QUEST®

For Serial Nos.720,000 & HigherPart No. 4500-338 Rev. A

WARNINGCALIFORNIA

Proposition 65 Warning

The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects, orother reproductive harm.

Important: This engine is not equipped witha spark arrester muffler. It is a violation ofCalifornia Public Resource Code Section 4442 touse or operate the engine on any forest-covered,brush-covered, or grass-covered land. Otherstates or federal areas may have similar laws.

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

The enclosed Engine Owner’s Manual issupplied for information regarding the USEnvironmental Protection Agency (EPA) andthe California Emission Control Regulation ofemission systems, maintenance, and warranty.Replacements may be ordered through theengine manufacturer.

For models with stated engine horsepower, the grosshorsepower of the engine was laboratory rated by theengine manufacturer in accordance with SAE J1940.As configured to meet safety, emission, and operatingrequirements, the actual engine horsepower on thisclass of lawn mower will be significantly lower.

© 2007–2008—Exmark Mfg. Co., Inc.Industrial Park Box 808Beatrice, NE 68310 2

Contact us at www.Exmark.com.Printed in the USA.

All Rights Reserved

IntroductionRead this information carefully to learn how tooperate and maintain your product properly and toavoid injury and product damage. You are responsiblefor operating the product properly and safely.

You may contact Exmark directly atwww.Exmark.com for product and accessoryinformation or help finding a dealer.

Whenever you need service, genuine Exmark parts,or additional information, contact an AuthorizedService Dealer or Exmark Customer Service and havethe model and serial numbers of your product ready.Figure 1 identifies the location of the model and serialnumbers on the product. Write the numbers in thespace provided.

Figure 1Behind the seat

1. Model and serial number location

Model No.

Serial No.

3

ContentsIntroduction ........................................................... 3Safety ..................................................................... 5

Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Instructional Decals ....................... 8

Specifications ....................................................... 13Model Numbers ............................................ 13Systems ......................................................... 13Dimensions................................................... 14Torque Requirements .................................... 15

Product Overview ................................................ 15Operation ............................................................. 16

Controls ........................................................ 16Operating Instructions .................................. 17Recommended Gasoline................................ 18Checking the Engine Oil Level ....................... 19Starting the Engine ........................................ 19Operating the Blades ..................................... 20Stopping the Engine ...................................... 21The Safety Interlock System........................... 21Driving Forward or Backward........................ 22Stopping the Machine.................................... 23Tracking Adjustment ..................................... 23Adjusting the Height of Cut ........................... 23Adjusting the Anti-Scalp Rollers..................... 24Positioning the Seat ....................................... 24Changing the Seat Ride Suspension ................ 24Adjusting theMotion Control Levers ............. 25Pushing theMachine by Hand........................ 25Side Discharge............................................... 26Transporting ................................................. 26Operating Tips ............................................. 27

Maintenance ......................................................... 29RecommendedMaintenance Schedule(s) ........... 29Premaintenance Procedures .............................. 30Raising the Seat ............................................. 30Accessing the Battery .................................... 30

Periodic Maintenance ....................................... 30Lubrication.................................................... 30Engine Maintenance...................................... 31Servicing the Engine Oil ................................ 32Checking theHydraulic Oil Level ................... 34Change theHydraulic System Filter................ 34Servicing the Spark Plug ................................ 35Cleaning the Blower Housing......................... 35Fuel SystemMaintenance .............................. 36Electrical SystemMaintenance....................... 36Charging the Battery...................................... 37Servicing the Fuses and Relay......................... 38

Drive SystemMaintenance ............................ 39Checking the Tire Pressure ............................ 39Mower Maintenance ...................................... 39Servicing the Cutting Blades .......................... 39Mower Belt Maintenance ............................... 41Leveling the Mower Deck .............................. 42Adjusting the Blade Slope .............................. 42Removing theMower Deck ........................... 44Installing theMower Deck............................. 44Replacing theDischargeDeflector ................. 45

Cleaning ........................................................... 46Washing theUnderside of theMower ............. 46

Storage ................................................................. 47Cleaning and Storage ..................................... 47

Troubleshooting ................................................... 48Schematics ........................................................... 50

4

Safety

SafetySafety Alert SymbolThis manual identifies potential hazards and hassafety messages identified by the safety alert symbol(Figure 2), which signals a hazard that may causeserious injury or death if you do not follow therecommended precautions.

Figure 21. Safety alert symbol

This manual uses two other words to highlightinformation. Important calls attention to specialmechanical information and Note emphasizesgeneral information worthy of special attention.

This machine meets or exceeds the safetyspecifications of the American NationalStandards Institute B71.1-2003 in effect at thetime of production. However, improper useor maintenance by the operator or owner canresult in injury. To reduce the potential forinjury, comply with these safety instructionsand always pay attention to the safety alertsymbol, which means CAUTION, WARNING,or DANGER-"personal safety instruction."Failure to comply with the instruction may resultin personal injury or death.

Safe Operating PracticesThe following instructions are from ANSI standardB71.1-2003.

This product is capable of amputating hands andfeet and throwing objects. Always follow all safetyinstructions to avoid serious injury or death.

General Operation• Read, understand, and follow all instructions in

the operator’s manual and on the machine beforestarting.

• Do Not place hands or feet near rotating parts orunder the machine. Keep clear of the dischargeopening at all times.

• Allow only responsible adults who are familiarwith 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 theblade.

• Be sure the area is clear of other people beforemowing. Stop the machine if anyone enters thearea.

• Never carry passengers.

• Do Not mow in reverse unless absolutelynecessary. Always look down and behind beforeand while backing up.

• Be aware of the mower discharge direction andDo Not point it at anyone. Avoid dischargingmaterial against a wall or obstruction. Materialmay ricochet back toward the operator. Stop theblades when crossing gravel surfaces.

• Do Not operate the mower without either theentire grass collection system or the dischargedeflector in place.

• Be alert, slow down and use caution when makingturns. Look behind and to the side beforechanging 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 theengine, wait for all parts to come to a completestop, engage parking brake, and remove keybefore cleaning the machine, removing the grassor unclogging the deflector.

• Operate the machine only in daylight or goodartificial light.

• Do Not operate the machine while under theinfluence of alcohol or drugs.

• Watch for traffic when operating near or crossingroadways.

• Use extra care when loading or unloading themachine into a trailer or truck

• Always wear eye protection when operating themower.

• Data indicates that operators, age 60 years andabove, are involved in a large percentage of ridingmower-related injuries. These operators shouldevaluate their ability to operate the riding mower

5

Safety

safely enough to protect themselves and othersfrom serious injury.

• Always follow the recommendations for wheelweights or counterweights.

Slope OperationSlopes are a major factor related to loss of controland tip-over accidents, which can result in severeinjury or death. Operation on all slopes requires extracaution. If you cannot back up the slope or if youfeel 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 couldoverturn the machine.

• Choose a low ground speed so you will not haveto stop while operating on a slope.

• Do Not mow slopes when grass is wet. Slipperyconditions reduce traction and could cause slidingand 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 canhide obstacles.

• Avoid sudden starts when mowing uphill becausethe mower may tip backwards.

• Be aware that loss of traction may occur goingdownhill. Weight transfer to the front wheelsmay cause drive wheels to slip and cause loss ofbraking and steering.

• Always avoid sudden starting or stopping on aslope. If tires lose traction, disengage the bladesand proceed slowly off the slope.

• Use extreme care with grass collection systems orother attachments. These can change the stabilityof the machine and cause loss of control.

• Do Not try to stabilize the machine by puttingyour foot on the ground.

• Do Not mow near drop-offs, ditches, steep banksor water. Wheels dropping over edges can causerollovers, which may result in serious injury, deathor drowning.

• Use a walk behind mower and/or a hand trimmernear drop-offs, ditches, steep banks or water.

ChildrenTragic accidents can occur if the operator is notalert to the presence of children. Children are oftenattracted to the machine and the mowing activity.Never assume that children will remain where youlast 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 enterthe area.

• Before and while backing or changing direction,look behind, down, and side-to-side for smallchildren.

• Never carry children, even with the blades off.They may fall off and be seriously injured orinterfere with safe machine operation.

• Children who have been given rides in the pastmay suddenly appear in the mowing area foranother ride and be run over or backed over bythe mower.

• Never allow children to operate the machine.• Use extra care when approaching blind corners,

shrubs, trees, the end of a fence or other objectsthat may obscure vision.

Towing• Use for towing only if equipped with an Exmark

hitch kit. Do Not attach towed equipment exceptat the hitch point.

• Follow Exmark’s recommendation for weightlimits for towed equipment and towing on slopes.This information can be found in the hitch kitinstruction sheet and on the decal.

• Never allow children or others in or on towedequipment.

• On slopes, the weight of the towed equipmentmay cause loss of traction and loss of control.

• Travel slowly and allow extra distance to stop.

ServiceSafe Handling of Gasoline

To avoid personal injury or property damage, useextra care when handling gasoline and other fuels.They are flammable and the vapors are explosive.

6

Safety

• Extinguish all cigarettes, cigars, pipes and othersources of ignition.

• Use only an approved container.• Never remove the gas cap or add fuel when the

engine is running. Allow the engine to cool beforerefueling.

• Never refuel the machine indoors.• Never store the machine or fuel container inside

where there is an open flame, such as near a waterheater or furnace.

• Never fill containers inside a vehicle or on atruck or trailer with a plastic liner. Always placecontainers on the ground away from your vehiclebefore filling.

• Remove gas-powered equipment from the truckor trailer and refuel it on the ground. If this isnot possible, then refuel such equipment with aportable container, rather than from a gasolinedispenser nozzle.

• Keep the nozzle in contact with the rim of thefuel tank or container opening at all times untilthe fueling is complete. Do Not use a nozzlelock-open device.

• If fuel is spilled on clothing, change clothingimmediately.

• Never overfill the fuel tank. Replace gas cap andtighten securely.

General Service:• Never run a machine inside a closed area.• Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in goodcondition.

• Never tamper with safety devices. Check theirproper operation regularly.

• Keep the machine free of grass, leaves, or otherdebris build-up. Clean up oil or fuel spillage andfuel soaked debris. Allow the machine to coolbefore storing.

• Stop and inspect the equipment if you strike anobject. Repair, if necessary, before restarting.

• Never make any adjustments or repairs with theengine running.

• Grass collection system components are subjectto wear, damage and deterioration, which couldexpose moving parts or allow objects to bethrown. Frequently check components and

replace with manufacturers’ recommended parts,when necessary.

• Mower blades are sharp and can cut. Wrap theblades or wear gloves, and use extra caution whenservicing them.

• Check for proper brake operation frequently.Adjust and service as required.

• Maintain or replace safety and instruction decalsas necessary.

• Use only genuine Exmark replacement parts toensure that original standards are maintained.

Exmark Riding Mower SafetyThe following list contains safety information specificto Exmark products or other safety information thatyou must know that is not included in the ANSIstandards.• Engine exhaust contains carbon monoxide, which

is an odorless, deadly poison that can kill you. DoNot run engine indoors or in an enclosed area.

• Stop the engine, wait for all moving parts to stop,engage parking brake, disconnect spark plugwire(s) and remove key before performing anyservice, repairs, maintenance or adjustments.

• Keep hands, feet, hair, and loose clothing awayfrom attachment discharge area, underside ofmower and any moving parts while engine isrunning.

• Do Not touch equipment or attachment partswhich may be hot from operation. Allow to coolbefore 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 whenworking with a battery.

• Battery gases can explode. Keep cigarettes, sparksand flames away from battery.

• Use only Exmark approved attachments.Warranty may be voided if used with unapprovedattachments.

• If loading the machine onto a trailer or truck, usea single, full-width ramp only. The ramp angleshould not exceed 15 degrees.

Note: The left and right sides of the machine aredetermined while sitting in the seat in the normaloperating position

7

Safety

Safety and Instructional Decals

Safety decals and instructions are easily visible to the operator and are located near any areaof potential danger. Replace any decal that is damaged or lost.

93-70091. Warning–Do Not operate

the mower with thedischarge deflector upor removed; keep thedischarge deflector inplace.

2. Cutting/dismembermenthazard of hand or foot,mower blade–stay awayfrom moving parts.

106-55171. Warning–Do Not touch the hot surface.

109-60081. Read the Operator’s

Manual.3. Push the machine.

2. Rotate the drive releaseknob to loosen, slide theknob, and tighten.

109-6014Traction Drive Belt Routing

109-60291. Engine–stop 6. Throttle–fast2. Engine–run 7. Choke–on3. Engine–start 8. Throttle–slow4. Power take-off (PTO),

Blade control switch9. Choke–off

5. Read the Operator’sManual.

8

Safety

109-6035Deck Drive Belt Routing

109-60361. Read the Operator’s Manual.2. Remove the ignition key and read the instructions before

servicing or performing maintenance.3. Height of cut.

109-62101. Read the Operator’s Manual.2. Cutting/dismemberment hazard, fan and entanglement

hazard, belt–stay away from moving parts.

109-64591. Entanglement hazard, belt—Do Not open or remove

safety shields while engine is running, keep shields inplace.

109-87591. Height of cut

109-91201. Fuse 2. Diode

9

Safety

109-91731. Parking brake 4. Neutral2. Fast 5. Reverse3. Slow 6. Machine Speed

109-91821. Machine speed 4. Neutral2. Fast 5. Reverse3. Slow

110-66911. Thrown objects

hazard–keep bystandersa safe distance from themachine.

3. Cutting/dismembermentof hand or foot–stayaway from moving parts.

2. Thrown objects hazard,mower–keep thedischarge deflectoror collection system inplace.

PTO Symbols1. PTO—Off 2. PTO—On

10

Safety

109-60161. Read the instructions before servicing or performing

maintenance.4. Refer to the Operator’s manual for grease instructions.

2. Time interval 5. Check hydraulic oil level and refer to the Operator’sManual for further instructions.

3. Check oil level. 6. Check tire pressure.

109-89651. Warning–read the Operator’s Manual. 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 only mow up anddown slopes less than 15 degrees.

2. Read the instructions before servicing or performingmaintenance; apply parking brake, remove the ignition keyand disconnect the spark plug wire.

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

3. Thrown object hazard—keep bystanders a safe distancefrom the machine, pick up debris before operating, keepthe discharge deflector in place.

7. Crushing/dismemberment hazard of bystanders,reversing–Do Not carry passengers, look behind anddown when reversing.

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

11

Safety

Battery SymbolsSome or all of these symbols are on your battery.

1. Explosion hazard 5. Read the Operator’s Manual. 9. Flush eyes immediately with waterand get medical help fast.

2. No fire, open flames, or smoking 6. Keep bystanders a safe distancefrom the battery.

10. Contains lead; do not discard.

3. Caustic liquid/chemical burn hazard 7. Wear eye protection; explosivegases can cause blindness andother injuries.

4. Wear eye protection 8. Battery acid can cause blindness orsevere burns.

12

Specifications

SpecificationsModel NumbersSerial Nos: 720,000 and Higher

QST22BE482; QST23KC482; QST23KC522; QST24BE522

SystemsEngine• Engine Specifications: See your Engine Owner’s

Manual• RPM:

Briggs & Stratton: Full Speed: 3650 ±100 (max)RPM (No Load) Idle: 1650 (min) RPM

Kohler Command: Full Speed: 3600 ±75 (max)RPM (No Load) Idle: 1750 (min) RPM

Fuel System• Capacity: 4.0 gal. (15.1 L)• Type of Fuel: Regular unleaded gasoline, 87

octane or higher.• Fuel Filter:

Briggs & Stratton: Briggs & Stratton P/N 695666

Kohler Command: Kohler P/N 24 050 10• Fuel Shut-Off Valve: 1/4 turn increments (“ON”,

“OFF”)

Electrical System• Charging System: Flywheel Alternator• Charging Capacity:

Briggs & Stratton: 16 amps

Kohler Command: 15 amps• Battery Type: BCI Group U1• Battery Voltage: 12 Volt• Polarity: Negative Ground• Fuses: One 25 amp, one 20 amp; one 15 amp

blade type• Diode: TVS

Safety Interlock System• PTO must be disengaged, brake engaged, and

motion control levers out (neutral lock) to start

engine. (It is not necessary for the operator to bein the seat to start the engine.)

• Operator must be in seat when PTO is engaged,brake is disengaged, or motion control levers aremoved in or engine will stop.

• Engine will stop if either the left, the right, orboth levers are moved from neutral lock positionwhile brake is engaged.

Operator Controls• Steering and Motion Control:

Note: Motion control levers are adjustable totwo heights.

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

– Steering is controlled by varying the positionof the levers relative to each other.

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

• PTO Engagement Switch: Engages electric clutch(to drive belt) which engages mower blades.

• Parking Brake Lever: Engages parking brake.

• Deck Height Adjustment Pin: Sets cutting heightto desired position.

• Deck Lift Assist Lever: Foot pedal that assistsin raising the deck.

Seat• Type: Standard seat with high back, foam padded

with spring suspension and armrests.

• Mounting: Hinged to tilt up for access tohydraulic pumps, battery and other components.Held in tilted position with lanyard. Adjustablefore and aft seat track.

13

Specifications

• Armrests: Standard–foam padded flip-upadjustable height armrests.

• Seat Safety Switch: Incorporated into the SafetyInterlock System.

Hydrostatic Ground Drive System• Hydrostatic Pumps: Two Hydro Gear ZT2800

Integrated drive systems.• Hydraulic Oil Type: Use Mobil 1 15W-50

Synthetic motor oil.• Speeds:

– 0-7.0 mph (11.3 km/hr) forward.– 0-5.0 mph (8.0 km/hr) reverse.

• Drive wheel releases, located on left and rightsides of engine deck, allow machine to be movedwhen the engine is not running and brake is off.

Tires & WheelsDrive Front

Caster

Pneumatic (Air-Filled) Pneumatic(Air-Filled)

Deck Size 48 52 All Decks

Quantity 2 2 2

Tread Turf Tec Turf Tec Smooth

Size 20 x 8.00-8 20 x 10.00-8 10 x 4

Ply Rating 4 4

Pressure 13 psi(90 kPa)

13 psi(90 kPa)

13 psi(90 kPa)

Cutting Deck• Cutting Width:

– 48 inch Deck: 48 inches (122 cm)– 52 inch Deck: 52 inches (132 cm)

• Discharge: Side• Blade Size: (3 ea.)

– 48 inch Deck: 16.25 inches (41.3 cm)– 52 inch Deck: 18.00 inches (45.7 cm)

• Blade Spindles: Solid steel spindles with nomaintenance bearings.

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

• Deck: Full floating deck is attached to out-frontsupport frame. Maximum turf protection isprovided with three anti-scalp rollers (both decksizes).

Deck design allows for bagging, mulching or sidedischarge.

• Deck Depth:

– 48 inch Deck: 5.0 inches (12.7 cm)

– 52 inch Deck: 5.0 inches (12.7 cm)

• Cutting Height Adjustment: A foot deck lift leveris used to adjust the cutting height from 1 1/2inch (3.8 cm) to 4 1/2 inches (11.4 cm) in 1/2inch (1.3 cm) increments.

• Mulching Kit: Optional.

Dimensions

Overall Width:48 inch Deck 52 inch Deck

Without Deck 45.5 inches(116 cm)

47.0 inches(119 cm)

Deflector Up 48.3 inches(122 cm)

53.0 inches(135 cm)

Deflector Down 59.4 inches(151 cm)

64.2 inches(163 cm)

Overall Length:48 inch Deck 52 inch Deck

73.4 inches (186 cm) 73.4 inches (186 cm)

Overall Height:48 inch Deck 52 inch Deck

41.8 inches (106 cm) 41.8 inches (106 cm)

14

Product Overview

Tread Width: (Center to Center ofTires, Widthwise)

48 inch Deck 52 inch Deck

Drive Wheels 36.0 inches(91 cm)

36.8 inches(93 cm)

Caster Wheels 33.5 inches(85 cm)

33.5 inches(85 cm)

Wheel Base: (Center of Caster Tire toCenter of Drive Tire)48 inch Deck 52 inch Deck

48.9 inches (124 cm) 48.9 inches (124 cm)

Curb Weight:48 inch Deck 52 inch Deck

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

Torque RequirementsBolt Location Torque

Spindle Pulley Nut 95-105 ft-lb (129-142 N-m)

Blade Mounting Bolt(lubricate with anti-seize)

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

Engine Mounting Bolts 27-33 ft-lb (37-45 N-m)

Anti-Scalp Roller NylocNut

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

Wheel Lug Nuts 70-90 ft-lb (95-122 N-m)

Clutch Mounting Bolt(secured with threadlocker)

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

Spark Plug 15 ft-lb (20 N-m)

Product Overview

Figure 31. Front caster wheel 8. Engine2. Anti-scalp roller 9. Seat3. Height of cut foot lever 10. Armrest4. Discharge deflector 11. Motion control levers5. Height of cut adjustment 12. Park brake6. Rear drive wheel 13. Footrest7. Control panel 14. Washout fitting

15

Operation

OperationControlsNote: Become familiar with all of the controls inFigure 3 and Figure 4 before you start the engine andoperate the machine.

Ignition SwitchLocated on control panel.

The ignition switch is used to start and stop theengine. The switch has three positions “OFF”,“RUN” and “START” ( Figure 4). Insert key intoswitch and rotate clockwise to the “ON” position.Rotate clockwise to the next position to engage thestarter (key must be held against spring pressure inthis position).

Figure 41. Ignition switch 4. Throttle2. Blade control switch

(power take-off)5. Choke

3. Hour meter

Note: Brake must be engaged, motion control leversout (neutral lock position) and PTO switch “OFF” tostart engine. (It is not necessary for the operator tobe in the seat to start the engine.)

Turning the key to the Off position will stop theengine; however, always remove the key when leavingthe machine to prevent someone from accidentallystarting the engine

Blade Control Switch (PowerTake-Off)Located on the control panel.

The blade control switch, represented by a powertake-off (PTO) symbol, engages and disengagespower to the mower blades.

Pull out on the blade control switch to “On” toengage the blades

Push the blade control switch to “Off ” to disengagethe blades

Choke ControlLocated on control panel.

The choke is used to aid in starting a cold engine. DoNot run a warm engine with the choke in the “ON”position. Moving the choke lever forward will put thechoke in the “ON” position and moving the chokelever to the rear will put the choke in the “OFF”position (Figure 4).

Throttle ControlLocated on control panel.

The throttle is used to control engine speed. Movingthrottle lever forward will increase engine speed andmoving throttle lever to the rear will decrease enginespeed. Moving the throttle forward into the detent isfull throttle (see Figure 4).

Motion Control LeversThe motion control levers located on each side ofthe seat (Figure 3).

The motion control levers are speed sensitive controlsof independent wheel motors. Moving a leverforward or backward turns the wheel on the same sideforward or in reverse; wheel speed is proportional tothe amount the lever is moved. Moving the controllevers outward from the center position locks themin the neutral position. Always position the motioncontrol levers into the neutral position and engagethe park brake lever when you stop the machine orleave it unattended. The unit must be tied down andbrake engaged when transporting.

16

Operation

Parking Brake LeverLocated on left side of the console (Figure 3).

The brake lever engages a parking brake on the drivewheels.

Pull the lever up and rearward to engage the brake.

Push the lever forward and down to disengage thebrake.

Height-of-Cut Foot LeverThe height of cut lever allows the operator to lowerand raise the deck from the seated position (Figure 3).When the lever is moved forward, away from theoperator the deck is raised from the ground andwhen moved back, towards the operator it is loweredtoward the ground. Only adjust the height of cutwhile machine is not moving.

Hour MeterLocated on the control panel.

The hour meter is connected to a pressure switchinstalled in the engine block and it records the numberof hours that the engine has run ( Figure 4). If theignition switch is left on without engine running,hour meter will not run.

Note: This switch is not a low oil sensor and will notalert the operator if the engine oil is low.

Operating Instructions

Think Safety FirstNote: Determine the left and right sides of themachine from the normal operating position.

Please carefully read all of the safety instructionsand decals in the safety section. Knowing thisinformation could help you, your family, pets orbystanders avoid injury.

DANGERMowing on wet grass or steep slopes cancause sliding and loss of control. Wheelsdropping over edges can cause rollovers,which may result in serious injury, deathor drowning. A loss of traction is a loss ofsteering control.

To avoid loss of control and possibility ofrollover:

• Do not mow near drop-offs or near water.

• Do not mow slopes greater than 15degrees.

• Reduce speed and use extreme cautionon slopes.

• When mowing slopes, gradually workfrom lower to higher areas on the incline.

• Avoid sudden turns or rapid speedchanges.

• Turn up, into an incline when changingdirections on slopes. Turning down theslope reduces traction.

• Attachments change the handlingcharacteristics of the machine. Use extracaution when using attachments with themachine.

Figure 51. Water 3. Safe Zone-use the Quest

here.2. Use walk behind mower

and/or hand trimmernear drop-offs andwater.

17

Operation

See inside back cover to determine the approximateslope angle to be mowed.

Recommended GasolineUse UNLEADED Regular Gasoline suitable forautomotive use (87 pump octane minimum).

Important: Never use methanol, gasolinecontaining methanol, or gasohol containingmore than 10% ethanol because the fuel systemcould be damaged. Do Not mix oil with gasoline.

DANGERIn certain conditions gasoline is extremelyflammable and vapors are explosive.

A fire or explosion from gasoline can burnyou, others, and cause property damage.

• Fill the fuel tank outdoors in an openarea, when the engine is cold. Wipe upany gasoline that spills.

• Never refill the fuel tank or drain themachine indoors or inside an enclosedtrailer.

• Do Not fill the fuel tank completely full.Add gasoline to the fuel tank until thebody of the tank is full but fuel does notfill the neck of the tank. This empty spacein the tank allows gasoline to expand.

• Never smoke when handling gasoline,and stay away from an open flame orwhere gasoline fumes may be ignited byspark.

• Store gasoline in an approved containerand keep it out of the reach of children.Never buy more than a 30-day supply ofgasoline.

• Do Not operate without entire exhaustsystem in place and in proper workingcondition.

DANGERIn certain conditions during fueling, staticelectricity can be released causing a sparkwhich can ignite gasoline vapors. A fire orexplosion from gasoline can burn you andothers and cause property damage.

• Always place gasoline containers on theground away from your vehicle beforefilling.

• Do Not fill gasoline containers inside avehicle or on a truck or trailer bed becauseinterior carpets or plastic truck bed linersmay insulate the container and slow theloss of any static charge.

• When practical, remove gas-poweredequipment from the truck or trailer andrefuel the equipment with its wheels onthe ground.

• If this is not possible, then refuel suchequipment on a truck or trailer from aportable container, rather than from agasoline dispenser nozzle.

• If a gasoline dispenser nozzle must beused, keep the nozzle in contact with therim of the fuel tank or container openingat all times until fueling is complete.

WARNINGGasoline is harmful or fatal if swallowed.Long-term exposure to vapors has causedcancer in laboratory animals. Failure to usecaution may cause serious injury or illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gastank/container opening.

• Keep away from eyes and skin.

• Never siphon by mouth.

18

Operation

Using Stabilizer/ConditionerUse a fuel stabilizer/conditioner in the machine toprovide the following benefits:

• Keeps gasoline fresh during storage of 30 days orless. For longer storage it is recommended thatthe fuel tank be drained.

• Cleans the engine while it runs.

• Eliminates gum-like varnish buildup in the fuelsystem, which causes hard starting Add thecorrect amount of gas stabilizer/conditioner tothe gas.

Note: A fuel stabilizer/conditioner is most effectivewhen mixed with fresh gasoline. To minimize thechance of varnish deposits in the fuel system, use fuelstabilizer at all times.

Gasoline/Alcohol blendsGasohol (up to 10 percent ethyl alcohol, 90 percentunleaded gasoline by volume) is approved for fuel useby the engine manufacturer. Other gasoline/alcoholblends are not approved.

Filling the Fuel Tank1. 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 thecap.

3. Add unleaded regular gasoline until the body ofthe tank is full but fuel does not fill the neck ofthe tank (Figure 6). This space in the neck of thetank allows gasoline to expand. Do not fill thefuel tank completely full.

Figure 61. Gas tank opening 3. Gas tank body2. Fill to here,

approximately

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

Checking the Engine OilLevelBefore you start the engine and use the machine,check the oil level in the engine crankcase; refer toChecking the Oil Level in Engine Maintenance.

Starting the Engine1. Sit down on the seat and move the motion

controls outward to the neutral position andengage the parking brake.

2. Disengage the blades by moving the blade controlswitch to Off (Figure 7).

19

Operation

Figure 71. Control panel 2. Blade control

switch—Off position

3. Move the throttle lever to midway and the chokelever forward before starting a cold engine(Figure 8).

Note: A warm or hot engine may not requirechoking.

Figure 81. Control panel 4. Throttle—slow2. Choke—on 5. Throttle—fast3. Choke–off

4. Turn the ignition key to Start to energize thestarter. When the engine starts, release the key(Figure 9).

Important: Do not engage the starter formore than 5 seconds at a time. If the enginefails to start, allow a 60 second cool-downperiod between attempts. Failure to followthese instructions can burn out the startermotor.

Figure 91. Ignition key—start

position4. Start

2. Control panel 5. Run3. Choke 6. Off

5. If the engine stalls or hesitates, move thechoke lever partially forward for a few seconds(Figure 9).

Operating the BladesThe blade control switch, represented by a powertake-off (PTO) symbol, engages and disengagespower to the mower blades. This switch controlspower to any attachments that draw power from theengine, including the mower deck and cutting blades.

Engaging the Blades1. Release pressure on the motion control levers and

place the machine in neutral.

2. Move the throttle midway to the Fast position.

Note: Always engage the blades with the throttlein the midway position.

3. Pull out on the blade control switch to On toengage the blades (Figure 10).

20

Operation

Figure 101. Control panel 2. Blade control

switch—On position

4. Move throttle to full forward position beforemowing.

Disengaging the BladesSet throttle to midway position. Push the bladecontrol switch to Off to disengage the blades(Figure 11).

Figure 111. Control panel 2. Blade control

switch—Off position

Stopping the Engine1. Move the throttle lever to between Fast and half

throttle (Figure 9).2. Disengage the blades by moving the blade control

switch to Off (Figure 11).3. Turn the ignition key to Off (Figure 9).4. Pull the wire off of the spark plug(s) to prevent

the possibility of someone accidentally startingthe machine before transporting or storing themachine.

The Safety Interlock System

CAUTIONIf safety interlock switches are disconnectedor damaged the machine could operateunexpectedly causing personal injury.

• Do Not tamper with the interlockswitches.

• Check the operation of the interlockswitches daily and replace any damagedswitches before operating the machine.

Understanding the Safety InterlockSystemThe safety interlock system is designed to prevent theengine from starting unless:• The blades are disengaged.• The motion control levers are in the neutral

position.• The parking brake is engaged.

The safety interlock system is designed to initiateengine shutdown when:• The parking brake is disengaged and the operator

gets off machine.• The PTO is engaged and the operator gets off

machine.• The parking brake is disengaged and levers are in

and the operator gets off machine.• The parking brake is engaged and motion control

levers are in.

Testing the Safety Interlock SystemTest the safety interlock system before you use themachine each time1. Check starting circuit. Starter should crank with

parking brake engaged, PTO disengaged andmotion control levers moved out in the neutrallock position. The operator does not need to bein the seat to start the engine.

Try to start with operator in seat, parking brakedisengaged, PTO disengaged and motion controllevers in the neutral lock position - starter mustnot crank.

21

Operation

Try to start with operator in seat, parking brakeengaged, PTO engaged and motion controllevers in the neutral lock position - starter mustnot crank.

Try to start with operator in seat, parking brakeengaged, PTO disengaged, and the left motioncontrol lever in, starter must not crank, repeatagain with the right lever in, then with bothlevers in - starter must not crank.

2. Check kill circuits. Run engine at one-thirdthrottle, disengage parking brake and raise offof seat (but do not get off of machine) enginemust initiate shutdown.

Run engine at one-third throttle, engage PTOand raise off of seat (but do not get off ofmachine) engine must initiate shutdown.

Run engine at one-third throttle, with brakedisengaged, move levers in and raise off seat (butdo not get off of machine) engine must initiateshutdown.

Again, run engine at one-third throttle, brakeengaged, and move left motion control lever in- engine must initiate shutdown.

Repeat again moving the right lever in, thenmoving both levers in - engine must initiateshutdown whether operator is on seat or not.

Note: If machine does not pass any of these tests,do not operate. Contact your authorized EXMARKSERVICE DEALER.

Important: It is essential that operator safetymechanisms be connected and in properoperating condition prior to use for mowing.

Driving Forward or BackwardThe throttle control regulates the engine speed asmeasured in rpm (revolutions per minute). Placethe throttle control in the Fast position for bestperformance. Always operate in the Fast (full throttle)position.

CAUTIONMachine can spin very rapidly by positioningone lever too much ahead of the other.Operator may lose control of the machine,which may cause damage to the machineor injury.

• Use caution when making turns.

• Slow the machine down before makingsharp turns.

Forward1. Move the levers to the center, unlocked position.2. To go forward, slowly push the motion control

levers forward (Figure 12).

Figure 121. Neutral position 3. Backward2. Center unlock position 4. Forward

To go straight, apply equal pressure to bothmotion control levers (Figure 12).To turn, pull back on the motion control levertoward the direction you want to turn (Figure 12).The farther you move the motion control leversin either direction, the faster the machine willmove in that direction.To stop, pull the motion control levers to neutral.

22

Operation

Backward1. Move the levers to the center, unlocked position.2. To go backward, slowly pull the motion control

levers rearward (Figure 12).To go straight, apply equal pressure to bothmotion control levers (Figure 12).To turn, release the pressure on the motioncontrol lever toward the direction you want toturn (Figure 12).To stop, push the motion control levers to neutral.

Stopping the MachineTo stop the machine, move the motion controllevers to neutral and outward to the neutral position,disengage the blade control switch, move the throttlelever to between Fast and half throttle, and turn theignition key to off. Remember to remove the keyfrom the ignition switch.

Tracking AdjustmentIf the machine turns right or left when handles arepushed forward together, adjust the stop on the sideopposite the direction of turn (see Figure 13). Loosenthe 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. Readjusthandles if necessary.

Figure 131. Control arm shaft 3. Adjust stop2. Limiter stop screws

CAUTIONChildren or bystanders may be injured if theymove or attempt to operate the mower whileit is unattended.

Always remove the ignition key and move themotion control levers outward to the neutralposition and apply the parking brake whenleaving the machine unattended, even if justfor a few minutes.

Adjusting the Height of Cut1. Raise the deck to the transport position (4.5 inch

(114 mm) cut height) by pushing the foot actuatedlever forward (Figure 14). The spring loadedtransport pin will automatically engage and willclick into place.

Figure 141. Push forward 4. Height adjuster pin2. Foot actuated

height-of-cut lever5. Transport release handle

3. Height-of-cut positions

2. Move the deck height adjuster pin to the desiredcut height.

3. Push the foot lever forward, pull the transportrelease handle up and let the deck lower down to

23

Operation

the predetermined cut height by slowly decreasingfoot pressure allowing the foot lever to travelrearward.

Adjusting the Anti-ScalpRollersIt is recommended to change the anti-scalp rollerposition when the height of cut has changed.

1. Stop the machine and move the drive levers tothe neutral lock position.

2. Disengage the PTO.

3. Engage the park brake.

4. Stop the engine, remove the key and wait for allmoving parts to stop.

5. After adjusting the height of cut, adjust theanti-scalp rollers by removing the nyloc nut.

6. Adjust the anti-scalp rollers for the normaloperating conditions. Place rollers in one ofthe positions shown in Figure 15. Rollers willmaintain 3/4 inches (19 mm) clearance to theground to minimize gouging and roller wear ordamage.

Note: For Maximum Deck Flotation, placethe rollers one hole position lower. Rollers shouldmaintain 1/4 inch (6.35 mm) clearance to theground. Do Not adjust rollers to support thedeck.

Figure 15For cutting heights above 3 1/2 inches (38 mm) use thebottom hole. The rollers will still be effective against

scalping.

1. Anti-scalp rollermounting bracket

2. Cutting height

7. Torque hardware to 27-33 ft-lb (37-45 N-m) orloss of roller may result.

Positioning the SeatThe seat can move forward and backward. Positionthe seat where you have the best control of themachine and are most comfortable.

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

Figure 161. Adjustment lever

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

Changing the Seat RideSuspensionThe number of seat springs can be changed tomaximize rider comfort. More springs should be usedwith heavier operators and on rough terrain. Fewersprings should be used with lighter operators andwhen mowing smooth, well established lawns. Alwayskeep the number of springs on the left and right sidethe same when adding and removing springs.

24

Operation

Figure 171. Bolt 3. Nut2. Spring 4. Additional mounting

holes

Up to five springs can be secured to the seat box witha nut and bolt, see Figure 17.

Refer to your Parts Manual for spring and hardwarepart numbers.

Adjusting the Motion ControlLeversAdjusting the HeightThe motion control levers can be adjusted higher orlower for maximum operator comfort.1. Remove the two bolts holding the control lever to

the control arm shaft (Figure 18).

Figure 181. Control arm shaft 4. Bolt2. Control lever 5. Slotted holes3. Washer

2. Move the control lever to the next set of holes.Secure the lever with the two bolts.

3. Repeat the adjustment for the opposite controllever.

Adjusting the TiltThe motion control levers can be tilted fore or aft formaximum operator comfort.

1. Loosen the upper bolt holding the control leverto the control arm shaft.

2. Loosen the lower bolt just enough to pivot thecontrol lever fore or aft (Figure 18). Tighten bothbolts to secure the control in the new position.

3. Repeat the adjustment for the opposite controllever.

Pushing the Machine byHandImportant: Always push the machine by hand.Never tow the machine because damage mayoccur.

To Push the Machine1. Park the machine on a level surface and disengage

the blade control switch.

2. Move the motion control levers outward toneutral position, engage parking brake, stop theengine, remove the key, and wait for all movingparts to stop before leaving the operating position.

3. Locate the bypass release knobs on either side ofthe engine deck (Figure 19).

25

Operation

Figure 191. Front of the machine. 5. Lever position for

pushing the machine2. Rotate bypass release

knob counterclockwise6. Rotate bypass release

knob clockwise3. Lever position for

operating the machine.7. Release lever

4. Pull lever in this direction

4. Loosen the knob by turning counterclockwise.Then pull the release lever on the underside ofmachine (Figure 19) towards the back of themachine and retighten the knob to hold therelease lever back in the released state. Repeat thison each side of the machine.

5. Release the parking brake. The machine is nowable to be pushed by hand.

To Operate the MachineLoosen the bypass knob, push the release leversforward, and retighten the knob to engage the drivesystem (Figure 19).

Side DischargeThe mower has a hinged discharge deflector thatdisperses clippings to the side and down toward theturf.

DANGERWithout the discharge deflector, mulch kit,or entire grass collection system mounted inplace, you and others are exposed to bladecontact and thrown debris. Contact withrotating mower blade(s) and thrown debriswill cause injury or death.

• Never remove the discharge deflectorfrom the mower because the dischargedeflector routes material down towardthe turf. If the discharge deflector is everdamaged, replace it immediately.

• Never put your hands or feet under themower.

• Never try to clear discharge area ormower blades unless you move the movethe blade control switch to Off and rotatethe ignition key to Off. Also remove thekey and pull the wire off the spark plug(s).

Transporting

Transporting a UnitUse a heavy-duty trailer or truck to transport themachine. Lock brake and block wheels. Securelyfasten the machine to the trailer or truck with straps,chains, cable, or ropes. Be sure that the trailer or truckhas all necessary lighting and marking as required bylaw. Secure a trailer with a safety chain.

CAUTIONThis unit does not have proper turnsignals, lights, reflective markings, or aslow moving vehicle emblem. Driving on astreet or roadway without such equipmentis dangerous and can lead to accidentscausing personal injury. Driving on a streetor roadway without such equipment may alsobe a violation of State laws and the operatormay be subject to traffic tickets and/or fines.

Do Not drive a unit on a public street orroadway.

26

Operation

WARNINGLoading a unit on a trailer or truck increasesthe possibility of backward tip-over.Backward tip-over could cause serious injuryor death.

• Use extreme caution when operating aunit on a ramp.

• Use only a single, full width ramp; DoNot use individual ramps for each sideof the unit.

• If individual ramps must be used, useenough ramps to create an unbrokenramp surface wider than the unit.

• Do Not exceed a 15° angle between rampand ground or between ramp and traileror truck.

• Avoid sudden acceleration while drivingunit up a ramp to avoid tipping backward.

• Avoid sudden deceleration while backingunit down a ramp to avoid tippingbackward.

Loading a UnitUse extreme caution when loading units on trailers ortrucks. One full width ramp that is wide enough toextend beyond the rear tires is recommended insteadof individual ramps for each side of the unit. Thelower rear section of the tractor frame extends backbetween the rear wheels and serves as a stop fortipping backward. Having a full width ramp providesa surface for the frame members to contact if theunit starts to tip backward. If it is not possible to useone full width ramp, use enough individual ramps tosimulate a full width continuous ramp.

Ramp should be long enough so that the anglesbetween the ramp and the ground and the ramp andthe trailer or truck do not exceed 15°. A steeper anglemay cause mower deck components to get caught asthe unit moves from ramp to trailer or truck. Steeperangles may also cause the unit to tip backward. Ifloading on or near a slope, position the trailer ortruck so it is on the down side of the slope and theramp extends up the slope. This will minimize theramp angle. The trailer or truck should be as levelas possible.

Important: Do Not attempt to turn the unitwhile on the ramp, you may lose control anddrive off the side.

Avoid sudden acceleration when driving up a rampand sudden deceleration when backing down a ramp.Both maneuvers can cause the unit to tip backward.

Operating TipsFast Throttle SettingFor best mowing and maximum air circulation,operate the engine at the Fast position. Air is requiredto thoroughly cut grass clippings, so do not set theheight-of-cut so low as to totally surround the mowerby uncut grass. Always try to have one side of themower free from uncut grass, which allows air to bedrawn into the mower.

Cutting a Lawn for the First TimeCut grass slightly longer than normal to ensure thatthe cutting height of the mower does not scalp anyuneven ground. However, the cutting height used inthe past is generally the best one to use. When cuttinggrass longer than six inches tall, you may want to cutthe lawn twice to ensure an acceptable quality of cut.

Cut 1/3 of the Grass BladeIt is best to cut only about 1/3 of the grass blade.Cutting more than that is not recommended unlessgrass is sparse, or it is late fall when grass grows moreslowly.

Mowing DirectionAlternate mowing direction to keep the grass standingstraight. This also helps disperse clippings whichenhances decomposition and fertilization.

Mow at Correct IntervalsNormally, mow every four days. But remember,grass grows at different rates at different times. So tomaintain the same cutting height, which is a goodpractice, mow more often in early spring. As thegrass growth rate slows in mid summer, mow lessfrequently. If you cannot mow for an extendedperiod, first mow at a high cutting height; then mowagain two days later at a lower height setting.

27

Operation

Cutting SpeedTo improve cut quality, use a slower ground speed.

Avoid Cutting Too LowIf the cutting width of the mower is wider than themower you previously used, raise the cutting heightto ensure that uneven turf is not cut too short.

Long GrassIf the grass is ever allowed to grow slightly longerthan normal, or if it contains a high degree ofmoisture, raise the cutting height higher than usualand cut the grass at this setting. Then cut the grassagain using the lower, normal setting.

When StoppingIf the machine’s forward motion must be stoppedwhile mowing, a clump of grass clippings may droponto your lawn. To avoid this, move onto a previouslycut area with the blades engaged.

Keep the Underside of the MowerCleanClean clippings and dirt from the underside of themower after each use. If grass and dirt build up insidethe mower, cutting quality will eventually becomeunsatisfactory.

Blade MaintenanceMaintain a sharp blade throughout the cutting seasonbecause a sharp blade cuts cleanly without tearing orshredding the grass blades. Tearing and shreddingturns grass brown at the edges, which slows growthand increases the chance of disease. Check thecutter blades daily for sharpness, and for any wear ordamage. File down any nicks and sharpen the bladesas necessary. If a blade is damaged or worn, replaceit immediately with a genuine Exmark replacementblade. Only Exmark blades are to be used with thisunit. No other blades are approved.

28

Maintenance

MaintenanceNote: Determine the left and right sides of the machine from the normal operating position.

WARNINGWhile maintenance or adjustments are being made, someone could start the engine. Accidentalstarting of the engine could seriously injure you or other bystanders.

Remove the key from the ignition switch, engage parking brake, and pull the wire(s) off the sparkplug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentallycontact the spark plug(s).

WARNINGThe engine can become very hot. Touching a hot engine can cause severe burns.

Allow the engine to cool completely before service or making repairs around the engine area.

Recommended Maintenance Schedule(s)Maintenance Service

Interval Maintenance Procedure

After the first 5 hours • Change the engine oil.

After the first 200 hours • Change the hydraulic system filter.

Before each use or daily

• Check the safety interlock system.• Check the air cleaner for dirty, loose, or damage.• Check the air intake and cooling areas, clean as necessary.• Check the oil level before starting or after every 8 hours.• Check the hydraulic oil level in the expansion tank.• Check the mower blades.• Clean the mower housing.

Every 25 hours

• Grease all lubrication points.• Service the air cleaner. (May need more often under extremely dusty or dirty conditions.)• Check the tire pressure.• Check the belts.

Every 100 hours

• Replace the paper element. (More often under extremely dusty, dirty conditions.)• Replace the air cleaner element.• Change the engine oil and filter.• Clean the blower housing. More often under dirty conditions.• Replace the fuel filter.

Every 200 hours • Service the spark plug.

Every 500 hours • Replace the spark plug.

Before storage• Charge the battery and disconnect the battery cables.• Perform all maintenance procedures before storage.• Paint any chipped surfaces.

Monthly • Check the battery charge.

29

Maintenance

Important: Refer to your Engine Operator’s Manual for additional maintenance procedures.

PremaintenanceProceduresRaising the SeatMake sure the motion control levers are locked inthe neutral position. Lift the seat forward until thelanyard is tight. The following components can beaccessed by raising the seat:

• Auxiliary 12V Plug (12V accessory up to 15 amp)

• Fuses

• Battery cables

Accessing the BatteryThe battery is located under the seat. To access, raisethe seat (Figure 20).

Figure 201. Auxiliary 12V Plug 3. Seat2. Battery

Periodic MaintenanceLubrication

Greasing the BearingsGrease Type: NGLI grade #2 multi-purpose gungrease.

Grease the front caster pivots and wheels (Figure 21).

1

G007184

Figure 211. Front caster tire

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

2. Move the motion control levers outward to theneutral position, engage parking brake, stop theengine, remove the key, and wait for all movingparts to stop before leaving the operating position.

3. Clean the grease fittings (Figure 21 and Figure 22)with a rag. Make sure to scrape any paint off ofthe front of the fitting(s).

30

Maintenance

Figure 22Located on the back of the seat.

1. Read the instructionsbefore servicing orperforming maintenance

4. Check oil level.

2. Grease idler pivots. 5. Check hydraulic oil leveland refer to Operator’smanual for furtherinstructions.

3. Time interval. 6. Check tire pressure.

4. Connect a grease gun to each fitting (Figure 21and Figure 22). Pump grease into the fittings untilgrease begins to ooze out of the bearings.

5. Wipe up any excess grease.

Engine Maintenance

Servicing the Air CleanerService Interval: Before each use or daily

Every 100 hours—Replacethe paper element. (Moreoften under extremelydusty, dirty conditions.)

This engine is equipped with a replaceable, highdensity paper air cleaner element. Check the air

cleaner daily or before starting the engine. Check fora buildup of dirt and debris around the air cleanersystem. Keep this area clean. Also check for loose ordamaged components. Replace all bent or damagedair cleaner components.

Note: Operating the engine with loose or damagedair cleaner components could allow unfiltered air intothe engine causing premature wear and failure.

Note: Service the air cleaner more often underextremely dusty, dirty conditions.

Figure 23Briggs & Stratton engine

1. Air cleaner 3. Air cleaner cover2. Knobs

Figure 24Kohler Command engine

1. Air cleaner cover 3. Air cleaner2. Knob

31

Maintenance

Servicing Paper ElementService Interval: Every 25 hours (May

need more often underextremely dusty or dirtyconditions.)Every 100 hours/Yearly(whichever comesfirst)—Replace the aircleaner element.

1. Remove the air cleaner cover (Figure 23).

2. Remove the air cleaner element with the integralrubber seal.

3. Gently tap the pleated side of the paper elementto dislodge dirt. Do Not wash the paper elementor use pressurized air, as this will damage theelement. Replace a dirty, bent, or damagedelement. Handle new elements carefully; Do Notuse if the rubber seal or foam sleeve is damaged.

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

5. Install the air cleaner element with the pleatedside “out” and seat the rubber seal onto the edgesof the air cleaner base.

6. Reinstall the air cleaner cover and secure withthe knobs.

Servicing the Engine Oil

Checking the Oil LevelService Interval: Before each use or daily1. Park the machine on a level surface, disengage

the blade control switch, stop the engine, engageparking brake, and remove the key.

2. Make sure the engine is stopped, level, and is coolso the oil has had time to drain into the sump.

3. To keep dirt, grass clippings, etc., out ofthe engine, clean the area around the oil fillcap/dipstick before removing it.

4. Pull and remove the oil fill cap/dipstick; wipe oiloff. Reinsert the dipstick and push firmly intoplace (Figure 25).

Figure 251. Oil dipstick 3. Oil level2. Filler tube

5. Remove the dipstick and check the oil level.

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 tothe “F” mark on the dipstick. Always check thelevel with the dipstick before adding more oil.

Note: To prevent extensive engine wear ordamage, always maintain the proper oil level inthe crankcase. Never operate the engine with theoil level below the “L” mark or over the “F” markon the dipstick.

Changing the Oil and FilterService Interval: After the first 5 hours

Every 100 hours/Yearly(whichever comes first)thereafter.

Change the oil and filter while the engine is stillwarm. The oil will flow more freely and carry awaymore impurities. Make sure the engine is level whenfilling, checking, or changing the oil.

1. Start the engine and let it run until warm. Thiswarms the oil so it drains better.

2. Disengage the blade control switch and move themotion controls outward to the neutral positionand engage parking brake.

32

Maintenance

3. Stop the engine, remove the key, and wait for allmoving parts to stop before leaving the operatingposition.

4. Clean the area around the drain plug and on themachine frame. Place a pan underneath machinedirectly below the drain hole in the frame asshown in Figure 26 and Figure 27.

Figure 26Briggs & Stratton engine

1. Oil drain 3. Pan2. Oil drain plug

Figure 27Kohler Command engine

1. Oil drain hose 3. Pan2. Oil drain plug

5. Remove the oil drain plug (Figure 26 andFigure 27). Remove the oil fill cap/dipstick(Figure 25).

Figure 281. Oil filter 2. Gasket

6. Be sure to allow ample time for completedrainage.

7. Remove the old filter and wipe off the mountingpad (Figure 28).

8. When the oil has drained completely, install theoil drain plug. Tighten the plug to 14 N-m (125in-lb) torque. Wipe up any excess oil on the frame(Figure 26 and Figure 27).

Note: Dispose of the used oil at a recyclingcenter.

9. Apply a thin film of clean oil to the rubber gasketon the new filter.

10. Install the replacement oil filter to the mountingpad. Turn the oil filter clockwise until the rubbergasket contacts the pad, then tighten the filter anadditional 1/2 to 3/4 turn (Figure 28).

11. Slowly pour approximately 80% of the specifiedoil into the filler tube—use oil recommended inthe Engine Owner’s Manual.

12. Install the oil fill cap/dipstick and push firmlyinto place.

13. Check the oil level (Figure 25); refer to Checkingthe Oil Level.

14. Slowly add additional oil to bring it to the fullmark. Do Not overfill.

15. Install the oil fill cap/dipstick and push firmlyinto place.

16. Start the engine and check for leaks.

33

Maintenance

Checking the Hydraulic OilLevelService Interval: Before each use or daily

Check expansion tank and if necessary add MOBIL 115W-50 synthetic motor oil to the FULL COLD line

Figure 291. Engine 2. Expansion tank

Change the HydraulicSystem FilterService Interval: After the first 200 hours

Note: Use only MOBIL 1 15W-50 Synthetic motoroil.

1. Stop engine, wait for all moving parts to stop, andallow engine to cool. Remove key and engageparking brake.

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

3. Carefully clean area around filters. It is importantthat no dirt or contamination enter hydraulicsystem.

4. Unscrew filters to remove and allow oil to drainfrom drive system.

Important: Before reinstalling new filters,apply a thin coat of oil on the surface of thefilters rubber seal.

Turn the filters clockwise until rubber sealcontacts the filter adapter then tighten the filteran additional 3/4 to 1 full turn.

5. Remove the vent plug on each transmission andfill through expansion reservoir, when oil comesout of vent reinstall plug. Torque plugs to 180in-lb (244 N-m). Continue to add oil until itreaches the FULL COLD line on the expansionreservoir.

Figure 301. Oil filter 3. Left rear tire2. Vent plug

6. Raise the rear of machine up and support withjack stands (or equivalent support) just highenough to allow drive wheels to turn freely.

7. Start engine and move throttle control ahead to1/2 throttle position. Disengage parking brake.

A. With the bypass valve open and the enginerunning, slowly move the directional controlin both forward and reverse (5 or 6 times).

B. With the bypass valve closed and the enginerunning, slowly move the directional controlin both forward and reverse directions (5 to6 times). Check the oil level, and add oil asrequired after stopping the engine.

C. It may be necessary to repeat steps A andB until all the air is completely purged fromthe system. When the transaxle operates atnormal noise levels and moves smoothlyforward and reverse at normal speeds, thenthe transaxle is considered purged.

Do Not change hydraulic system oil (except for whatcan be drained when changing filter), unless it is feltthe oil has been contaminated or been extremely hot.

Changing oil unnecessarily could damage hydraulicsystem by introducing contaminates into the system.

34

Maintenance

Servicing the Spark PlugService Interval: Every 200 hours/Every 2

years (whichever comesfirst)Every 500 hours—Replacethe spark plug.

As stated in the maintenance intervals, remove thespark plug, check condition, and reset the gap orreplace with a new plug as necessary.

The spark plug is RFI compliant. Equivalent alternatebrand plugs can also be used.

Type: Champion XC92YC (for Briggs & Stratton)

Champion RC12YC or QC12C may be used if yourarea does not require compliance with CanadianICES-002, ISO 14982, or EN 55012.

Type: Champion RC12YC (for Kohler Command)

Air Gap: 0.030 inch (0.76 mm)

Removing the Spark Plug1. 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 31).Clean around the spark plug to prevent dirt fromfalling into the engine and potentially causingdamage.

Note: Due to the deep recess around the sparkplug, blowing out the cavity with compressed airis usually the most effective method for cleaning.The spark plug is most accessible when theblower housing is removed for cleaning.

3. Remove the spark plug and metal washer.

Figure 311. Spark plug and wire location

Checking the Spark Plug1. Look at the center of the spark plug (Figure 32).

If you see light brown or gray on the insulator, theengine is operating properly. A black coating onthe insulator usually means the air cleaner is dirty.

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

2. Check the gap between the center and sideelectrodes (Figure 32). Bend the side electrode ifthe gap is not correct.

Figure 321. Side electrode 3. Air gap (not to scale)2. Center electrode

insulator

Installing the Spark Plug1. Install the spark plug. Make sure that the air gap

is set correctly.

2. Tighten the spark plug to 15 ft-lb (20 N-m).

3. Push the wire onto the spark plug (Figure 31).

Cleaning the Blower HousingService Interval: Every 100 hours/Yearly

(whichever comes first)More often under dirtyconditions.

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

1. Remove the blower housing and any other coolingshrouds.

2. Clean the cooling fins and external surfaces asnecessary.

3. Make sure the cooling shrouds are reinstalled

35

Maintenance

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

Fuel System Maintenance

Replacing the Fuel FilterService Interval: Every 100 hours/Yearly

(whichever comes first)

DANGERIn certain conditions, gasoline is extremelyflammable and highly explosive. A fire orexplosion from gasoline can burn you andothers and can damage property.

• Perform any fuel related maintenancewhen the engine is cold. Do this outdoorsin an open area. Wipe up any gasolinethat spills.

• Never smoke when draining gasoline, andstay away from an open flame or where aspark may ignite the gasoline fumes.

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

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

2. Move the motion control levers outward to theneutral position, engage parking brake, stop theengine, remove the key, and wait for all movingparts to stop before leaving the operating position.

3. The fuel filter is in the fuel line between the tankand engine.

Figure 331. Fuel tank 6. Hose clamps2. Fuel shut off valve—off 7. Fuel line to engine3. Fuel shut off valve 8. Filter4. Fuel shut off valve—on 9. Flow direction arrow5. Fuel line from tank

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

5. Squeeze the ends of the hose clamps together andslide them away from the filter (Figure 33).

6. Remove the filter from the fuel lines.

7. Install a new filter with the flow direction arrowcoming from the fuel tank and pointing to theengine. Move the hose clamps close to the filter(Figure 33) to secure it in place.

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

Electrical SystemMaintenance

WARNINGCALIFORNIA

Proposition 65 Warning

Battery posts, terminals, and relatedaccessories contain lead and lead

compounds, chemicals known to the State ofCalifornia to cause cancer and reproductive

harm. Wash hands after handling.

36

Maintenance

Charging the Battery

Removing the Battery

WARNINGBattery terminals or metal tools could shortagainst metal machine components causingsparks. Sparks can cause the battery gassesto explode, resulting in personal injury.

• When removing or installing the battery,Do Not allow the battery terminals totouch any metal parts of the machine.

• Do Not allowmetal tools to short betweenthe battery terminals and metal parts ofthe machine.

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

2. Move the motion control levers outward to theneutral position, engage parking brake stop theengine, remove the key, and wait for all movingparts to stop before leaving the operating position.

3. Raise the seat.

4. Disconnect the negative (black) ground cablefrom the battery post (Figure 34). Retain allfasteners.

Figure 341. Battery hold-down 5. Terminal boot2. Wingnut 6. Positive battery post3. Negative battery post 7. Battery4. Bolt, washer, and nut

WARNINGIncorrect battery cable routing could damagethe machine and cables causing sparks.Sparks can cause the battery gasses toexplode, resulting in personal injury.

• Always disconnect the negative (black)battery cable before disconnecting thepositive (red) cable.

• Always connect the positive (red) batterycable before connecting the negative(black) cable.

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

6. Remove the battery hold-down (Figure 34) andlift the battery from the battery tray.

Charging the Battery1. Remove the battery from the chassis; refer to

Removing the Battery.

2. Allowing batteries to stand for an extended periodwithout recharging them will result in reducedperformance and service life. To preserveoptimum battery performance and life, rechargebatteries in storage when the open circuit voltagedrops to 12.4 volts.

Note: To prevent damage due to freezing,battery should be fully charged before puttingaway for winter storage.

3. Check the voltage of the battery with a digitalvoltmeter. Locate the voltage reading of thebattery in the table below and charge the batteryfor the recommended time interval to bring thecharge up to a full charge of 12.6 volts or greater.

Important: Make sure the negative batterycables are disconnected and the batterycharger used for charging the battery has anoutput of 16 volts and 7 amps or less to avoiddamaging the battery (see chart below forrecommended charger settings).

37

Maintenance

VoltageReading

PercentCharge

MaximumChargerSettings

ChargingInterval

12.6 orgreater

100% 16 volts/7amps

NoChargingRequired

12.4 – 12.6 75–100% 16 volts/7amps

30 Minutes

12.2 – 12.4 50–75% 16 volts/7amps

1 Hour

12.0–12.2 25–50% 14.4 volts/4amps

2 Hours

11.7–12.0 0–25% 14.4 volts/4amps

3 Hours

11.7 or less 0% 14.4 volts/2amps

6 Hours orMore

4. When the battery is fully charged, unplugthe charger from the electrical outlet, thendisconnect the charger leads from the batteryposts (Figure 35).

Figure 351. Negative battery post 3. Red (+) charger lead2. Black (-) charger lead 4. Positive battery post

Note: Do Not run the machine with the batterydisconnected, electrical damage may occur.

Installing the Battery1. Position the battery in the tray with the terminal

posts toward the operating position (Figure 34).

2. Install the positive (red) battery cable to thepositive (+) battery terminal using the fastenersremoved previously

3. Install the negative battery cable to the negative(-) battery terminal using the fasteners removedpreviously.

4. Slide the red terminal boot onto the positive (red)battery post.

5. Secure the battery with the hold-down (Figure 34).

Servicing the Fuses andRelayThe electrical system is protected by fuses. It requiresno maintenance; however, if a fuse blows, checkthe component/circuit for a malfunction or short.There is also a replaceable relay/s next to the fuse.Refer to your Parts manual for correct replacementcomponents.

Fuse Block:• Main fuse: 25 amp fuse, blade-type• Charge Circuit: 20 amp fuse, blade-type• Auxiliary circuit: 15 amp fuse, blade-type• Diode: TVS1. Raise the seat to gain access to the fuse holder

(Figure 36).

Figure 361. Cover 5. Main–25 amp2. Relay 6. Diode3. Auxilliary–15 amp 7. Briggs & Stratton unit4. Charge–20 amp 8. Kohler Command unit

38

Maintenance

2. Remove cover as shown in Figure 36.

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

Drive System Maintenance

Checking the Tire PressureService Interval: Every 25 hours/Monthly

(whichever comes first)

Maintain the air pressure in the front and rear tires asspecified. Uneven tire pressure can cause uneven cut.Check the pressure at the valve stem (Figure 37).

Check the tires when they are cold to get the mostaccurate pressure reading.

Rear Tires: 13 psi (90 kPa)

Front Tires (caster wheels): 13 psi (90 kPa)

Figure 371. Valve stem

Mower Maintenance

Servicing the Cutting BladesService Interval: Before each use or daily

Maintain sharp blades throughout the cutting seasonbecause sharp blades cut cleanly without tearing orshredding the grass blades. Tearing and shreddingturns grass brown at the edges, which slows growthand increases the chance of disease.

Check the cutter blades daily for sharpness, and forany wear or damage. File down any nicks and sharpenthe blades as necessary. If a blade is damaged orworn, replace it immediately with a genuine Exmarkreplacement blade. For convenient sharpening andreplacement, you may want to keep extra blades onhand.

WARNINGA worn or damaged blade can break, and apiece of the blade could be thrown into theoperator’s or bystander’s area, resulting inserious personal injury or death.

• Inspect the blade periodically for wear ordamage.

• Replace a worn or damaged blade.

Before Inspecting or Servicing theBladesPark the machine on a level surface, disengage theblade control switch, and move the motion controllevers outward to the neutral position and engageparking brake. Stop the engine, remove the key, anddisconnect the spark plug wire(s) from the sparkplug(s).

Inspecting the Blades1. Inspect the cutting edges (Figure 38). If the edges

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

2. Inspect the blades, especially the curved area. Ifyou notice any damage, wear, or a slot forming inthis area (item 3 in Figure 38), immediately installa new blade.

Figure 381. Cutting edge 3. Wear/slot forming2. Curved area

Checking for Bent Blades1. Rotate the blades until the ends face forward

and backward (Figure 39). Measure from a levelsurface to the cutting edge, of the blades. Notethis dimension.

39

Maintenance

Figure 391. Blades front to rear 3. Measure here2. Outside cutting edges

2. Rotate the opposite ends of the blades forward.

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

WARNINGA blade that is bent or damaged could breakapart and could seriously injure or kill youor bystanders.

• Always replace bent or damaged bladewith a new blade.

• Never file or create sharp notches in theedges or surfaces of blade.

Checking for Loose Blades orDamaged Spring Disc Washers1. Place a wrench on the blade bolt and torque to

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

2. With the wrench still on the blade bolt, hold theblade spindle stationary and using a rag or thicklypadded glove, try to rotate the blade. If the bladerotates relative to the spindle guard withoutfurther tightening the blade bolt, the springdisc washer has been flattened or damaged andthe bolt and washer assembly must be replaced

(Figure 40). Refer to Removing the Blades andInstalling the Blades.

3. Once the blade has been removed, inspect thespring disc washer. If the washer appears to bedamaged (the washer surface has been marred)or flattened, the bolt and washer assembly mustbe replaced.

Removing the BladesThe blades must be replaced if a solid object is hit, ifthe blade is out of balance, or the blade is bent. Toensure optimum performance and continued safetyconformance of the machine, use genuine Exmarkreplacement blades. Replacement blades made byother manufacturers may result in an unsafe machine.

Hold the blade end using a rag or thickly-paddedglove (or place a wrench on the top sheave nut).Remove the blade bolt and washer assembly, washer,and blade from the spindle shaft (Figure 40).

Figure 401. Blade2. Washer3. Bolt and washer assembly. Apply lubricant to

threads—torque to 32-42 ft-lb (43-57 N-m).

Sharpening the Blades1. Use a file to sharpen the cutting edge at both ends

of the blade (Figure 41). Maintain the originalangle. The blade retains its balance if the sameamount of material is removed from both cuttingedges.

40

Maintenance

Figure 411. Sharpen at original angle

2. Check the balance of the blade by putting it on ablade balancer (Figure 42). If the blade stays in ahorizontal position, the blade is balanced and canbe used. If the blade is not balanced, file somemetal off the end of the sail area only (Figure 42).Repeat this procedure until the blade is balanced.

Figure 421. Blade 2. Balancer

Installing the Blades1. Install the blade onto the spindle shaft (Figure 40).

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

2. Hold the blade end using a rag or thickly-paddedglove (or place a wrench on the top sheave nut).Apply lubricant to the threads of the blade boltas needed to prevent seizing. Copper basedanti-seize is preferable. Grease is an acceptablesubstitute. Install the washer and blade bolt andwasher assembly.

3. Torque the blade bolt to 32-42 ft-lb (43-57 N-m).

WARNINGIncorrect installation of the blade orcomponents used to retain the blade causethe blade to come loose and could seriouslyinjure or kill you or bystanders.

Always install the original Exmark blades,washers and blade bolts as shown.

Mower Belt Maintenance

Inspecting the BeltsService Interval: Every 25 hours

Check the belts for cracks, frayed edges, burn marks,or any other damage. Replace damaged belts.

Replacing the Mower BeltSquealing when the belt is rotating, blades slippingwhen cutting grass, frayed belt edges, burn marks,and cracks are signs of a worn mower belt. Replacethe mower belt if any of these conditions are evident.

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

2. Move the motion control levers outward to theneutral position, engage parking brake, stop theengine, remove the key, and wait for all movingparts 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 inFigure 48 and roll the belt off of the pulleys.

WARNINGThe spring is under tension when installedand can cause personal injury.

Be careful when removing the belt.

Figure 431. Outside puley 4. Mower belt2. Spring 5. Engine pulley3. Idler pulley 6. Pull idler in this direction.

41

Maintenance

6. Route the new belt around the engine pulley andmower pulleys.

7. Pull the idler pulley in the direction shown inFigure 43 and route the belt onto the idler pulley.

8. Install the belt covers over the outside spindles.

Leveling the Mower DeckThe mower blades must be level from side to side.Check the side-to-side level any time you install themower 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 theengine, remove the key, and wait for all movingparts to stop before leaving the operating position.

3. Check the air pressure of all four tires. If needed,adjust to the recommended inflation; refer toChecking the Tire Pressure in Drive SystemMaintenance section. If either one is out of rangethen follow adjustment procedure.

4. Carefully rotate the blades side to side.5. Measure between the outside cutting edges and

the flat surface (Figure 44). If both measurementsare not within 3/16 inch (5 mm), an adjustment isrequired; continue with this procedure.

Figure 441. Blades side to side 3. Measure here2. Outside cutting edges

6. Check the front-to-rear blade level any time youinstall the mower. If the front blade tip is not1/16-5/16 inch (1.6-7.9 mm) lower than the rearblade tip, adjust the blade level. If measurementsfrom steps 5 or 6 are out of range, then followAdjusting the Blade Slope.

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

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

9. Carefully rotate the blades side to side (Figure 44).10. Loosen the leveling adjust locking nuts (item 4)

on all four corners so that the deck is sittingsecurely on all four blocks. Make sure that thedeck hangers are all the way down (at the top ofthe slot) and the deck lift foot lever is pushed backagainst the stop, then tighten the four levelingadjust locking nuts

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

12. Continue leveling the deck by checking thefront-to-rear blade slope; refer to Adjusting theFront-to-Rear Blade Slope.

13. Recheck blades for levelness and repeat deckleveling procedure if necessary.

Figure 451. Deck lift arm 3. Deck hanger2. Float retaining nut 4. Leveling adjust locking

nut

Adjusting the Blade Slope1. Check the front-to-rear blade level any time you

install the mower. If the front blade tip is not1/16-5/16 inch (1.6-7.9 mm) lower than the rearblade tip, adjust the blade level using the followinginstructions:

42

Maintenance

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

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

4. Check the air pressure of all four tires. If needed,adjust to the recommended inflation; refer toChecking the Tire Pressure in Drive SystemMaintenance section.

5. Check and adjust the side-to-side blade level if youhave not checked the setting; refer to Levelingthe Mower.

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

7. Loosen the leveling adjust locking nuts (item 4)on all four corners so that the deck is sittingsecurely on all four blocks. Make sure that thedeck hangers are all the way down (at the top ofthe slot) and the deck lift foot lever is pushed backagainst the stop, then tighten the four levelingadjust locking nuts (Figure 46).

Figure 461. Deck lift arm 3. Deck hanger2. Float retaining nut 4. Leveling adjust locking

nut

8. Carefully rotate the blades so they are facing frontto rear (Figure 47).

9. Measure from the tip of the front blade to the flatsurface and the tip of the rear blade to the flatsurface (Figure 47). If the front blade tip is not1/16-5/16 inch (1.6-7.9 mm) lower than the rearblade tip, adjust the front deck hanger.

Figure 471. Blades front to rear 3. Measure here2. Outside cutting edges

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

43

Maintenance

Removing the Mower Deck1. Park the machine on a level surface and disengage

the blade control switch

2. Move the motion control levers outward to theneutral position, engage parking brake, stop theengine, remove the key, and wait for all movingparts to stop before leaving the operating position.

3. Place blocks under deck for support. Lower theheight-of-cut lever to the lowest position.

4. Remove the hardware from the deck hanger anddeck lift arm on both sides of the deck (Figure 48).

Figure 481. Deck lift arm 2. Deck hanger

5. Remove the nut, bolt, and pivot bushing from thedeck strut (Figure 48). Carefully lower the frontof the mower deck to the ground (Figure 49).

Figure 491. Deck lift arm 2. Deck strut

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

7. Slide the mower out from underneath themachine.

Note: Retain all parts for future installation.

Installing the Mower Deck1. Park the machine on a level surface and disengage

the blade control switch.

2. Move the motion control levers outward to theneutral position, engage parking brake, stop theengine, remove the key, and wait for all movingparts to stop before leaving the operating position.

3. Slide the mower under the machine.

4. Lower the height-of-cut lever to the lowestposition.

5. Use the existing hardware to attach the rear deckstrut of the mower to the deck lift arm (Figure 49).

6. Attach the hardware from the deck hanger anddeck lift arm on both sides of the deck (Figure 48).

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

44

Maintenance

Replacing the DischargeDeflector

DANGERAn uncovered discharge opening could allowthe lawn mower to throw objects in theoperator’s or bystander’s direction and resultin serious injury. Also, contact with the bladecould occur.

Never operate the lawn mower unless youinstall a mulch plate, discharge deflector, orgrass collection system.

1. Locate items shown in Figure 50.

Figure 501. Rod 4. Mower deck2. Spring 5. Discharge deflector

bracket3. Discharge deflector 6. Assembled view

2. Slide the rod out of the short stand-off, spring,and discharge deflector. Remove the damaged orworn discharge deflector.

3. Install new discharge deflector.

4. Orient the spring so that the short leg pointstowards the discharge deflector and the longer legpoints towards the deck as shown in Figure 50.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 installedso that the rod is retained from sliding outby the front bracket and the spring holds thedischarge deflector in the down position. Refer to(Figure 50) for proper orientation.

Important: The discharge deflector must bespring loaded in the down position. Lift thedeflector up to test that it snaps to the fulldown position.

45

Maintenance

CleaningWashing the Underside ofthe MowerService Interval: Before each use or daily

After each use, wash the underside of the mower toprevent grass buildup for improved mulch action andclipping dispersal.

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

2. Move the motion control levers outward to theneutral position, engage parking brake, stop theengine, remove the key, and wait for all movingparts to stop before leaving the operating position.

3. Attach the hose coupling to the end of the mowerwashout fitting, and turn the water on high(Figure 51).

Note: Spread petroleum jelly on the washoutfitting O-ring to make the coupling slide on easierand protect the O-ring.

Figure 51

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

5. Sit on the seat and start the engine. Engage theblade control switch and let the mower run forone to three minutes.

6. Disengage the blade control switch, stop theengine, and remove the ignition key. Wait for allmoving parts to stop.

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

Note: If the mower is not clean after onewashing, soak it and let it stand for 30 minutes.Then repeat the process.

8. Run the mower again for one to three minutesto remove excess water.

WARNINGA broken or missing washout fitting couldexpose you and others to thrown objects orblade contact. Contact with blade or throwndebris can cause injury or death.

• Replace broken or missing washoutfitting immediately, before using moweragain.

• Plug any hole(s) in mower with bolts andlocknuts.

• Never put your hands or feet under themower or through openings in the mower.

46

Storage

StorageCleaning and Storage1. Disengage the blade control switch, move the

motion controls outward to the neutral position,engage parking brake, stop the engine, andremove the key.

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

Important: You can wash the machine withmild detergent and water. Do Not pressurewash the machine. Avoid excessive use ofwater, especially near the control panel,engine, hydraulic pumps, and motors.

3. Service the air cleaner; refer to Servicing the AirCleaner in Engine Maintenance section.

4. Grease and oil the machine; refer to Lubricationsection.

5. Change the crankcase oil and filter; referto Servicing the Engine Oil in EngineMaintenance section.

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

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

8. Check the condition of the blades; refer toServicing the Cutting Blades in MowerMaintenance section.

9. Prepare the machine for storage when non-useoccurs over 30 days. Prepare the machine forstorage as follows.

A. Add a petroleum based stabilizer/conditionerto the fuel in the tank. Follow the mixinginstructions from the stabilizer manufacturer.Do Not use an alcohol based stabilizer(ethanol or methanol).

Note: A fuel stabilizer/conditioner is mosteffective when mixed with fresh gasoline andused at all times.

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

C. Stop the engine, allow it to cool, and drain thefuel tank; refer to Draining the Fuel Tank inFuel System Maintenance section.

D. Restart the engine and run it until it stops.

E. Choke the engine. Start and run the engineuntil it will not start.

F. Dispose of fuel properly. Recycle as per localcodes.

Important: Do Not storestabilizer/conditioned gasoline over30 days.

10. Remove the spark plug(s) and check its condition;refer to Servicing the Spark Plug in EngineMaintenance section. With the spark plug(s)removed from the engine, pour two tablespoonsof engine oil into the spark plug hole. Use thestarter to crank the engine and distribute the oilinside the cylinder. Install the spark plug(s). DoNot install the wire on the spark plug(s).

11. Clean any dirt and chaff from the top of themower.

12. Scrape any heavy buildup of grass and dirt fromthe underside of the mower, then wash the mowerwith a garden hose.

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

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

15. Paint all scratched or bare metal surfaces. Paint isavailable from your Authorized Service Dealer.

16. Store the machine in a clean, dry garage or storagearea. Remove the key from the ignition switchand keep it in a memorable place. Cover themachine to protect it and keep it clean.

47

Troubleshooting

TroubleshootingImportant: It is essential that all operator safety mechanisms be connected and in proper operatingcondition prior to mower use.

When a problem occurs, Do Not overlook the simple causes. For example: starting problems could becaused by an empty fuel tank.

The following table lists some of the common causes of trouble. Do Not attempt to service or replace majoritems or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Havethis work done by your Engine Service Dealer.

Note: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.

Problem Possible Cause Corrective Action

1. The engine load is excessive. 1. Reduce ground speed.

2. The oil level in the crankcase is low. 2. Add oil to the crankcase.3. The cooling fins and air passages under

the engine blower housing are plugged.3. Remove the obstruction from the cooling

fins and air passages.4. The air cleaner is dirty. 4. Clean or replace the air cleaner element.

The engine overheats.

5. Dirt, water, or stale fuel is in fuel system. 5. Contact an Authorized Service Dealer.

1. The blade control switch is engaged. 1. Move the blade control switch toDisengaged.

2. The motion control levers are not in thepark position.

2. Move the motion control levers outwardto the park position.

3. The operator is not seated. 3. Sit on the seat.4. The battery is dead. 4. Charge the battery.5. The electrical connections are corroded

or loose.5. Check the electrical connections for good

contact.6. A fuse is blown. 6. Replace the fuse.

The starter does not crank

7. A relay or switch is damaged. 7. Contact an Authorized Service Dealer.

1. Fuel tank is empty. 1. Fill the fuel tank.

2. The choke is not on. 2. Move the choke lever to On.3. The air cleaner is dirty. 3. Clean or replace the air cleaner element.4. The spark plug wire(s) is loose or

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

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

5. Install a new, correctly gapped sparkplug(s).

6. There is dirt in fuel filter. 6. Replace the fuel filter.7. Dirt, water, or stale fuel is in the fuel

system.7. Contact an Authorized Service Dealer.

8. There is incorrect fuel in the fuel tank. 8. Drain the tank and replace the fuel withthe proper type.

Engine will not start, starts hard, or fails tokeep running

9. The oil level in the crankcase is low. 9. Add oil to the crankcase.

48

Troubleshooting

Problem Possible Cause Corrective Action

1. Engine load is excessive. 1. Reduce the ground speed.

2. Air cleaner is dirty. 2. Clean or replace the air cleaner element.3. Oil level in the crankcase is low. 3. Add oil to the crankcase.4. Cooling fins and air passages for the

engine are plugged.4. Remove the obstructions from the cooling

fins and air passages.5. The spark plug(s) is pitted, fouled, or the

gap is incorrect.5. Install a new, correctly gapped spark

plug(s).6. Vent hole in the fuel cap is closed. 6. Open the vent in the fuel cap.7. Dirt in fuel filter. 7. Replace the fuel filter.8. Dirt, water, or stale fuel is in the fuel

system.8. Contact an Authorized Service Dealer.

Engine loses power

9. There is incorrect fuel in the fuel tank. 9. Drain the tank and replace the fuel withthe proper type.

1. The drive belts are worn, loose, or broken. 1. Contact an Authorized Service Dealer.

2. The drive belts are off of the pulleys. 2. Contact an Authorized Service Dealer.

The machine does not drive.

3. The drive is in bypass mode. 3. Take machine out of bypass mode. Referto Pushing the Machine by Handsection.

1. Engine mounting bolts are loose. 1. Tighten the engine mounting bolts.

2. Loose engine pulley, idler pulley, or bladepulley.

2. Tighten the appropriate pulley.

3. Engine pulley is damaged. 3. Contact an Authorized Service Dealer.4. Cutting blade(s) is/are bent or unbalanced. 4. Install new cutting blade(s).5. Blade is loose. 5. Tighten the blade mounting bolt and

inspect the blade spring disc washer fordamage (See Servicing the CuttingBlades section).

Abnormal vibration

6. Blade spindle is bent. 6. Contact an Authorized Service Dealer.

1. Blade(s) not sharp. 1. Sharpen the blade(s).

2. Cutting blade(s) is/are bent. 2. Install new cutting blade(s).3. A blade is loose. 3. Tighten the blade mounting bolt and

inspect the blade spring disc washer fordamage (See Servicing the CuttingBlades section).

4. Mower deck is not level. 4. Level mower deck from side-to-side andfront-to-rear.

5. An anti-scalp wheel is not set correctly 5. Adjust the anti-scalp wheel height.6. Underside of mower is dirty. 6. Clean the underside of the mower.7. Tire pressure in drive tires not correct. 7. Adjust tire pressure.

Uneven cutting height.

8. Blade spindle bent. 8. Contact an Authorized Service Dealer.

1. Drive belt is worn, loose or broken. 1. Install new drive belt.

2. Drive belt is off pulley. 2. Install drive belt and check adjustingshafts and belt guides for correct position.

3. Deck belt is worn, loose or broken. 3. Install new deck belt.4. Deck belt is off pulley. 4. Install deck pulley and check the idler

pulley, idler arm and spring for correctposition and function.

Blades do not rotate.

5. The mower belt is worn, loose, or broken. 5. Install a new mower belt.

49

Schematics

SchematicsElectrical Diagram—Briggs & Stratton

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50

Schematics

Electrical Diagram—Kohler Command

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51

Consumer Warranty Conditions and Products CoveredExmark 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 Warranty Period• Attachments 1 year• Belts and Tires 90 days• Battery 1 Year Prorated• Engine* 3-Year, 3rd Year Covered by Exmark

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

This warranty only includes the cost of parts and labor.

** 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.

Limited Warranty for Commercial UseExmark 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 Warranty Period• Air Cooled Gas Engines 90 day limited warranty• All other items 30 day limited warranty

Items and Conditions Not CoveredThis warranty does not cover the following:• Pickup and delivery charges to and from any authorized Exmark Service Dealer beyond first warrantable service.• Any damage or deterioration due to normal use, wear and tear, or exposure.• Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune-up parts, and adjustments.• Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance.• Any repairs necessary due to use of parts, accessories or supplies, including gasoline, oil or lubricants, incompatible with the turf equipment or other than as recommended in the operator's manual or other operational instructions provided by Exmark.

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

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

Instructions for Obtaining Warranty ServiceThe 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 service@exmark.com

Owner’s ResponsibilitiesThe 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 ConditionsThe sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair and replacement as set forth herein. Neither Exmark nor Exmark Warranty Company 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.

3-Year Limited Consumer Warranty(30-Day Limited Commercial Warranty)

Exmark Quest Riding Mowers(For units purchased on or after January 1, 2007)

G007486

52

Notes:

53

Service Record

Date: Description of Work Done: Service Done By:

54

55

© 2007—2008 Exmark Mfg. Co., Inc. Part No. 4500-338 Rev. AIndustrial Park Box 808 (402) 223-6300 Beatrice, NE 68310 Fax (402) 223-5489 All Rights Reserved Printed In USA.