before
disconnecting the positive (red)
cable.

• Always connect the positive (red)

battery cable before connecting the
negative (black) cable.

5. Slide the rubber cover up the positive
(red) cable. Disconnect the positive (red)
cable from the battery post (Figure 32).
Retain all fasteners.

6. Remove the battery hold-down (Figure 32)
and lift the battery from the battery tray.

Figure 32

1. Battery 5. Negative battery post

2. Positive battery post 6. Bolt, washer, and nut

3. Bolt, washer, and nut 7. Battery hold-down

4. Terminal boot 8. Wingnut

Charging the Battery

1. Remove the battery from the chassis;
refer to Removing the Battery.

2. Allowing batteries to stand for an
extended period without recharging them
will result in reduced performance and
service life. To preserve optimum battery
performance and life, recharge batteries in
storage when the open circuit voltage
drops to 12.4 volts.

35

NOTE:

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

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

IMPORTANT:

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

Voltage

Reading

12.6

or greater

12.4 – 12.6 75 – 100%

12.2 – 12.4 50 – 75%

12.0 – 12.2 25 – 50%

11.7 – 12.0 0 – 25%

11.7 or less 0%

Percent

Charge

100%

Maximum

Charger
Settings

16 volts /

7 amps

16 volts /

7 amps

16 volts /

7 amps

14.4 volts /
4 amps

14.4 volts /
4 amps

14.4 volts /
2 amps

Charging

Interval

No Charging

Required

30 Minutes

1 Hour

2 Hours

3 Hours
6 Hours

or More

4. When the battery is fully charged, unplug
the charger from the electrical outlet, then
disconnect the charger leads from the
battery posts (Figure 33).

Figure 33

1. Positive battery post 3. Red (+) charger lead

2. Negative battery post 4. Black (-) charger lead

Note:

Do not run the machine with the
battery disconnected, electrical damage may
occur.

Installing the Battery

1. Position the battery in the tray with the

terminal posts toward the operating
position (Figure 32).

2. Install the positive (red) battery cable to

the positive (+) battery terminal using the
fasteners removed previously.

3. Install the negative battery cable to the

negative (-) battery terminal using the
fasteners removed previously.

4. Slide the red terminal boot onto the

positive (red) battery post.

5. Secure the battery with the hold-down

(Figure 32).

Servicing the Fuses and
Relay

The electrical system is protected by fuses. It
requires no maintenance; however, if a fuse
blows, check the component/circuit for a
malfunction or short. There is also a
replaceable relay next to the fuse. Refer to
your Parts manual for correct replacement
relay.

Fuse:

•

Main 25 amp, blade-type

•

Charge Circuit 20 amp, blade-type

1. Raise the seat to gain access to the fuse

2. Remove cover as shown in (Figure 34).

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

holder (Figure 34).

remove it (Figure 34).

36

Figure 34

1. Cover 4. Main-25 amp

2. Auxilliary-15 amp 5. Relay

3. Charge-20 amp

Drive System
Maintenance

Checking the Tire Pressure

Maintain the air pressure in the front and rear
tires as specified. Uneven tire pressure can
cause uneven cut. Check the pressure at the
valve stem after every 25 operating hours or
monthly, whichever occurs first (Figure 35).
Check the tires when they are cold to get the
most accurate pressure reading.
Rear Tires: 13 psi (90 kPa)
Front Tires (caster wheels): 13 psi (90 kPa)

G000554

Figure 35

1. Valve stem

1

Mower Maintenance

Servicing the Cutting Blade s

Maintain sharp blades throughout the cutting
season because sharp blades cut cleanly
without tearing or shredding the grass blades.
Tearing and shredding turns grass brown at
the edges, which slows growth and increases
the chance of disease.

Check the cutter blades daily for sharpness,
and for any wear or damage. File down any
nicks and sharpen the blades as necessary. If
a blade is damaged or worn, replace it
immediately with a genuine Exmark
replacement blade. For convenient
sharpening and replacement, you may want
to keep extra blades on hand.

A worn or damaged blade can break,
and a piece of the blade could be
thrown into the operator’s or
bystander’s area, resulting in serious
personal injury or death.

• Inspect the blade periodically for

wear or damage.

• Replace a worn or damaged blade.

Before Inspecting or Servicing the
Blades

Park the machine on a level surface,
disengage the blade control switch, and move
the motion control levers outward to the
neutral position and engage parking brake.
Stop the engine, remove the key, and
disconnect the spark plug wire(s) from the
spark plug(s).

Inspecting the Blades

1. Inspect the cutting edges (Figure 36). If

2. Inspect the blades, especially the curved

the edges are not sharp or have nicks,
remove and sharpen the blades; refer to
Sharpening the Blades.

area (Figure 36). If you notice any
damage, wear, or a slot forming in this
area (item 3 in Figure 36), immediately
install a new blade.

37

Figure 36

1. Cutting edge

2. Curved area

3. Wear/slot forming

Checking for Bent Blades

1. Rotate the blades until the ends face
forward and backward (Figure 37).
Measure from a level surface to the
cutting edge, of the blades (Figure 37).
Note this dimension.

1. Blades front to rear

2. Outside cutting edges

3. Measure here

Figure 37

2. Rotate the opposite ends of the blades
forward.

3. Measure from a level surface to the
cutting edge of the blades at the same
position as in step 1. The difference
between the dimensions obtained in steps
1 and 3 must not exceed 1/8 inch (3 mm).
If this dimension exceeds 1/8 inch (3 mm),
the blade is bent and must be replaced.
Refer to Removing the Blades and
Installing the Blades.

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

• Always replace bent or damaged

blade with a new blade.

• Never file or create sharp notches

in the edges or surfaces of blade.

Checking for Loose Blades or
Damaged Spring Disk Washers

1. Place a wrench on the blade bolt and
torque to 45-55ft lbs (61-75 N-m).

2. With the wrench still on the blade bolt, hold
the blade spindle stationary and using a
rag or thickly padded glove, try to rotate
the blade. If the blade rotates relative to
the spindle guard without further tightening
the blade bolt, the two spring disk washers
have been flattened or damaged and must
be replaced (Figure 38). Refer to
Removing and Installing the Blades.

3. Once the blade has been removed, inspect
the two spring disk washers. If the
washers appeared to be damaged (the
washer surface has been marred) or
flattened they must be replaced. (Figure

38).

Note:

If the blade hits a solid object, the blade
bolt will tighten. The tightened blade bolt may
flatten or even invert the spring disk washers,
possibly causing damage. A damaged spring
disk washer must be replaced.

Removing the Blades

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

Hold the blade end using a rag or thickly-
padded glove (or place a wrench on the top
sheave nut). Remove the blade bolt, two
spring disk washers, bushing, and blade from
the spindle shaft (Figure 38).

38

#

Figure 38

1. Blade 2. Sail area of blade

3. Bushing 4. Spring disk washers

5. Blade bolt

#

Sharpening the Blades

1. Use a file to sharpen the cutting edge at
both ends of the blade (Figure 39).
Maintain the original angle. The blade
retains its balance if the same amount of
material is removed from both cutting
edges.

1. Sharpen at original angle

2. Check the balance of the blade by putting
it on a blade balancer (Figure 40). If the
blade stays in a horizontal position, the
blade is balanced and can be used. If the
blade is not balanced, file some metal off
the end of the sail area only (Figure 39).
Repeat this procedure until the blade is
balanced.

1

Figure 39

Orientation of washers

G000552

1. Blade

2. Balancer

Figure 40

Installing the Blades

1. Install the blade onto the spindle shaft
(Figure 38

).

Important: The curved part of the blade
must be pointing upward toward the
inside of the mower to ensure proper
cutting.

2. Hold the blade end using a rag or thickly-
padded glove (or place a wrench on the
top sheave nut). Install the bushing, two
spring disk washers (cupped side toward
the blade) and blade bolt (Figure 38

).

3. Torque the blade bolt to 45-55 ft-lbs
(61-75 N-m).

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

• Always install the original Exmark

blades, blade bushing, spring disk
washers and blade bolts as shown.

Leveling the Mower Deck

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

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

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

3. Check the air pressure of all four tires. If
needed, adjust to the recommended
inflation; refer to Checking the Tire
Pressure in Drive System Maintenance. If
either one is out of range then follow
adjustment procedure.

4. Carefully rotate the blades side to side
(Figure 41).

39

5. Measure between the outside cutting
edges and the flat surface (Figure 41). If
both measurements are not within
3/16 inch (5mm), an adjustment is
required; continue with this procedure.

6. Check the front-to-rear blade level any
time you install the mower. If the front
blade tip is not 1/16-5/16 inch
(1.6-7.9 mm) lower than the rear blade tip,
adjust the blade level. If measurements
from step 5 or 6 are out of range, then
follow Adjusting the Blade Slope.

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

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

9. Carefully rotate the blades side to side
(Figure 41).

Figure 41

1. Blades side to side 3. Measure here

2. Outside cutting edges

10. Loosen the leveling adjust locking nuts
(item 3) on all four corners so that the
deck is sitting securely on all four blocks.
Make sure that the deck hangers are all
the way down (at the top of the slot) and
the deck lift foot lever is pushed back
against the stop, then tighten the four
leveling adjust locking nuts (Figure 42).

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

12. Continue leveling the deck by checking
the front-to-rear blade slope; refe r to
Adjusting the Front-to-Rear Blade Slope.

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

1. Deck lift arm 3. Leveling adjust locking nut

2. Float retaining nut 4. Deck hanger

Figure 42

Adjusting the Blade Slope

1. Check the front-to-rear blade level any
time you install the mower. If the front
blade tip is not 1/16-5/16 inch
(1.6-7.9 mm) lower than the rear blade tip,
adjust the blade level using the following
instructions:

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

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

4. Check the air pressure of all four tires. If
needed, adjust to the recommended
inflation; refer to Checking the Tire
Pressure in Drive System Maintenance.

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

40

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

7. Loosen the leveling adjust locking nuts
(item 3) on all four corners so that the
deck is sitting securely on all four blocks.
Make sure that the deck hangers are all
the way down (at the top of the slot) and
the deck lift foot lever is pushed back
against the stop, then tighten the four
leveling adjust locking nuts (Figure 44).

8. Carefully rotate the blades so they are
facing front to rear (Figure 43).

9. Measure from the tip of the front blade to
the flat surface and the tip of the rear
blade to the flat surface (Figure 43). If the
front blade tip is not 1/16-5/16 inch
(1.6-7.9 mm) lower than the rear blade tip,
adjust the front deck hanger.

Figure 43

1. Blades front to rear 3. Measure here

2. Outside cutting edges

Figure 44

1. Deck lift arm 3. Leveling adjust locking nut

2. Float retaining nut 4. Deck hanger

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

Removing the Mower Deck

1. Park the machine on a level surface and

disengage the blade control switch.

2. Move the motion control levers outward to

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

3. Place blocks under deck for support.

Lower the height-of-cut lever to the lowest
position.

4. Remove the hardware from the deck

hanger and deck lift arm on both sides of
the deck (Figure 45).

1. Deck lift arm

2. Deck hanger

Figure 45

41

5. Remove the nut, bolt, and pivot bushing
from the deck strut (Figure 45
lower the front of the mower deck to the
ground (Figure 46

).

). Carefully

Figure 46

1. Deck lift arm

2. Deck strut

6. Slide the mower rearward to remove the
mower belt from the engine pulley.

7. Slide the mower out from underneath the
machine.

Note:

Retain all parts for future installation.

Mower Belt Maintenance

Inspecting the Belts

Inspect all belts every 25 hours.
Check the belts for cracks, frayed edges, bu rn

marks, or any other damage. Replace
damaged belts.

Replacing the Mower Belt

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

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

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

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

4. Remove the belt covers over the outside
spindles.

5. Pull the idler pulley in the direction shown
in Figure 45 and roll the belt off of the
pulleys.

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

Be careful when removing the belt.

Figure 47

1. Idler pulley 4. Spring

2. Mower belt 5. Engine pulley

3. Outside pulley

6. Route the new belt around the engine
pulley and mower pulleys (Figure 47).

7. Pull the idler pulley in the direction shown
in Figure 47 and route the belt onto the
idler pulley (Figure 47).

8. Install the belt covers over the outside
spindles.

Installing the Mower Deck

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

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

3. Slide the mower under the machine.

4. Lower the height-of-cut lever to the lowest
position.

42

5. Use the existing hardware to attach the
rear deck strut of the mower to the deck
lift arm (Figure 46).

6. Attach the hardware from the deck hanger
and deck lift arm on both sides of the deck
(Figure 45).

7. Install the mower belt onto the engine
pulley; refer to Replacing the Mower Belt.

Replacing the Discharge
Deflector

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

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

Figure 48

1. Mower deck 4. Spring

2. Discharge deflector 5. Rod

3. Discharge deflector bracket 6. Assembled view

1. Locate items shown in Figure 48.

2. Slide the rod out of the short stand-off,
spring, and discharge deflector (Figure 48).
Remove the damaged or worn discharge
deflector.

3. Install new discharge deflector (Figure 48).

4. Orient the spring so that the short leg points
towards the discharge deflector and the
longer leg points towards the deck as
shown in Figure 48. Place spring on rod
and slide rod, straight end, through the front
discharge deflector bracket, discharge
deflector, and rear deflector bracket.

5. Make sure that the spring and rod are
installed so that the rod is retained from
sliding out by the front bracket and the
spring holds the discharge deflector in the
down position. Refer to (Figure 48) for
proper orientation.

Important: The discharge deflector
must be spring loaded in the down
position. Lift the deflector up to test
that it snaps to the full down position.

Cleaning

Washing the Underside of
the Mower

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

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

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

3. Attach the hose coupling to the end of the
mower washout fitting, and turn the water
on high (Figure 49).

Note:

fitting O-ring to make the coupling slide on
easier and protect the O-ring.

Spread petroleum jelly on the washout

43

Figure 49

1. Washout fitting

2. Hose

3. O-Ring

3. Coupling

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

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

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

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

Note:

washing, soak it and let it stand for
30 minutes. Then repeat the process.

8. Run the mower again for one to three

If the mower is not clean after one

minutes to remove excess water.

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

• Replace broken or missing

washout fitting immediately, before
using mower again.

• Plug any hole(s) in mower with

bolts and locknuts.

• Never put your hands or feet under

the mower or through openings in
the mower.

Storage

Cleaning and Storage

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

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

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

3. Service the air cleaner; refer to Servicing
the Air Cleaner in Engine Maintenance.

4. Grease and oil the machine; refer to

Lubrication.

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

Maintenance.

6. Check the tire pressure; refer to Checking
the Tire Pressure in Drive System

Maintenance.

7. Charge the battery; refer to Servicing the
Battery in Electrical System Maintenance.

8. Check the condition of the blades; refer to
Servicing the Cutting Blades in Mower

Maintenance.

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

10. Add a petroleum based
stabilizer/conditioner to the fuel in the
tank. Follow the mixing instructions from
the stabilizer manufacturer. Do not use an
alcohol based stabilizer (ethanol or
methanol).

44

Note:

effective when mixed with fresh gasoline
and used at all times.

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

Stop the engine, allow it to cool, and drain
the fuel tank; refer to Draining the Fuel
Tank in Fuel System Maintenance.

Restart the engine and run it until it stops.
Choke the engine. Start and run the

engine until it will not start.
Dispose of fuel properly. Recycle as per

local codes.

A fuel stabilizer/conditioner is most

Important: Do not store
stabilizer/conditioned gasoline over 30
days.

11. Remove the spark plug(s) and check its
condition; refer to Servicing the Spark
Plug in Engine Maintenance. With the
spark plug(s) removed from the engine,
pour two tablespoons of engine oil into the

spark plug hole. Use the starter to crank
the engine and distribute the oil inside the
cylinder. Install the spark plug(s). Do not
install the wire on the spark plug(s).

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

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

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

15. Check and tighten all bolts, nuts, and
screws. Repair or replace any part that is
worn or damaged.

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

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

45

Troubleshooting

Problem Possible Cause Corrective Action

The engine overheats. 1. The engine load is excessive.

2. The oil level in the crankcase is
low.

3. The cooling fins and air
passages under the engine
blower housing are plugged.

4. The air cleaner is dirty.

5. Dirt, water, or stale fuel is in fuel
system.

The starter does not
crank

1. The blade control switch is
engaged.

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

3. The operator is not seated.

4. The battery is dead.

5. The electrical connections are
corroded or loose.

6. A fuse is blown.

7. A relay or switch is damaged.

1. Reduce ground speed.

2. Add oil to the crankcase.

3. Remove the obstruction
from the cooling fins and
air passages.

4. Clean or replace the air
cleaner element.

5. Contact an Authorized
Service Dealer.

1. Move the blade control
switch to Disengaged.

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

3. Sit on the seat.

4. Charge the battery.

5. Check the electrical
connections for good
contact.

6. Replace the fuse.

7. Contact an Authorized
Service Dealer.

The engine will not start,
starts hard, or fails to
keep running.

1. The fuel tank is empty.

2. The choke is not on.

3. The air cleaner is dirty.

4. The spark plug wire(s) is loose or
disconnected.

5. The spark plug(s) is pitted, fouled,
or the gap is incorrect.

6. There is dirt in fuel filter.

7. Dirt, water, or stale fuel is in fuel
system.

8. There is incorrect fuel in the fuel
tank.

9. The oil level in the crankcase is
low.

46

1. Fill the fuel tank.

2. Move the choke lever to
On.

3. Clean or replace the air
cleaner element.

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

5. Install a new, correctly
gapped spark plug(s).

6. Replace the fuel filter.

7. Contact an Authorized
Service Dealer.

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

9. Add oil to the crankcase.

Problem Possible Cause Corrective Action

The engine loses power. 1. The engine load is excessive.

2. The air cleaner is dirty.

3. The oil level in the crankcase is
low.

4. The cooling fins and air passages
under the engine blower housing
are plugged.

5. The spark plug(s) is pitted,
fouled, or the gap is incorrect.

6. The vent in the fuel cap is closed.

7. There is dirt in the fuel filter.

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

9. There is incorrect fuel in the fuel
tank.

The machine does not
drive.

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

2. The drive belts are off of the
pulleys.

3. The drive is in bypass mode.

1. Reduce ground speed.

2. Clean the air cleaner
element.

3. Add oil to the crankcase.

4. Remove the obstruction
from the cooling fins and
air passages.

5. Install a new, correctly
gapped spark plug(s).

6. Open the vent in the fuel
cap.

7. Replace the fuel filter.

8. Contact an Authorized
Service Dealer.

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

1. Contact an Authorized
Service Dealer.

2. Contact an Authorized
Service Dealer.

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

There is abnormal
vibration.

1. The engine mounting bolts are
loose.

2. The engine pulley, idler pulley, or
blade pulley is loose.

3. The engine pulley is damaged.

4. The cutting blade(s) is/are bent or
unbalanced.

5. A blade is loose.

6. A blade bushing is missing.

7. A blade spindle is bent.

47

1. Tighten the engine
mounting bolts.

2. Tighten the appropriate
pulley.

3. Contact an Authorized
Service Dealer.

4. Install a new cutting
blade(s).

5. Tighten the blade mounting
bolt and inspect the blade
spring disk washers for
damage (See Servicing the
Cutting Blades, page 37).

6. Install a blade bushing
(See Figure 38, page 39).

7. Contact an Authorized
Service Dealer.

Problem Possible Cause Corrective Action

Uneven cutting height or
poor quality of cut.

The blades do not
rotate.

1. The blade(s) is not sharp.

2. A cutting blade(s) is/are bent.

3. A blade is loose.

4. The mower is not level.

5. An anti-scalp wheel is not set
correctly.

6. The underside of the mower is
dirty.

7. The tire pressure is incorrect.

8. A blade spindle is bent.

1. The drive belt is worn, loose or
broken.

2. The drive belt is off of the pulley.

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

1. Sharpen the blade(s).

2. Install a new cutting
blade(s).

3. Tighten the blade mounting
bolt and inspect the blade
spring disk washers for
damage (See Servicing the
Cutting Blades, page 37).

4. Level the mower from side-
to-side and front-to-rear.

5. Adjust the anti-scalp wheel
height.

6. Clean the underside of the
mower.

7. Adjust the tire pressure.

8. Contact an Authorized
Service Dealer.

1. Install a new drive belt.

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

3. Install a new mower belt.

48

Schematics

49

Notes

50

3-Year Limited Consumer Warranty

(30-Day Limited Commercial Warranty)

Exmark Quest Riding Mowers

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 manufactured by Exmark 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 mowers.

This warranty applies to Exmark Quest mowers purchased on or
after January 1, 2007 sold in the US 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.

Products

•

•

•

•

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

This warranty only includes the cost of parts and labor.
** 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.

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

Exmark Quest mowers and attachments used for commercial,
institutional, or rental use are warranted against defects in
materials or workmanship for the following time periods from the
date of purchase:

Products

Air Cooled Gas Engines 90 day limited warranty
All other items 30 day limited warranty

This warranty does not cover the following:

•

•

•

•

•

There are no other express warranties except for engine and
special emission system coverage stated elsewhere herein or
included with the product.

Warranty Period

Attachments 1 year
Belts and Tires 90 days
Battery 1 Year Prorated
Engine* 3-Year, 3

Limited Warranty for Commercial Use

Warranty Period

Items and Conditions Not Covered

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.

(For units purchased on or after January 1, 2007)

rd

Year Covered by Exmark

rd

year of warranty.

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. 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
[e-mail]

Owner’s Responsibilities

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

General Conditions

The sole liability of Exmark and Exmark Warranty Company with
respect to this warranty shall be repair and replacement as set
forth herein.

shall have any liability for any other cost, loss or damage,
including but not limited to, any incidental or consequential
loss or damage.

In particular, we shall have no liability or responsibility for:

•

Expenses related to gasoline, oil or lubricants.

•

Travel time, overtime, after hours time or other

extraordinary repair charges or charge 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.

Some states do not allow exclusions of incidental or
consequential damages, 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.

Neither Exmark nor Exmark Warranty Company

51

6232

SEE EXMARK’S COMPLETE

LINE OF ACCESSORIES

RIDING ACCESSORIES

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WALK BEHIND ACCESSORIES

GRASS CATCHER

MICRO-MULCH SYSTEM

STEERABLE SULKY

SULKY HITCH KIT

TURF STRIPER

STANDON

Check us out on the Web:

www.exmark.com

© 2007 EXMARK MFG. CO. INC. PART NO. 109-
INDUSTRIAL PARK BOX 808 [phone]
BEATRICE, NE 68310 FAX [phone]

ALL RIGHTS RESERVED PRINTED IN U.S.A.

Rev. B

®

MFG. CO.