QUEST™
For Serial Nos.
312,000,000 & Higher
Part No. 4501-191 Rev. A
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Introduction
Read this information carefully to learn how to
operate and maintain your product properly and to
avoid injury and product damage. You are responsible
for operating the product properly and safely.
Exmark parts manuals are available online at
directly at www.Exmark.com for product and
accessory information or help finding a dealer.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
numbers on the product. Write the numbers in the
space provided.
Figure 1
Under the seat
1. Model and serial number location
Model No.
Serial No.
3
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Changing the Hydraulic System Filter and
Clean Engine and Exhaust System
Contents
4
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Safety
• Allow only responsible adults who are familiar
Safety
Safety Alert Symbol
This manual identifies potential hazards and has
safety messages identified by the safety alert symbol
serious injury or death if you do not follow the
recommended precautions.
with the instructions to operate the machine.
• Clear the area of objects such as rocks, toys, wire,
etc., which could be picked up and thrown by the
blade.
• Be sure the area is clear of other people before
mowing. Stop the machine if anyone enters the
area.
• Never carry passengers.
• Do Not mow in reverse unless absolutely
necessary. Always look down and behind before
and while backing up.
Figure 2
Safety Alert Symbol
• Be aware of the mower discharge direction and
Do Not point it at anyone. Avoid discharging
material against a wall or obstruction. Material
may ricochet back toward the operator. Stop the
blades when crossing gravel surfaces.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
• Do Not operate the mower without either the
entire grass collection system or the discharge
deflector in place.
This machine meets or exceeds the safety
specifications of the American National
Standards Institute B71.1-2003 in effect at the
time of production. However, improper use
or maintenance by the operator or owner can
result in injury. To reduce the potential for
injury, comply with these safety instructions
and always pay attention to the safety alert
symbol, which means CAUTION, WARNING,
or DANGER-"personal safety instruction."
Failure to comply with the instruction may result
in personal injury or death.
• Be alert, slow down and use caution when
making turns. Look behind and to the side before
changing directions.
• Never leave a running machine unattended.
Always turn off blades, engage parking brake,
stop engine, and remove key before dismounting.
• Turn off blades when not mowing. Stop the
engine, wait for all parts to come to a complete
stop, engage parking brake, and remove key
before cleaning the machine, removing the grass
or unclogging the deflector.
• Operate the machine only in daylight or good
artificial light.
Safe Operating Practices
The following instructions are from ANSI standard
B71.1-2003.
• Do Not operate the machine while under the
influence of alcohol or drugs.
This product is capable of amputating hands and
feet and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
• Watch for traffic when operating near or crossing
roadways.
• Use extra care when loading or unloading the
machine into a trailer or truck
General Operation
• Always wear eye protection when operating the
mower.
• Read, understand, and follow all instructions in
the operator’s manual and on the machine before
starting.
• Data indicates that operators, age 60 years and
above, are involved in a large percentage of riding
mower-related injuries. These operators should
evaluate their ability to operate the riding mower
• Do Not place hands or feet near rotating parts or
under the machine. Keep clear of the discharge
opening at all times.
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Safety
safely enough to protect themselves and others
from serious injury.
Children
Tragic accidents can occur if the operator is not
alert to the presence of children. Children are often
attracted to the machine and the mowing activity.
Never assume that children will remain where you
last saw them.
• Always follow the recommendations for wheel
weights or counterweights.
Slope Operation
Slopes are a major factor related to loss of control
and tip-over accidents, which can result in severe
injury or death. Operation on all slopes requires extra
caution. If you cannot back up the slope or if you feel
uneasy on it, Do Not mow it.
• Keep children out of the mowing area and under
the watchful care of another responsible adult,
not the operator.
• Be alert and turn the machine off if children enter
the area.
• Do Not mow slopes greater than 15 degrees.
• Before and while backing or changing direction,
look behind, down, and side-to-side for small
children.
• Watch for ditches, holes, rocks, dips, and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Never carry children, even with the blades off.
They may fall off and be seriously injured or
interfere with safe machine operation.
• Choose a low ground speed so you will not have
to stop while operating on a slope.
• Do Not mow slopes when grass is wet. Slippery
conditions reduce traction and could cause sliding
and loss of control.
• Children who have been given rides in the past
may suddenly appear in the mowing area for
another ride and be run over or backed over by
the mower.
• Reduce speed and use extreme caution on slopes.
• Do Not make sudden turns or rapid speed
changes.
• Never allow children to operate the machine.
• Use extra care when approaching blind corners,
shrubs, trees, the end of a fence or other objects
that may obscure vision.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
Towing
• Use for towing only if equipped with an Exmark
hitch kit. Do Not attach towed equipment except
at the hitch point.
• Be aware that operating on wet grass, across steep
slopes or downhill may cause the mower to lose
traction. Loss of traction to the drive wheels may
result in sliding and a loss of braking and steering.
• Follow Exmark’s recommendation for weight
limits for towed equipment and towing on slopes.
This information can be found in the hitch kit
instruction sheet and on the decal.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• Never allow children or others in or on towed
equipment.
• Use extreme care with grass collection systems or
other attachments. These can change the stability
of the machine and cause loss of control.
• On slopes, the weight of the towed equipment
may cause loss of traction and loss of control.
• Do Not try to stabilize the machine by putting
your foot on the ground.
• Travel slowly and allow extra distance to stop.
• Do Not mow near drop-offs, ditches, steep banks
or water. Wheels dropping over edges can cause
rollovers, which may result in serious injury, death
or drowning.
Service
Safe Handling of Gasoline
• Use a walk behind mower and/or a hand trimmer To avoid personal injury or property damage, use
on slopes greater than 15 degrees, near drop-offs,
ditches, steep banks or water.
extra care when handling gasoline and other fuels.
They are flammable and the vapors are explosive.
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Safety
• Extinguish all cigarettes, cigars, pipes and other
sources of ignition.
thrown. Frequently check components and
replace with manufacturers’ recommended parts,
when necessary.
• Use only an approved container.
• Mower blades are sharp and can cut. Wrap the
blades or wear gloves, and use extra caution when
servicing them.
• Never remove the gas cap or add fuel when the
engine is running. Allow the engine to cool before
refueling.
• Check for proper brake operation frequently.
Adjust and service as required.
• Never refuel the machine indoors.
• Never store the machine or fuel container inside
where there is an open flame, such as near a water
heater or furnace.
• Maintain or replace safety and instruction decals
as necessary.
• Use only genuine Exmark replacement parts to
ensure that original standards are maintained.
• Never fill containers inside a vehicle or on a
truck or trailer with a plastic liner. Always place
containers on the ground away from your vehicle
before filling.
Exmark Riding Mower Safety
• Remove gas-powered equipment from the truck
or trailer and refuel it on the ground. If this is
not possible, then refuel such equipment with a
portable container, rather than from a gasoline
dispenser nozzle.
The following list contains safety information specific
to Exmark products or other safety information that
you must know that is not included in the ANSI
standards.
• Only adults and mature teenagers should operate
a mower, and even mature teenagers should have
adult supervision. Be sure a teenager:
• Keep the nozzle in contact with the rim of the
fuel tank or container opening at all times until
the fueling is complete. Do Not use a nozzle
lock-open device.
1. has read and understands the Operator's
Manual and recognizes the risks involved;
• If fuel is spilled on clothing, change clothing
immediately.
2. is sufficiently mature to use caution; and
3. is of sufficient size and weight to operate
the controls comfortably and to manage the
mower without taking risks.
• Never overfill the fuel tank. Replace gas cap and
tighten securely.
General Service:
• Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you. Do
Not run engine indoors or in an enclosed area.
• Never run a machine inside a closed area.
• Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good
condition.
• Park machine on level ground. Stop the engine,
wait for all moving parts to stop, engage parking
brake, disconnect spark plug wire(s) and remove
key before performing any service, repairs,
maintenance or adjustments.
• Never tamper with safety devices. Check their
proper operation regularly.
• Keep the machine free of grass, leaves, or other
debris build-up. Clean up oil or fuel spillage and
fuel soaked debris. Allow the machine to cool
before storing.
• Keep hands, feet, hair, and loose clothing away
from attachment discharge area, underside of
mower and any moving parts while engine is
running.
• Stop and inspect the equipment if you strike an
object. Repair, if necessary, before restarting.
• Do Not touch equipment or attachment parts
which may be hot from operation. Allow to cool
before attempting to maintain, adjust or service.
• Never make any adjustments or repairs with the
engine running.
• Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes, and clothing.
Protect your face, eyes, and clothing when
working with a battery.
• Grass collection system components are subject
to wear, damage and deterioration, which could
expose moving parts or allow objects to be
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Safety
• Battery gases can explode. Keep cigarettes, sparks
and flames away from battery.
• Use only Exmark approved attachments.
Warranty may be voided if used with unapproved
attachments.
• If loading the machine onto a trailer or truck, use
a single, full-width ramp only. The ramp angle
should not exceed 15 degrees.
Note: The left and right sides of the machine are
determined while sitting in the seat in the normal
operating position
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Safety
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area of
potential danger. Replace any decal that is damaged or lost.
93-7009
1. Warning—don't operate the mower with the deflector up
or removed; keep the deflector in place.
2. Cutting/dismemberment hazard of hand or foot, mower
blade—stay away from moving parts.
105-7015
For Models with 42 Inch Decks
1. Belt routing
99-3943
For Models with 50 Inch Decks
106-8717
1. Engine
1. Read the instructions before servicing or performing
maintenance.
2. Check tire pressure every 25 operating hours.
3. Grease every 25 operating hours.
4. Engine
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Safety
110-6691
119-8814
4. Neutral
5. Reverse
1. Thrown object hazard—keep bystanders a safe distance
from the machine.
2. Thrown object hazard, mower—do not operate without
the deflector, discharge cover, or grass collection
system in place.
1. Parking position
2. Fast
3. Slow
3. Cutting/dismemberment of hand or foot—stay away
from moving parts.
119-8815
1. Parking position
4. Neutral
5. Reverse
2. Fast
3. Slow
112-9840
1. Read the Operator's
Manual.
3. Remove the ignition key
and read the instructions
before servicing or
performing maintenance.
2. Height of cut
114-1606
1. Entanglement hazard, belt—keep all guards in place.
119-8870
50 Inch Model
1. Height-of-cut
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Safety
PTO Switch Symbols
1. PTO–disengage 2. PTO–engage
119-8871
42 Inch Model
1. Height-of-cut
121-2989
42 Inch Model
1. Bypass lever position for 2. Bypass lever position for
pushing the machine operating the machine
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Safety
116-4220
50 Inch Model
1. Fast
2. Continuous variable setting
3. Slow
4. Choke
120-5462
42 Inch Model
3. Slow
4. Choke
1. Fast
2. Continuous variable setting
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Safety
120-2239
1. Warning—read the Operator's Manual.
5. Warning—do not use split ramps, use a full ramps when
transporting machine.
2. Warning—read the instructions before servicing or
performing maintenance; move the motion control levers
to the park (brake) position, remove the ignition key and
disconnect the spark plug wire.
6. Loss of traction/control hazard, slopes—loss of
traction/control on a slope, disengage the blade control
switch (PTO), proceed off the slope slowly.
3. Cutting/dismemberment hazard, mower blade;
entanglement hazard, belt—stay away from moving parts,
keep all guards and shields in place.
7. Crushing/dismemberment hazard of bystanders, reversing;
crushing/dismemberment hazard of bystanders—do not
carry passengers, look behind and down when reversing.
4. Thrown object hazard—keep bystanders a safe distance
from the machine, pick up debris before operating, keep
deflector in place.
8. Tipping hazard—do not mow slopes greater than 15
degrees, avoid sudden and sharp turns while on slopes.
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
5. Read the Operator's Manual.
9. Flush eyes immediately with water
and get medical help fast.
2. No fire, open flames, or smoking
6. Keep bystanders a safe distance
from the battery.
10. Contains lead; do not discard.
3. Caustic liquid/chemical burn hazard 7. Wear eye protection; explosive
gases can cause blindness and
other injuries.
4. Wear eye protection
8. Battery acid can cause blindness or
severe burns.
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Specifications
Specifications
Model Numbers
Serial Nos: 312,000,000 and Higher
QTE651KA421; QTE691KA501; QTS691KA502
Systems
• Polarity: Negative Ground
• Fuses: One 30 amp, one 25 amp; blade type
Engine
Safety Interlock System
• Engine Specifications: See your Engine Owner’s
Manual
• PTO must be disengaged, motion control levers
out (brake engaged) to start engine. (It is not
necessary for the operator to be in the seat to
start the engine.)
• Engine Oil Type: Exmark 4-Cycle Premium
Engine Oil
• RPM:
• Operator must be in seat when PTO is engaged
or motion control levers are moved in or engine
will stop.
Full Speed: 3300 ±100 (max) RPM (No Load)
Idle: 1650 (min) RPM
Fuel System
• Capacity: 3.0 gal. (11.4 L)
Operator Controls
• Steering and Motion Control:
• Fuel Recommendations:
Note: Motion control levers are adjustable to
two heights.
– For best results, use only clean, fresh, unleaded
gasoline with an octane rating of 87 or higher
((R+M)/2 rating method).
– Separate levers, on each side of the console,
control speed and direction of travel of the
respective drive wheels.
– Oxygenated fuel with up to 10% ethanol or
15% MTBE by volume is acceptable.
– Steering is controlled by varying the position
of the levers relative to each other.
– Do Not use ethanol blends of gasoline (such
as E15 or E85) with more than 10% ethanol
by volume. Performance problems and/or
engine damage may result which may not be
covered under warranty.
– Moving motion control levers outward (in
slots) locks the drive system in neutral and
applies the parking brake.
– Do Not use gasoline containing methanol.
• PTO Engagement Switch: Engages electric clutch
(to drive belt) which engages mower blades.
– Do Not store fuel either in the fuel tank or
fuel containers over the winter unless a fuel
stabilizer is used.
• Deck Height Adjustment Lever: Sets cutting
height to desired position.
– Do Not add oil to gasoline.
• Fuel Filter:
• Deck Lift Assist Lever: Foot pedal that assists in
raising the deck.
Kawasaki P/N 49019-7005
Seat
• Type:
Electrical System
– 42 inch unit: Standard seat with high back,
foam padded with spring suspension and
armrests.
• Charging System: Flywheel Alternator
• Charging Capacity: 15 amps
• Battery Type: 195 CCA
– 50 inch unit: Two tone upholstered seat with
spring suspension and armrests.
• Battery Voltage: 12 Volt
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Specifications
• Mounting: Hinged to tilt up for access to battery
and other components. Adjustable fore and aft.
Cutting Deck
• Cutting Width:
• Armrests: Standard–padded flip-up armrests.
– 42 inch Deck: 42 inches (107 cm)
– 50 inch Deck: 50 inches (127 cm)
• Discharge: Side
• Seat Safety Switch: Incorporated into the Safety
Interlock System.
Hydrostatic Ground Drive System
• Blade Size:
• Hydrostatic Pumps:
– 42 inch Deck: 21.60 inches (54.9 cm)–Qty: 2
– 50 inch Deck: 17.50 inches (44.5 cm)–Qty: 3
– 42 inch unit: Two Hydro Gear ZT2100
Integrated drive systems.
• Blade Spindles: Solid steel spindles with no
maintenance bearings.
– 50 inch E-Series unit: Two Hydro Gear
ZT2200 Integrated drive systems.
• Deck Drive: Electric clutch mounted on vertical
engine shaft. Blades are driven by one belt
(w/self-tensioning idler) direct from the engine.
– 50 inch S-Series unit: Two Hydro Gear
ZT2800 Integrated drive systems.
• Hydraulic Oil Type: Exmark Premium Hydro Oil.
• Speeds:
• Deck: Full floating deck is attached to out-front
support frame. Maximum turf protection is
provided with anti-scalp rollers.
– 0-7.0 mph (11.3 km/hr) forward.
– 0-5.0 mph (8.0 km/hr) reverse.
Deck design allows for bagging, mulching or side
discharge.
• Drive wheel releases, located on left and right
sides of engine deck, allow machine to be moved
when the engine is not running and brake is off.
• Deck Depth:
– 42 inch Deck: 4.0 inches (10.2 cm)
– 50 inch Deck: 4.0 inches (10.2 cm)
Tires and Wheels
• Cutting Height Adjustment: A hand deck lift lever
with foot assist is used to adjust the cutting height
from 1 1/2 inch (3.8 cm) to 4 1/2 inches (11.4
cm) in 1/2 inch (1.3 cm) increments.
Drive
Pneumatic (Air-Filled)
Deck Size
Quantity
Tread
42
2
50 E-Series 50 S-Series
2
2
• Mulching Kit: Optional.
Hoosier
Premium
Hoosier
Premium
Carlisle Turf
Master
Dimensions
Size
18 x 7.50-8 18 x 9.50-8 20 x 8-10
2
4
4
Ply Rating
Pressure
Overall Width:
13 psi
13 psi
13 psi
42 inch Deck
50 inch Deck
(90 kPa)
(90 kPa)
(90 kPa)
Without Deck
Deflector Up
39.0 inches
(99 cm)
46.3 inches
(118 cm)
Front Caster
Pneumatic (Air-Filled)
45.3 inches
(115 cm)
54.6 inches
(139 cm)
Deck Size
Quantity
Tread
42
2
50
2
Deflector Down 53.8 inches
(137 cm)
63.0 inches
(160 cm)
Smooth
410/350 x 4
Ribbed
13 x 5-6
2
Size
Overall Length:
2
Ply Rating
Pressure
42 inch Deck
50 inch Deck
20 psi
(138 kPa)
13 psi
(90 kPa)
71.8 inches (182 cm)
72.9 inches (185 cm)
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Product Overview
Overall Height:
Product Overview
All Units
41.5 inches (105 cm)
Tread Width: (Center to Center of
Tires, Widthwise)
42 inch Deck
50 inch Deck
Drive Wheels
Caster Wheels
31.5 inches
(80 cm)
37.4 inches
(95 cm)
29.5 inches
(75 cm)
36.9 inches
(94 cm)
Wheel Base: (Center of Caster Tire to
Center of Drive Tire)
Figure 3
All Units
1. Front caster wheel
2. Anti-scalp roller
8. Control panel
9. Engine
45.6 inches (116 cm)
3. Height-of-cut foot lever 10. Seat
4. Discharge deflector
11. Fuel tank
Curb Weight:
5. Deck height adjustment 12. Armrest
lever
42 inch Deck
50 inch E-Series 50 inch S-Series
Deck
Deck
6. Washout fitting
13. Motion control levers
14. Footrest
7. Rear drive wheel
531 lb (241 kg)
614 lb (279 kg)
672 lb (305 kg)
Torque Requirements
Bolt Location
Torque
Spindle Pulley Nut
Blade Mounting Bolt
Engine Mounting Bolts
Wheel Lug Nuts
35-65 ft-lb (47-88 N-m)
35-65 ft-lb (47-88 N-m)
330-400 in-lb (37-45 N-m)
70-90 ft-lb (95-122 N-m)
50-60 ft-lb (68-81 N-m)
Clutch Mounting Bolt
(secured with threadlocker)
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Operation
Blade Control Switch (Power
Take-Off)
Operation
Located on the control panel.
Controls
The blade control switch, represented by a power
take-off (PTO) symbol, engages and disengages
Note: Become familiar with all of the controls in
operate the machine.
Pull out on the blade control switch to “On” to
engage the blades.
Ignition Switch
Push the blade control switch to “Off ” to disengage
the blades.
Located on control panel.
The ignition switch is used to start and stop the
engine. The switch has three positions “OFF”,
switch and rotate clockwise to the “ON” position.
Rotate clockwise to the next position to engage the
starter (key must be held against spring pressure in
this position).
Throttle Lever
Located on control panel.
The throttle is used to control engine speed. Moving
throttle lever forward will increase engine speed and
moving throttle lever to the rear will decrease engine
speed. Moving the throttle forward until it stops is
Choke Control
The choke is used to aid in starting a cold engine.
Pulling up on the choke control will put the choke in
the “ON” position and pushing down the control will
put the choke in the “OFF” position. Do Not run a
warm engine with the choke in the “ON” position.
Motion Control Levers and Parking
Brake Position
Figure 4
1. Ignition switch
2. Throttle lever
3. Choke control
The motion control levers located on each side of
4. Blade control switch
(power take-off)
The motion control levers are speed sensitive controls
of independent wheel motors. Moving a lever
forward or backward turns the wheel on the same side
forward or in reverse; wheel speed is proportional to
the amount the lever is moved. Moving the control
levers outward from the center position engages the
parking brake on the drive wheels. Always position
the motion control levers into the parking brake
position when you stop the machine or leave it
unattended. The unit must be tied down and brake
engaged when transporting.
Note: Brake must be engaged (motion control levers
out) and PTO switch “OFF” to start engine. (It is
not necessary for the operator to be in the seat to
start the engine.)
Turning the key to the Off position will stop the
engine; however, always remove the key when leaving
the machine to prevent someone from accidentally
starting the engine.
Deck Height Adjustment Lever
Located below the RH motion control lever
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Operation
Pull the lever inward and rearward to raise the cutting
deck. Allow the handle to move forward to lower the
cutting deck. Move the deck height adjustment lever
outward at the desired height-of-cut. Only adjust the
height of cut while the machine is not moving.
DANGER
Mowing on wet grass or steep slopes can cause
sliding and loss of control. Wheels dropping
over edges can cause rollovers, which may result
in serious injury, death or drowning. A loss of
traction is a loss of steering control.
Height-of-Cut Foot Lever
To avoid loss of control and possibility of rollover:
• Do Not mow near drop-offs or near water.
• Do Not mow slopes greater than 15 degrees.
The height-of-cut foot lever allows the operator to
use their leg to assist in lowering and raising the deck
is moved forward, away from the operator the deck
is raised from the ground and when moved back,
towards the operator it is lowered toward the ground.
• Reduce speed and use extreme caution on
slopes.
• When mowing slopes, gradually work from
lower to higher areas on the incline.
Fuel Window
• Avoid sudden turns or rapid speed changes.
• Turn up, into an incline when changing
directions on slopes. Turning down the slope
reduces traction.
The fuel window can be used to verify the presence
of fuel in the tank.
• Attachments change the handling
characteristics of the machine. Use extra
caution when using attachments with the
machine.
Figure 5
1. Fuel cap
2. Fuel window
Operating Instructions
Figure 6
Think Safety First
1. Water
Note: Determine the left and right sides of the
2. Danger Zone–Use walk behind mower and/or hand
trimmer on slopes greater than 15 degrees, near
drop-offs and water.
machine from the normal operating position.
Please carefully read all of the safety instructions and
decals in the safety section. Knowing this information
could help you, your family, pets or bystanders avoid
injury.
3. Safe Zone–use the Quest here.
See inside back cover to determine the approximate
slope angle to be mowed.
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Operation
Recommended Gasoline
Fill fuel tank on level ground. See Fuel
Recommendations in the Specifications section for
additional gasoline information.
DANGER
In certain conditions during fueling, static
electricity can be released causing a spark which
can ignite gasoline vapors. A fire or explosion
from gasoline can burn you and others and cause
property damage.
Do Not add oil to gasoline.
• Always place gasoline containers on the
ground away from your vehicle before filling.
Do Not overfill fuel tank. Fill the fuel tank to the
bottom of the filler neck. The empty space in the
tank allows gasoline to expand. Overfilling may result
in fuel leakage or damage to the engine or emission
system.
• Do Not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the loss
of any static charge.
DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.
• When practical, remove gas-powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
A fire or explosion from gasoline can burn you,
others, and cause property damage.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• Fill the fuel tank outdoors on level ground, in
an open area, when the engine is cold. Wipe
up any gasoline that spills.
• If a gasoline dispenser nozzle must be used,
keep the nozzle in contact with the rim of the
fuel tank or container opening at all times
until fueling is complete.
• Never refill the fuel tank or drain the machine
indoors or inside an enclosed trailer.
• Do Not fill the fuel tank completely full. Add
gasoline to the fuel tank until the body of the
tank is full but fuel does not fill the neck of
the tank. This empty space in the tank allows
gasoline to expand.
WARNING
Gasoline is harmful or fatal if swallowed.
Long-term exposure to vapors has caused cancer
in laboratory animals. Failure to use caution may
cause serious injury or illness.
• Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by spark.
• Avoid prolonged breathing of vapors.
• Store gasoline in an approved container and
keep it out of the reach of children. Never
buy more than a 30-day supply of gasoline.
• Keep face away from nozzle and gas
tank/container opening.
• Keep away from eyes and skin.
• Never siphon by mouth.
• Do Not operate without entire exhaust system
in place and in proper working condition.
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to
provide the following benefits:
• Keeps gasoline fresh during storage of 30 days or
less. For longer storage it is recommended that
the fuel tank be drained.
• Cleans the engine while it runs.
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting Add the
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Operation
correct amount of gas stabilizer/conditioner to
the gas.
Note: A fuel stabilizer/conditioner is most effective
when mixed with fresh gasoline. To minimize the
chance of varnish deposits in the fuel system, use fuel
stabilizer at all times.
Filling the Fuel Tank
Make sure the engine is shut off and the motion
controls are in the park position. Tank maximum
capacity is 2.9 gallons.
Important: Do Not overfill fuel tank. Fill the
fuel tank to the bottom of the filler neck. The
empty space in the tank allows the fuel to expand.
Overfilling may result in fuel leakage or damage
to the engine or emission system.
Figure 7
4. Fill opening
1. Fuel cap
2. Fuel window
5. Base of filler neck, DO
NOT FILL PAST HERE
6. Fuel
1. Shut the engine off and move the motion controls
outward to engage parking brake.
3. Empty space for fuel
expansion
2. Clean around the fuel tank cap and remove the
cap.
4. Install the fuel tank cap securely and tighten until
it “clicks”. Wipe up any gasoline that may have
spilled.
3. Add unleaded regular gasoline until the fuel
reaches the base of the filler neck and does not
at the base of the filler neck allows gasoline to
expand. Do Not fill the fuel tank completely full.
Overfilling may result in fuel leakage or damage
to the engine or emissions system.
Checking the Engine Oil
Level
Before you start the engine and use the machine,
check the oil level in the engine crankcase; refer to
Checking the Oil Level in Engine Maintenance
section.
Starting the Engine
1. Sit down on the seat and move the motion
controls outward to engage the parking brake.
2. Disengage the blades by moving the blade control
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Operation
2. Move the throttle midway to the Fast position.
Note: Always engage the blades with the throttle
in the midway position.
3. Pull out on the blade control switch, to the On
Figure 8
5. Throttle lever
1. Ignition key
2. Off
6. Choke control
3. Run
7. Blade control
switch—Off position
4. Start
Figure 9
3. Pull up on the choke control to engage the choke
1. Throttle–Midway position 2. Blade control
switch—On position
Note: A warm or hot engine may not require
choking.
4. Move throttle to full forward position before
mowing.
4. Turn the ignition key to Start to energize the
starter. When the engine starts, release the key
Disengaging the Blades
Important: Do Not engage the starter for
more than 5 seconds at a time. If the engine
fails to start, allow a 60 second cool-down
period between attempts. Failure to follow
these instructions can burn out the starter
motor.
Set throttle to midway position. Push the blade
control switch to Off to disengage the blades
Stopping the Engine
1. Bring the unit to a full stop.
2. Disengage the blades.
5. Once the engine starts, gradually push down the
choke control as the engine warms. If the engine
stalls or hesitates, slightly pull the control up for
a few seconds.
3. Move the motion control levers out to engage the
parking brake.
4. Place the throttle midway between the “SLOW”
and “FAST” positions.
Operating the Blades
The blade control switch, represented by a power
take-off (PTO) symbol, engages and disengages
power to the mower blades. This switch controls
power to any attachments that draw power from the
engine, including the mower deck and cutting blades.
5. Allow the engine to run for a minimum of 15
seconds, then turn the ignition switch to the
“OFF” position to stop the engine.
6. Remove the key to prevent children or other
unauthorized persons from starting engine.
Engaging the Blades
1. Release pressure on the motion control levers and
place the machine in neutral.
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Operation
do not get off of machine) engine must initiate
shutdown.
The Safety Interlock System
CAUTION
Run engine at one-third throttle, with brake
disengaged, move levers in and raise off seat (but
do not get off of machine) engine must initiate
shutdown.
If the safety interlock switches are disconnected
or damaged the machine could operate
unexpectedly causing personal injury.
• Do not tamper with the interlock switches.
Note: If machine does not pass any of these tests,
Do Not operate. Contact your authorized EXMARK
SERVICE DEALER.
• Check the operation of the interlock switches
daily and replace any damaged switches
before operating the machine.
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
Understanding the Safety Interlock
System
The safety interlock system is designed to prevent the
engine from starting unless:
• The blades are disengaged.
• The motion control levers are in the neutral
position.
• The parking brake is engaged.
Driving Forward or Backward
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place
the throttle control in the Fast position for best
performance. Always operate in the Fast (full throttle)
position.
The safety interlock system is designed to initiate
engine shutdown when:
• The parking brake is disengaged and the operator
gets off machine.
• The PTO is engaged and the operator gets off
machine.
CAUTION
Machine can spin very rapidly by positioning one
lever too much ahead of the other. Operator may
lose control of the machine, which may cause
damage to the machine or injury.
•
The parking brake is disengaged and levers are in
and the operator gets off machine.
• Use caution when making turns.
• Slow the machine down before making sharp
turns.
Testing the Safety Interlock System
Test the safety interlock system before you use the
machine each time
Forward
1. Move the levers to the center, unlocked position.
1. Check starting circuit. Starter should crank with
the PTO disengaged and motion control levers
moved out in the parking brake position. The
operator does not need to be in the seat to start
the engine.
2. To go forward, slowly push the motion control
Try to start with operator in seat, PTO
disengaged and motion control levers in the
parking brake position - starter must not crank.
Try to start with operator in seat, PTO
disengaged, and the left motion control lever
in, starter must not crank, repeat again with the
right lever in, then with both levers in - starter
must not crank.
2. Check kill circuits. Run engine at one-third
throttle, engage PTO and raise off of seat (but
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Operation
Figure 10
Figure 11
1. Parking brake position
4. Forward
(engaged)
2. Center unlock position
(neutral)
5. Backward
To turn, pull back on the motion control
lever toward the direction you want to turn
3. Front of unit
To go straight, apply equal pressure to both
The farther you move the motion control levers
in either direction, the faster the machine will
move in that direction.
To stop, pull the motion control levers to neutral.
Backward
1. Move the levers to the center, unlocked position.
2. To go backward, slowly pull the motion control
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Operation
adjustment lever inward and pulling up. The
height can also be adjusted by moving the deck
height adjustment lever inward and pushing the
transport lever will automatically engage and will
drop into place.
Figure 12
Figure 13
To go straight, apply equal pressure to both
1. Height-of-cut foot lever
2. Deck height adjustment 4. Transport position – 4.5
lever inch (115 mm)
3. Height-of-cut positions
To turn, release the pressure on the motion
control lever toward the direction you want to
2. Push the foot lever forward, pull the deck height
adjustment lever handle inward and let the deck
lower down to the desired cut height by slowly
decreasing foot pressure allowing the foot lever to
travel rearward. Move the deck height adjustment
lever outward at the desired height-of-cut.
To stop, push the motion control levers to neutral.
Stopping the Machine
To stop the machine, move the motion control levers
to neutral, disengage the blade control switch, move
the motion control levers outward to engage the
parking brake, move the throttle lever to between
Fast and half throttle, and turn the ignition key to
off. Remember to remove the key from the ignition
switch.
Adjusting the Anti-Scalp
Rollers
It is recommended to change the anti-scalp roller
position when the height of cut has changed.
CAUTION
1. Stop the machine and move the drive levers to
the neutral position.
Children or bystanders may be injured if they
move or attempt to operate the mower while it
is unattended.
2. Disengage the PTO.
3. Move the motion control levers outward to
engage the park brake.
Always remove the ignition key and move
the motion control levers outward to apply
the parking brake when leaving the machine
unattended, even if just for a few minutes.
4. Stop the engine, remove the key and wait for all
moving parts to stop.
5. After adjusting the height of cut, adjust the
anti-scalp rollers by removing the nyloc nut.
Adjusting the Height of Cut
1. Raise the deck to the transport position (4.5 inch
(114 mm) cut height) by moving the deck height
6. Adjust the anti-scalp rollers for the normal
operating conditions. Place rollers in one of
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Operation
maintain 3/4 inches (19 mm) clearance to the
ground to minimize gouging and roller wear or
damage.
1. Tip the seat forward.
2. Loosen the adjustment bolts.
Note: For Maximum Deck Flotation, place
the rollers one hole position lower. Rollers should
maintain 1/4 inch (6.35 mm) clearance to the
ground. Do Not adjust rollers to support the
deck.
Figure 14
Figure 16
42 Inch Deck
1. Adjustment bolt
1. Anti-scalp roller mounting bracket
2. Below 2 1/2 inches (64mm) cutting height
3. 2 1/2 inches (64mm) and above cutting height
3. Move the seat to the desired position and
tighten bolts.
4. Tip the seat back to the closed position.
• 50 Inch Units:
1. Push the adjustment lever towards the center
of the machine to release the seat adjuster
Figure 15
50 Inch Deck
For cutting heights above 3 1/2 inches (90 mm)
use the bottom hole. The rollers will still be effective
against scalping.
1. Anti-scalp roller
mounting bracket
2. Cutting height
7. Torque hardware to 27-33 ft-lb (37-45 N-m) or
loss of roller may result.
Figure 17
1. Adjustment lever
Positioning the Seat
The seat can move forward and backward. Position
the seat where you have the best control of the
machine and are most comfortable.
2. Move the seat to the desired position and
release the lever to lock in that position.
• 42 Inch Unit:
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Operation
Changing the Seat Ride
Suspension
The number of seat springs can be changed to
maximize rider comfort. More springs should be used
with heavier operators and on rough terrain. Fewer
springs should be used with lighter operators and
when mowing smooth, well established lawns. Always
keep the number of springs on the left and right side
the same when adding and removing springs.
Figure 19
3. Washer
1. Control arm shaft
2. Control lever
4. Bolt
2. Move the control lever to the next set of holes.
Secure the lever with the hardware.
3. Repeat the adjustment for the opposite control
lever.
Adjusting the Tilt
The motion control levers can be tilted fore or aft for
maximum operator comfort.
Figure 18
1. Bolt
3. Nut
1. Loosen the upper bolt holding the control lever
to the control arm shaft.
2. Spring
4. Additional mounting
holes
2. Loosen the lower bolt just enough to pivot the
bolts to secure the control in the new position.
Up to five springs can be secured to the seat box with
3. Repeat the adjustment for the opposite control
lever.
Refer to your Parts Manual for spring and hardware
part numbers.
Pushing the Machine by
Hand
Adjusting the Motion Control
Levers
Important: Always push the machine by hand.
Never tow the machine because damage may
occur.
Adjusting the Height
The motion control levers can be adjusted higher or
lower for maximum operator comfort.
This machine has an electric brake mechanism and to
push the machine the ignition key needs to be in the
Run position. The battery needs to be charged and
functioning for the electric brake to be disengage.
1. Remove the hardware holding the control lever to
To Push the Machine
1. Park the machine on a level surface and disengage
the blade control switch.
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Operation
2. Move the motion control levers outward to park
position, stop the engine, and wait for all moving
parts to stop before leaving the operating position.
Side Discharge
The mower has a hinged discharge deflector that
disperses clippings to the side and down toward the
turf.
3. Locate the bypass levers on the frame on both
sides of the engine.
4. Move the bypass levers forward through the key
hole and down to lock them in place as shown in
DANGER
Without the discharge deflector, mulch kit, or
entire grass collection system mounted in place,
you and others are exposed to blade contact and
thrown debris. Contact with rotating mower
blade(s) and thrown debris will cause injury or
death.
5. Move the motion control levers inward to the
neutral position and turn the ignition key to the
run position. Do Not start the machine.
The machine is now able to be pushed by hand.
• Never remove the discharge deflector from
the mower because the discharge deflector
routes material down toward the turf. If the
discharge deflector is ever damaged, replace
it immediately.
• Never put your hands or feet under the
mower.
• Never try to clear discharge area or mower
blades unless you move the move the blade
control switch to Off and rotate the ignition
key to Off. Also remove the key and pull the
wire off the spark plug(s).
Transporting
Figure 20
1. Bypass lever location
3. Lever position for
pushing the machine
Transporting a Unit
2. Lever position for
operating the machine
Use a heavy-duty trailer or truck to transport the
machine. Lock brake and block wheels. Securely
fasten the machine to the trailer or truck with straps,
chains, cable, or ropes. Be sure that the trailer or truck
has all necessary lighting and marking as required by
law. Secure a trailer with a safety chain.
6. When finished, ensure the key has been returned
to the Stop position to avoid draining the battery
charge.
If the machine fails to move the electric brake may
still be engaged. If necessary the electric brake can
be released manually. Refer to the Releasing the
Electric Brake procedure in Drive Maintenance.
CAUTION
This unit does not have proper turn signals,
lights, reflective markings, or a slow moving
vehicle emblem. Driving on a street or roadway
without such equipment is dangerous and
can lead to accidents causing personal injury.
Driving on a street or roadway without such
equipment may also be a violation of State laws
and the operator may be subject to traffic tickets
and/or fines.
To Operate the Machine
Move the bypass levers rearward through the key
hole and down to lock them in place as shown in
Do Not drive a unit on a public street or roadway.
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Operation
Operating Tips
WARNING
Loading a unit on a trailer or truck increases
the possibility of backward tip-over. Backward
tip-over could cause serious injury or death.
Fast Throttle Setting
For best mowing and maximum air circulation,
operate the engine at the Fast position. Air is required
to thoroughly cut grass clippings, so Do Not set the
height-of-cut so low as to totally surround the mower
by uncut grass. Always try to have one side of the
mower free from uncut grass, which allows air to be
drawn into the mower.
• Use extreme caution when operating a unit
on a ramp.
• Use only a single, full width ramp; Do Not
use individual ramps for each side of the unit.
• If individual ramps must be used, use enough
ramps to create an unbroken ramp surface
wider than the unit.
Cutting a Lawn for the First Time
• Do Not exceed a 15° angle between ramp and
ground or between ramp and trailer or truck.
Cut grass slightly longer than normal to ensure that
the cutting height of the mower does not scalp any
uneven ground. However, the cutting height used in
the past is generally the best one to use. When cutting
grass longer than six inches tall, you may want to cut
the lawn twice to ensure an acceptable quality of cut.
• Avoid sudden acceleration while driving unit
up a ramp to avoid tipping backward.
• Avoid sudden deceleration while backing unit
down a ramp to avoid tipping backward.
Loading a Unit
Cut 1/3 of the Grass Blade
Use extreme caution when loading units on trailers or
trucks. One full width ramp that is wide enough to
extend beyond the rear tires is recommended instead
of individual ramps for each side of the unit. The
lower rear section of the tractor frame extends back
between the rear wheels and serves as a stop for
tipping backward. Having a full width ramp provides
a surface for the frame members to contact if the
unit starts to tip backward. If it is not possible to use
one full width ramp, use enough individual ramps to
simulate a full width continuous ramp.
It is best to cut only about 1/3 of the grass blade.
Cutting more than that is not recommended unless
grass is sparse, or it is late fall when grass grows more
slowly.
Mowing Direction
Alternate mowing direction to keep the grass standing
straight. This also helps disperse clippings which
enhances decomposition and fertilization.
Mow at Correct Intervals
Ramp should be long enough so that the angles
between the ramp and the ground and the ramp and
the trailer or truck Do Not exceed 15°. A steeper
angle may cause mower deck components to get
caught as the unit moves from ramp to trailer or
truck. Steeper angles may also cause the unit to tip
backward. If loading on or near a slope, position
the trailer or truck so it is on the down side of the
slope and the ramp extends up the slope. This will
minimize the ramp angle. The trailer or truck should
be as level as possible.
Normally, mow every four days. But remember,
grass grows at different rates at different times.
So to maintain the same cutting height, which is a
good practice, mow more often in early spring. As
the grass growth rate slows in mid summer, mow
less frequently. If you cannot mow for an extended
period, first mow at a high cutting height; then mow
again two days later at a lower height setting.
Cutting Speed
To improve cut quality, use a slower ground speed.
Important: Do Not attempt to turn the unit
while on the ramp, you may lose control and
drive off the side.
Avoid Cutting Too Low
Avoid sudden acceleration when driving up a ramp
and sudden deceleration when backing down a ramp.
Both maneuvers can cause the unit to tip backward.
If the cutting width of the mower is wider than the
mower you previously used, raise the cutting height
to ensure that uneven turf is not cut too short.
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Operation
Long Grass
If the grass is ever allowed to grow slightly longer
than normal, or if it contains a high degree of
moisture, raise the cutting height higher than usual
and cut the grass at this setting. Then cut the grass
again using the lower, normal setting.
When Stopping
If the machine’s forward motion must be stopped
while mowing, a clump of grass clippings may drop
onto your lawn. To avoid this, move onto a previously
cut area with the blades engaged.
Keep the Underside of the Mower
Clean
Clean clippings and dirt from the underside of the
mower after each use. If grass and dirt build up inside
the mower, cutting quality will eventually become
unsatisfactory.
Blade Maintenance
Maintain a sharp blade throughout the cutting season
because a sharp blade cuts cleanly without tearing or
shredding the grass blades. Tearing and shredding
turns grass brown at the edges, which slows growth
and increases the chance of disease. Check the
cutter blades daily for sharpness, and for any wear or
damage. File down any nicks and sharpen the blades
as necessary. If a blade is damaged or worn, replace
it immediately with a genuine Exmark replacement
blade. Only Exmark blades are to be used with this
unit. No other blades are approved.
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Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could seriously
injure you or other bystanders.
Removing standard original equipment parts
and accessories may alter the warranty, traction,
and safety of the machine. Failure to use original
Exmark parts could cause serious injury or
death. Making unauthorized changes to the
engine or fuel system, may violate EPA and
CARB regulations.
Remove the key from the ignition switch, engage
parking brake, and pull the wire(s) off the spark
plug(s) before you do any maintenance. Also
push the wire(s) aside so it does not accidentally
contact the spark plug(s).
Replace all parts including, but not limited to,
tires, belts, blades, and fuel system components
with original Exmark parts.
WARNING
The 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
Maintenance Procedure
Interval
• Change the engine oil.
After the first 5 hours
After the first 50 hours
• Change the hydraulic system filter and oil.
• Check the safety interlock system.
• Check the oil level before starting or after every 8 hours.
• Check the mower blades.
• Clean the mower housing.
• Clean the engine and exhaust system area.
Before each use or daily
Every 25 hours
• Grease all lubrication points.
• Check the air cleaner for dirt, looseness, or damage. (May need more often under extremely
dusty or dirty conditions.)
• Check the tire pressure.
• Check the hydraulic oil level in the expansion tank.
• Check the belts.
• Service the paper element. (more often in dusty, dirty conditions)
• Change the engine oil and filter.
• Clean the blower housing. More often under dirty conditions.
• Replace the fuel filter.
Every 100 hours
Every 200 hours
• Replace the paper element. (more often in dusty, dirty conditions)
• Service the spark plug.
• Change the hydraulic system filter and oil.
• Replace the spark plug.
Every 400 hours
Every 500 hours
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Maintenance
Maintenance Service
Interval
Maintenance Procedure
• Charge the battery and disconnect the battery cables.
• Perform all maintenance procedures listed above before storage.
• Paint any chipped surfaces.
Before storage
• Check the battery charge.
• Inspect the emissions filter.
Monthly
Yearly
Important: Refer to your Engine Operator's Manual for additional maintenance procedures.
Premaintenance
Procedures
Periodic Maintenance
Lubrication
Raising the Seat
Make sure the motion control levers are locked in the
park position. Lift the seat forward.
Greasing the Bearings
Service Interval: Every 25 hours/Monthly
(whichever comes first)
The following components can be accessed by raising
the seat:
Grease Type: NGLI grade #2 multi-purpose gun
grease.
• Serial plate
• Service decal
• Seat adjustment bolts
• Fuel filter
G007184
• Battery and battery cables
1
Figure 21
1. Front caster tire
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to
engage parking brake, stop the engine, remove the
key, and wait for all moving parts to stop before
leaving the operating position.
a rag. Make sure to scrape any paint off of the
front of the fitting(s).
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Maintenance
Figure 22
Located on the seat pan
1. Read the instructions before servicing or performing
maintenance.
2. Check tire pressure every 25 operating hours.
3. Grease every 25 operating hours.
4. Engine
4. Wipe up any excess grease.
Figure 23
3. Hose clamp
1. Cover
Engine Maintenance
2. Paper element
Servicing the Air Cleaner
Service Interval: Every 25 hours/Monthly
(whichever comes first)
(May need more often
Cleaning the Element
Service Interval: Every 100 hours—Service
the paper element. (more
often in dusty, dirty
under extremely dusty or
dirty conditions.)
conditions)
Check the air cleaner daily or before starting the
engine. Check for a buildup of dirt and debris around
the air cleaner system. Keep this area clean. Also
check for loose or damaged components. Replace all
bent or damaged air cleaner components.
Every 200 hours/Yearly
(whichever comes
first)—Replace the paper
element. (more often in
dusty, dirty conditions)
1. Lightly tap the element on a flat surface to remove
dust and dirt.
Note: Operating the engine with loose or damaged
air cleaner components could allow unfiltered air into
the engine causing premature wear and failure.
2. Inspect the element for tears, an oily film, and
damage to the seal.
Note: Service the air cleaner more often under
extremely dusty, dirty conditions.
Important: Never clean the paper element
with pressurized air or liquids, such as
solvent, gas, or kerosene. Replace the paper
element if it is damaged or cannot be cleaned
thoroughly.
1. Park the machine on a level surface, disengage the
blade control switch, move the motion control
levers to the brake position, stop the engine, and
remove the key.
2. Clean around the air cleaner cover to prevent dirt
from getting into the engine and causing damage.
Lift the cover and remove the hose clamp securing
Servicing the Engine Oil
Checking the Oil Level
Service Interval: Before each use or daily
3. Loosen the hose clamp and remove the paper
1. Park the machine on a level surface, disengage
the blade control switch, stop the engine, engage
parking brake, and remove the key.
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Maintenance
2. Make sure the engine is stopped, level, and is cool Change the oil and filter while the engine is still
so the oil has had time to drain into the sump.
warm. The oil will flow more freely and carry away
more impurities. Make sure the engine is level when
filling, checking, or changing the oil.
3. To keep dirt, grass clippings, etc., out of
the engine, clean the area around the oil fill
cap/dipstick before removing it.
1. Start the engine and let it run until warm. This
warms the oil so it drains better.
4. Remove the oil fill cap/dipstick; wipe oil off.
Reinsert the dipstick push into place, but Do Not
2. Disengage the blade control switch and move the
motion controls outward to the parking brake
position.
3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
4. Clean the area around the oil drain valve and on
the machine frame.
5. Install the oil drain hose, located in the literature
the oil fill cap/dipstick.
Figure 24
1. Oil dipstick
2. Filler tube
3. Oil level
5. Remove the dipstick and check the oil level.
The oil level should be up to, but not over, the
“FULL” mark on the dipstick.
6. If the level is low, wipe off the area around the oil
fill cap, remove cap and add oil to the “FULL”
mark on the dipstick. Exmark 4-Cycle Premium
Engine Oil is recommended; refer to the Engine
Owner's manual for an acceptable alternative.
Always check the level with the dipstick before
adding more oil. Do Not overfill.
Figure 25
1. Oil filter
2. Oil fill cap/dipstick
4. Oil drain hose
5. Pan
3. Oil drain valve
Note: To prevent extensive engine wear or
damage, always maintain the proper oil level in the
crankcase. Never operate the engine with the oil
level below the “ADD” mark or over the “FULL”
mark on the dipstick.
6. Place a pan under the open end of the hose.
7. Open the drain valve by turning hex end
counterclockwise. Be sure to allow ample time
for complete drainage.
8. Remove the old filter and wipe off the mounting
pad.
Changing the Oil and Filter
Service Interval: After the first 5 hours
9. When the oil has drained completely, close the oil
drain valve by rotating it clockwise and remove
Every 100 hours/Yearly
(whichever comes first)
thereafter.
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Maintenance
and retain the hose. Wipe up any excess oil on
Note: Due to the deep recess around the spark
plug, blowing out the cavity with compressed air
is usually the most effective method for cleaning.
The spark plug is most accessible when the blower
housing is removed for cleaning.
Note: Dispose of the used oil at a recycling
center.
10. Apply a thin film of clean Exmark 4-Cycle
Premium Engine Oil to the rubber gasket on the
new filter.
3. Remove the spark plug and metal washer.
11. Install the replacement oil filter to the mounting
pad. Turn the oil filter clockwise until the rubber
gasket contacts the pad, then tighten the filter an
additional 1/2 to 3/4 turn.
12. Slowly pour approximately 80% of the specified
oil into the filler tube—use oil recommended in
the Checking the Oil Level section.
Figure 26
1. Spark plug and wire location
13. Install the oil fill cap/dipstick and push into place,
but Do Not screw it in.
Checking the Spark Plug
the Oil Level section.
If you see light brown or gray on the insulator, the
engine is operating properly. A black coating on
the insulator usually means the air cleaner is dirty.
15. Slowly add additional oil to bring it to the full
mark. Do Not overfill.
16. Install the oil fill cap/dipstick.
Important: Never clean the spark plug.
Always replace the spark plug when it has a
black coating, worn electrodes, an oily film,
or cracks.
17. Start the engine and check for leaks.
Servicing the Spark Plug
2. Check the gap between the center and side
the gap is not correct.
Service Interval: Every 200 hours/Every 2
years (whichever comes
first)
Every 500 hours—Replace
the spark plug.
As stated in the maintenance intervals, remove the
spark plug, check condition, and reset the gap or
replace with a new plug as necessary.
The spark plug is RFI compliant. Equivalent alternate
brand plugs can also be used.
Figure 27
Type: NGK BPR4ES (or equivalent)
Air Gap: 0.030 inch (0.76 mm)
1. Side electrode
3. Air gap (not to scale)
2. Center electrode
insulator
Removing the Spark Plug
1. Disengage the blade control switch, move the
motion controls outward to the park position,
stop the engine, and remove the key.
Installing the Spark Plug
1. Install the spark plug. Make sure that the air gap
is set correctly.
Clean around the spark plug to prevent dirt from
falling into the engine and potentially causing
damage.
2. Tighten the spark plug to 16 ft-lb (22 N-m).
34
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Maintenance
3. The fuel filter is in the fuel line between the tank
and engine.
Cleaning the Blower Housing
Service Interval: Every 100 hours/Yearly
(whichever comes first)
More often under dirty
conditions.
To ensure proper cooling, make sure the grass screen,
cooling fins, and other external surfaces of the engine
are kept clean at all times.
1. Remove the blower housing and any other cooling
shrouds.
2. Clean the cooling fins and external surfaces as
necessary.
3. Make sure the cooling shrouds are reinstalled
Important: Operating the engine with a blocked
grass screen, dirty or plugged cooling fins,
and/or cooling shrouds removed, will cause
engine damage due to overheating.
Figure 28
1. Tee fitting, vent line
5. In-line fuel filter
2. Emissions filter
3. Open port
6. Flow direction arrow
7. Fuel line to engine
4. Fuel line from tank
8. Hose clamp
Fuel System Maintenance
4. Squeeze the ends of the hose clamps together and
Replacing the Fuel Filter
5. Remove the filter from the fuel lines.
Service Interval: Every 100 hours/Yearly
(whichever comes first)
6. Install a new filter with the flow direction arrow
coming from the fuel tank and pointing to the
engine. Move the hose clamps close to the filter
DANGER
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
Servicing the Emissions
Filter
• Perform any fuel related maintenance when
the engine is cold. Do this outdoors in an
open area. Wipe up any gasoline that spills.
Service Interval: Yearly
The machine is equipped with a emissions filter
coming from the gas tank. The filter has an open port
by design. The filter should be inspected regularly.
Replace the filter if the filter is dirty or clogged.
• Never smoke when draining gasoline, and
stay away from an open flame or where a
spark may ignite the gasoline fumes.
Never install a dirty filter if it is removed from the
fuel line.
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to
engage parking brake, stop the engine, remove the
key, and wait for all moving parts to stop before
leaving the operating position.
35
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Maintenance
Electrical System
Maintenance
DANGER
Battery electrolyte contains sulfuric acid, which
is poisonous and can cause severe burns.
Swallowing electrolyte can be fatal or if it touches
skin can cause severe burns.
WARNING
CALIFORNIA
• Wear safety glasses to shield eyes, and rubber
gloves to protect skin and clothing when
handling electrolyte.
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the State of
California to cause cancer and reproductive
harm. Wash hands after handling.
• Do Not swallow electrolyte.
• In the event of an accident, flush with water
and call a doctor immediately.
CAUTION
Charging the Battery
If the ignition is in the “ON” position there
is potential for sparks and engagement of
components. Sparks could cause an explosion or
moving parts could accidentally engage causing
personal injury.
Removing the Battery
WARNING
Battery terminals or metal tools could short
against metal machine components causing
sparks. Sparks can cause the battery gasses to
explode, resulting in personal injury.
Be sure ignition switch is in the “OFF” position
before charging the battery.
1. Park the machine on a level surface and disengage
the blade control switch.
• When removing or installing the battery, Do
Not allow the battery terminals to touch any
metal parts of the machine.
2. Move the motion control levers outward to
engage parking brake stop the engine, remove the
key, and wait for all moving parts to stop before
leaving the operating position.
• Do Not allow metal tools to short between
the battery terminals and metal parts of the
machine.
3. Raise the seat.
4. Disconnect the negative (black) ground cable
fasteners.
DANGER
Charging or jump starting the battery may
produce explosive gases. Battery gases can
explode causing serious injury.
• Keep sparks, flames, or cigarettes away from
battery.
• Ventilate when charging or using battery in
an enclosed space.
• Make sure venting path of battery is always
open once battery is filled with acid.
• Always shield eyes and face from battery.
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Maintenance
Note: To prevent damage due to freezing,
battery should be fully charged before putting
away for winter storage.
3. Check the voltage of the battery with a digital
voltmeter. Locate the voltage reading of the
battery in the table below and charge the battery
for the recommended time interval to bring the
charge up to a full charge of 12.6 volts or greater.
Important: Make sure the negative battery
cable is disconnected and the battery charger
used for charging the battery has an output of
16 volts and 7 amps or less to avoid damaging
the battery (see chart below for recommended
charger settings).
Figure 29
1. Negative battery post
Voltage
Reading
Percent
Charge
Maximum Charging
Charger
Settings
Interval
4. Positive battery post
5. Battery strap
6. Battery
2. Bolt, washer, and nut
3. Terminal boot
12.6 or
greater
100%
No
Charging
Required
16 volts/7
amps
12.4 – 12.6 75–100%
12.2 – 12.4 50–75%
30 Minutes
16 volts/7
amps
WARNING
Incorrect battery cable routing could damage
the machine and cables causing sparks.
Sparks can cause the battery gasses to
explode, resulting in personal injury.
1 Hour
16 volts/7
amps
12.0–12.2
11.7–12.0
25–50%
0–25%
2 Hours
3 Hours
14.4 volts/4
amps
• Always disconnect the negative (black)
battery cable before disconnecting the
positive (red) cable.
14.4 volts/4
amps
11.7 or less 0%
6 Hours or
More
14.4 volts/2
amps
• Always connect the positive (red) battery
cable before connecting the negative
(black) cable.
Recommended Jump Starting
Procedure
5. Slide the rubber cover up the positive (red) cable.
Disconnect the positive (red) cable from the
battery post. Retain all fasteners.
1. Check the weak battery for terminal corrosion
(white, green, or blue “snow”), it must be cleaned
off prior to jump starting. Clean and tighten
connections as necessary.
battery from the battery tray.
Checking the Battery Charge
1. Remove the battery from the chassis; refer to
CAUTION
Corrosion or loose connections can cause
unwanted electrical voltage spikes at anytime
during the jump starting procedure.
Removing the Battery.
2. Allowing batteries to stand for an extended
period without recharging them will result in
reduced performance and service life. To preserve
optimum battery performance and life, recharge
batteries in storage when the open circuit voltage
drops to 12.4 volts.
Do Not attempt to jump start with loose or
corroded battery terminals or damage to the
engine may occur.
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Maintenance
DANGER
Jump starting a weak battery that is cracked,
frozen, has low electrolyte level, or an
open/shorted battery cell, can cause an
explosion resulting in serious personal injury.
Do Not jump start a weak battery if these
conditions exist.
2. Make sure the booster is a good and fully charged
lead acid battery at 12.6 volts or greater. Use
properly sized jumper cables (4 to 6 AWG) with
short lengths to reduce voltage drop between
systems. Make sure the cables are color coded or
labeled for the correct polarity.
Figure 30
1. Positive (+) cable on discharged battery
2. Positive (+) cable on booster battery
3. Negative (–) cable on the booster battery
4. Negative (–) cable on the engine block
5. Booster battery
CAUTION
6. Discharged battery
Connecting the jumper cables incorrectly
(wrong polarity) can immediately damage the
electrical system.
7. Engine block
4. Connect the other end of the positive cable to the
positive terminal of the booster battery.
Be certain of battery terminal polarity and
jumper cable polarity when hooking up
batteries.
5. Connect the black negative (–) cable to the other
terminal (negative) of the booster battery.
Note: The following instructions are adapted
from the SAE J1494 Rev. Dec. 2001 – Battery
Booster Cables – Surface Vehicle Recommended
Practice (SAE – Society of Automotive
Engineers).
6. MAKE THE FINAL CONNECTION ON
THE ENGINE BLOCK OF THE STALLED
VEHICLE (NOT TO THE NEGATIVE POST)
AWAY FROM THE BATTERY. STAND BACK.
7. Start the vehicle and remove the cables in the
reverse order of connection (the engine block
(black) connection is the first to disconnect).
WARNING
Batteries contain acid and produce explosive
gases.
Installing the Battery
• Shield the eyes and face from the batteries
at all times.
1. Position the battery in the tray with the terminal
• Do Not lean over the batteries.
2. Install the positive (red) battery cable to the
positive (+) battery terminal using the fasteners
removed previously.
Note: Be sure the vent caps are tight and level.
Place a damp cloth, if available, over any vent
caps on both batteries. Be sure the vehicles do
not touch and that both electrical systems are
off and at the same rated system voltage. These
instructions are for negative ground systems only.
3. Install the negative battery cable to the negative
(-) battery terminal using the fasteners removed
previously.
4. Slide the red terminal boot onto the positive (red)
battery post.
3. Connect the positive (+) cable to the positive (+)
terminal of the discharged battery that is wired to
38
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Maintenance
Front Tires (caster wheels):
• Ribbed: 13 psi (90 kPa)
• Smooth: 20 psi (138 kPa)
Servicing the Fuses
Service Interval: As required
The electrical system is protected by fuses. It requires
no maintenance; however, if a fuse blows, check the
component/circuit for a malfunction or short.
Fuse:
• Main F1-30 amp, blade-type
• Charge Circuit F2-25 amp, blade-type
1. Remove the four screws securing the control
panel to the machine. Retain all fasteners
2. Lift the control pane up to access the main wiring
Figure 32
1. Valve stem
3. To replace a fuse, pull out on the fuse to remove
Releasing the Electric Brake
Service Interval: As required
The electric brake can be release by manually rotating
the link arms forward. Once the electric brake is
energized the brake will reset.
To release the brake:
Figure 31
1. Main-30 amp
2. Charge circuit-25 amp
4. Return the control panel to its original position.
Use the four screws removed previously to secure
the panel to the machine.
Drive System Maintenance
Checking the Tire Pressure
Figure 33
1. Brake link arm on the electric brake control module
Service Interval: Every 25 hours/Monthly
(whichever comes first)
1. Locate the shaft on the electric brake where the
brake link arms are connected.
Maintain the air pressure in the front and rear tires as
specified. Uneven tire pressure can cause uneven cut.
2. Rotate the shaft forward to release the brake.
Checking the Hydraulic Oil
Level
Check the tires when they are cold to get the most
accurate pressure reading.
Rear Tires: 13 psi (90 kPa)
Service Interval: Every 25 hours
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Maintenance
Check expansion reservoir and if necessary add
20W-50 engine oil to the FULL COLD line.
Figure 35
1. Jacking points
3. Remove the nuts holding the transaxle support in
Figure 34
1. Expansion reservoir
2. Full Cold line
3. Engine
Changing the Hydraulic
System Filter and Oil
Service Interval: After the first 50 hours
Every 400 hours thereafter.
The filter and oil are changed at the same time. Do
Not reuse oil. Once the new filter is installed and oil
is added any air in the system must be purged.
The bleeding process is repeated until the oil remains
at the FULL COLD line in the reservoir after purging.
Failure to properly perform this procedure can
result in irreparable damage to the transaxle
drive system.
Figure 36
1. Nut (5/16 inch) (27 to 33 3. Transaxle support
ft-lb)
Removing Hydraulic System Filters
2. Nut (3/8 inch) (15 to 19
ft-lb)
1. Stop engine, wait for all moving parts to stop, and
allow engine to cool. Remove the key and engage
the parking brake.
4. Locate the filter and filter guards on each transaxle
securing the filter guard and guard.
2. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
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Maintenance
Installing the Hydraulic System
Filters
Figure 37
Right side shown
1. Transaxle drive
2. Oil filter
4. Screws
5. Vent plug
3. Filter guard
5. Carefully clean area around filters. It is important
that no dirt or contamination enter hydraulic
system.
6. Place a container below the filter to catch the
oil that drains when the filter and vent plugs are
removed.
Figure 38
7. Locate and remove the vent plug on each
transmission
1. Apply a thin coat of oil on the surface of the
rubber seal of each filter.
8. Unscrew the filter to remove and allow oil to
drain from drive system.
2. Turn the filter clockwise until rubber seal contacts
the filter adapter then tighten the filter an
additional 3/4 to 1 full turn. Repeat for the other
filter
Repeat this procedure for both filters.
3. Install the filter guards over each filter as
previously removed. Use the three screws to
secure the filter guards.
4. Verify the vent plugs are removed before adding
the oil.
5. Slowly pour the specified oil through expansion
reservoir until oil comes out of one of the vent
plug holes. Stop and install that vent plug. Torque
the plug to 180 in-lb (20.3 N-m).
6. Continue to add oil through the expansion
reservoir until oil comes out of the remaining
vent plug hole on the second transmission. Stop
41
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Maintenance
and install that vent plug. Torque the plug to 180
in-lb (20.3 N-m).
Mower Maintenance
7. Continue to add oil through the expansion
reservoir until it reaches the FULL COLD line on
the expansion reservoir.
Servicing the Cutting Blades
Service Interval: Before each use or daily
the correct torque values for the nuts and bolts.
Maintain sharp blades throughout the cutting season
because sharp blades cut cleanly without tearing or
shredding the grass blades. Tearing and shredding
turns grass brown at the edges, which slows growth
and increases the chance of disease.
9. Proceed to the Bleeding the Hydraulic System
section.
Important: Failure to perform the Bleeding
the Hydraulic System procedure after
changing hydraulic filters and oil can result
in irreparable damage to the transaxle drive
system.
Check the cutter blades daily for sharpness, and for
any wear or damage. File down any nicks and sharpen
the blades as necessary. If a blade is damaged or
worn, replace it immediately with a genuine Exmark
replacement blade. For convenient sharpening and
replacement, you may want to keep extra blades on
hand.
Bleeding the Hydraulic System
1. Enter the operator's position. Start engine and
move throttle control ahead to 1/2 throttle
position. Disengage parking brake.
WARNING
A worn or damaged blade can break, and a piece
of the blade could be thrown into the operator's
or bystander's area, resulting in serious personal
injury or death.
A. Move the bypass levers into the pushing the
machine position; refer to the Pushing the
Machine by Hand section in Operation. With
the bypass valves open and the engine running,
slowly move the motion control levers in both
forward and reverse (5 or 6 times).
• Inspect the blade periodically for wear or
damage.
• Replace a worn or damaged blade.
B. Move the bypass levers into the operating
the machine position. With the bypass valve
closed and the engine running, slowly move
the directional control in both forward and
reverse directions (5 to 6 times).
Before Inspecting or Servicing the
Blades
Park the machine on a level surface, disengage the
blade control switch, and move the motion control
levers outward to engage parking brake. Stop the
engine, remove the key, and disconnect the spark plug
wire(s) from the spark plug(s).
C. Stop the engine and check the oil level in the
expansion reservoir. Add the specified oil as
until it reaches the FULL COLD line on the
expansion reservoir.
2. Repeat step 1 until all the air is completely purged
from the system.
Inspecting the Blades
are not sharp or have nicks, remove and sharpen
the blades; refer to Sharpening the Blades.
When the transaxle operates at normal noise
levels and moves smoothly forward and reverse at
normal speeds, then the transaxle is considered
purged.
2. Inspect the blades, especially the curved area. If
you notice any damage, wear, or a slot forming in
a new blade.
3. Check the oil level in the expansion reservoir one
last time. Add the specified oil as until it reaches
the FULL COLD line on the expansion reservoir
if necessary.
42
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Maintenance
Figure 39
3. Wear/slot forming
4. Damage
1. Cutting edge
2. Curved area
Figure 41
1. Blade, in position for measuring
2. Level surface
3. Measured distance between blade and surface (A)
Checking for Bent Blades
Note: The machine must be on a level surface for
the following procedure.
4. Rotate the same blade 180 degrees so that the
opposing cutting edge is now in the same position.
1. Raise the mower deck to the highest height-of-cut
position; also considered the 'transport' position.
2. While wearing thickly padded gloves or other
adequate hand protection slowly rotate blade to
be measure into a position that allows effective
measurement of the distance between the cutting
edge and the level surface the machine is on.
Figure 42
1. Blade, side previously measured
2. Measurement position used previously
3. Opposing side of blade being moved into measurement
position
5. Measure from the tip of the blade to the flat
surface here. The variance should be no more
than 1/8 inch (3mm).
Figure 40
1. Deck
2. Spindle housing
3. Blade
3. Measure from the tip of the blade to the flat
surface here.
43
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Maintenance
thickly padded glove, try to rotate the blade. If the
blade rotates relative to the spindle guard without
further tightening the blade bolt, the spring
disc washer has been flattened or damaged and
the bolt and washer assembly must be replaced
Installing the Blades.
3. Once the blade has been removed, inspect the
spring disc washer. If the washer appears to be
damaged (the washer surface has been marred)
or flattened, the bolt and washer assembly must
be replaced.
Figure 43
1. Opposing blade edge, in position for measuring
2. Level surface
3. Second measured distance between blade and surface
(B)
Removing the Blades
The blades must be replaced if a solid object is hit, if
the blade is out of balance, or the blade is bent. To
ensure optimum performance and continued safety
conformance of the machine, use genuine Exmark
replacement blades. Replacement blades made by
other manufacturers may result in an unsafe machine.
WARNING
A worn or damaged blade can break, and a
piece of the blade could be thrown into the
operator's or bystander's area, resulting in
serious personal injury or death.
Hold the blade end using a rag or thickly-padded
glove. Remove the blade bolt, curved washer, and
• Inspect the blade periodically for wear or
damage.
• Replace a worn or damaged blade.
A. If the difference between A and B is greater
than 1/8 inch (3mm) replace the blade with a
new blade. Refer to Removing the Blades and
Installing the Blades.
Note: If a bent blade is replaced with a new
one and the dimension obtained continues
to exceed 1/8 inch (3mm), the blade spindle
could be bent. Contact an Authorized Exmark
Dealer for service.
Figure 44
1. Sail area of blade
2. Blade
3. Curved washer
4. Blade bolt
B. If the variance is within constraints, move to
the next blade.
Repeat this procedure on each blade.
Sharpening the Blades
1. Use a file to sharpen the cutting edge at both ends
angle. The blade retains its balance if the same
amount of material is removed from both cutting
edges.
Checking for Loose Blades or
Damaged Spring Disc Washers
1. Place a wrench on the blade bolt and torque to
35-65 ft-lb (47-88 N-m).
2. With the wrench still on the blade bolt, hold
the blade spindle stationary and using a rag or
44
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Maintenance
Leveling the Mower Deck
Check to ensure the mower deck is level any time
you install the mower or when you see an uneven cut
on your lawn.
Figure 45
1. Sharpen at original angle
The mower deck must be checked for bent blades
prior to leveling; any bent blades must be removed
and replaced. Refer to the Checking for Bent
Blades procedure before continuing.
2. Check the balance of the blade by putting it on a
horizontal position, the blade is balanced and can
be used. If the blade is not balanced, file some
Repeat this procedure until the blade is balanced.
The mower deck must be leveled side-to-side first
then the front to rear slope can be adjusted.
Requirements:
• The machine must be on a level surface.
• All four tire must be properly inflated. Refer to
Checking the Tire Pressure in the Drive System
Maintenance section.
Side-to-Side Leveling
1. Park the machine on a level surface and disengage
the blade control switch.
Figure 46
1. Blade
2. Balancer
2. Move the motion control levers outward to the
park position, stop the engine, remove the key,
and wait for all moving parts to stop before
leaving the operating position.
Installing the Blades
3. Set the height-of-cut lever to middle position.
Important: The curved part of the blade
must be pointing upward toward the inside of
the mower to ensure proper cutting.
4. Carefully rotate the blades so that they are all side
2. Hold the blade end using a rag or thickly-padded
glove (or place a wrench on the top sheave nut).
Apply lubricant to the threads of the blade bolt
as needed to prevent seizing. Copper based
anti-seize is preferable. Grease is an acceptable
substitute. Install the washer and blade bolt and
washer assembly.
3. Torque the blade bolt to 35-65 ft-lb (47-88 N-m).
WARNING
Incorrect installation of the blade or
components used to retain the blade cause
the blade to come loose and could seriously
injure or kill you or bystanders.
Figure 47
42 Inch Decks
1. Blades side to side
2. Sail area of blade
3. Outside cutting edges
Always install the original Exmark blades,
washers and blade bolts as shown.
4. Measure from the tip
of the blade to the flat
surface here
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Maintenance
Figure 48
50 Inch Decks
Figure 49
4. Side locking nut
5. Side carriage bolt
1. Hanger bracket
1. Blades side to side
2. Sail area of blade
3. Outside cutting edges
2. Slotted adjustment
position
4. Measure from the tip
of the blade to the flat
surface here
3. Fixed position
5. Measure between the outside cutting edges and
measurements are not within 3/16 inch (5 mm),
an adjustment is required; continue with this
procedure.
8. Loosen the side locking nut on the hanger bracket
just enough to allow the hanger to be adjusted
bracket to measure the amount of adjustment.
Each notch surface is equivalent to 1/16 of an
inch. Adjust the height of the mower deck to the
desired height.
6. Support the weight of mower deck by placing
wood blocks under the edges of the deck.
Note: Avoid placing the supports under any
anti-scalp rollers if present on the deck.
7. Move to the left side of the machine. Remove
the side carriage bolt and locking nut from the
fixed position and install it into the rear, slotted
Figure 50
1. Hanger bracket
2. Rear locking nut
3. Side locking nut
4. Adjustment notches
9. Stop the deck at the adjusted position and tighten
the side locking nut on the hanger bracket to hold
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Maintenance
locking nut on the hanger bracket.
10. Continue leveling the deck by checking the
front-to-rear blade slope; refer to Adjusting the
Front-to-Rear Blade Slope.
Adjusting the Front-to-Rear Blade
Slope
Figure 52
50 Inch Decks
Check the front-to-rear blade level any time you install
the mower. If the front of the mower is more than
5/16 inch (7.9 mm) lower than the rear of the mower,
adjust the blade level using the following instructions:
1. Blades front to rear
2. Outside cutting edges
3. Measure from the tip of the blade to the flat surface here
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
park position, stop the engine, remove the key,
and wait for all moving parts to stop before
leaving the operating position.
5. Measure from the tip of the front blade to the flat
surface and the tip of the rear blade to the flat
blade tip is not 1/16-5/16 inch (1.6-7.9 mm) lower
than the rear blade tip, adjust the front locknut.
3. Set the height-of-cut lever to middle position.
6. To adjust the front-to-rear blade slope, rotate
the adjustment nut in the front of the mower
Note: Check and adjust the side-to-side blade
level if you have not checked the setting; refer to
Side-to-Side Leveling.
4. Carefully rotate the blades so they are facing front
Figure 51
42 Inch Decks
1. Blades front to rear
2. Measure from the tip of the blade to the flat surface here
Figure 53
1. Adjusting rod
3. Lock nut
2. Adjusting block
7. To raise the front of the mower, tighten the
adjustment nut. To lower the front of the mower,
loosen the adjustment nut.
8. After adjustment, check the front-to-rear slope
again. Continue adjusting the nut until the front
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Maintenance
blade tip is 1/16-5/16 inch (1.6-7.9 mm) lower
9. When the front-to-rear blade slope is correct
check the side-to-side level of the mower again;
refer to Leveling the Mower from Side-to-Side.
Removing the Mower
Service Interval: As required
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
park position, stop the engine, remove the key,
and wait for all moving parts to stop before
leaving the operating position.
Figure 55
3. Rear lift rod
1. Mower deck
2. Hanger bracket
3. Lower the height-of-cut lever to the lowest
position.
4. Remove the hairpin cotter from the front support
rod and remove the rod from the deck bracket
mower deck to the ground.
6. Slide the mower deck rearward to remove the
mower belt from the engine pulley.
7. Slide the mower deck out from underneath the
machine.
Note: Retain all parts for future installation.
Mower Belt Maintenance
Inspecting the Belts
Service Interval: Every 25 hours/Monthly
(whichever comes first)
Check the belts for cracks, frayed edges, burn marks,
or any other damage. Replace damaged belts.
Replacing the Mower Belt
Squealing when the belt is rotating, blades slipping
when cutting grass, frayed belt edges, burn marks,
and cracks are signs of a worn mower belt. Replace
the mower belt if any of these conditions are evident.
Figure 54
1. Park the machine on a level surface and disengage
the blade control switch.
1. Front support rod
2. Locking nut
3. Deck bracket
2. Move the motion control levers outward to the
park position, stop the engine, remove the key,
and wait for all moving parts to stop before
leaving the operating position.
5. Lift the mower deck and hanger brackets clear of
the rear lift rod and lower the mower carefully to
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Maintenance
3. Set the height-of-cut at the lowest cutting position
[1-1/2 inch (38 mm)].
4. Using a spring removal tool, (P/N. 92-5771),
remove the idler spring from the deck hook to
remove tension on the idler pulley and roll the
WARNING
The spring is under tension when installed
and can cause personal injury.
Be careful when removing the belt.
Figure 57
50 Inch Deck
1. Idler pulley
2. Mower belt
3. Outside pulley
4. Spring
5. Engine pulley
6. Spring removal tool
5. Route the new belt around the engine pulley and
6. Using a spring removal tool, (P/N 92-5771),
install the idler spring over the deck hook and
placing tension on the idler pulley and mower belt
Figure 56
42 Inch Deck
Installing the Mower
Service Interval: As required
1. Idler pulley
2. Mower belt
3. Outside pulley
4. Spring
5. Engine pulley
6. Spring removal tool
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
park position, stop the engine, remove the key,
and wait for all moving parts to stop before
leaving the operating position.
3. Slide the mower under the machine.
4. Lower the height-of-cut lever to the lowest
position.
5. Lift the rear of the mower deck and guide the
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Maintenance
6. Attach the front support rod to the mower deck
7. Install the mower belt onto the engine pulley;
4. Replace the discharge deflector.
5. Slide rod, straight end, through the rear
discharge deflector bracket.
refer to Replacing the Mower Belt.
6. Place the spring on the rod, with end wires
down, and between the discharge deflector
brackets. Slide rod through second discharge
deflector bracket.
Replacing the Discharge
Deflector
7. Insert rod at front of discharge deflector into
short stand-off on deck. Secure rear end of
rod into the mower with a nut (3/8 inch).
DANGER
An uncovered discharge opening could allow the
lawn mower to throw objects in the operator’s or
bystander’s direction and result in serious injury.
Also, contact with the blade could occur.
Important: The discharge deflector must
be spring loaded in the down position.
Lift the deflector up to test that it snaps to
the full down position.
Never operate the lawn mower unless you install
a mulch plate, discharge deflector, or grass
collection system.
• 50 inch S-Series Deck
1. Disengage the spring from the notch in the
deflector bracket and slide the rod out of the
welded deck brackets, spring, and discharge
worn discharge deflector.
Inspect the discharge deflector for damage before
each use. Replace any damaged parts before use.
• 42 inch and 50 inch E-Series Deck
Figure 58
1. Mower deck
5. Spring
2. Discharge deflector
6. Nut (3/8 inch)
7. Short stand-off
3. Discharge deflector
bracket
4. Rod
2. Remove the nut (3/8 inch) from the rod under
the mower.
3. Slide the rod out of the short stand-off,
spring, and discharge deflector . Remove the
damaged or worn discharge deflector.
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Maintenance
Figure 60
1. Rod and spring
assembly installed
3. Rod, short end, moved
behind mower bracket
2. Loop end of the spring
installed into the notch in
the deflector bracket
4. Short end, retained by
mower bracket.
5. Secure the rod and spring assembly by twisting
it so the short end of the rod can be placed
behind the front bracket welded to the deck
Figure 59
4. Deck brackets
Important: The grass deflector must be
spring loaded in the down position. Lift
the deflector up to test that it snaps to the
full down position.
1. Rod
2. Spring
5. Spring installed over the
rod
3. Deflector assembly
2. Position the new discharge deflector assembly
with the bracket ends between the welded
3. Install the spring onto the straight end of the
rod. Position the spring on the rod as shown
in so the shorter spring end is coming from
under the rod before the bend and going over
the rod as it returns from the bend.
4. Lift the loop end of the spring and place
it into the notch on the deflector assembly
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Maintenance
6. Disengage the blade control switch, stop the
engine, and remove the ignition key. Wait for all
moving parts to stop.
Cleaning
Washing the Underside of
the Mower
Service Interval: Before each use or
daily—Clean the mower
housing.
7. Turn the water off and remove the coupling from
the washout fitting.
Note: If the mower is not clean after one
washing, soak it and let it stand for 30 minutes.
Then repeat the process.
8. Run the mower again for one to three minutes
to remove excess water.
Wash the underside of the mower after each use to
prevent grass buildup for improved mulch action and
clipping dispersal.
WARNING
1. Park the machine on a level surface and disengage
the blade control switch.
A broken or missing washout fitting could
expose you and others to thrown objects or
blade contact. Contact with blade or thrown
debris can cause injury or death.
2. Move the motion control levers outward to the
park position, stop the engine, remove the key,
and wait for all moving parts to stop before
leaving the operating position.
• Replace broken or missing washout fitting
immediately, before using mower again.
3. Attach the hose coupling to the end of the mower
washout fitting, and turn the water on high
• Never put your hands or feet under the
mower or through openings in the mower.
Note: Spread petroleum jelly on the washout
fitting O-ring to make the coupling slide on easier
and protect the O-ring.
Clean Engine and Exhaust
System Area
Service Interval: Before each use or daily
(May be required more
often in dry or dirty
conditions.)
CAUTION
Excessive debris around engine cooling air
intake and exhaust system area can cause engine,
exhaust area, and hydraulic system to overheat
which can create a fire hazard.
Clean all debris from engine and exhaust system
area.
Figure 61
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
1. Washout fitting
2. Hose
3. O-ring
4. Coupling
2. Clean all debris from rotating engine air intake
screen, around engine shrouding, and exhaust
system area.
4. Lower the mower to the lowest height-of-cut.
3. Wipe up any excessive grease or oil around the
engine and exhaust system area.
5. Sit on the seat and start the engine. Engage the
blade control switch and let the mower run for
one to three minutes.
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Storage
Stop the engine, allow it to cool, and drain the
fuel tank; refer to Draining the Fuel Tank in the
Fuel System Maintenance section.
Storage
Cleaning and Storage
Restart the engine and run it until it stops.
1. Disengage the blade control switch, move the
motion controls outward to the park position,
stop the engine, and remove the key.
Choke the engine. Start and run the engine until
it will not start.
Dispose of fuel properly. Recycle pursuant to
local codes.
2. Remove grass clippings, dirt, and grime from the
external parts of the entire machine, especially the
engine. Clean dirt and chaff from the outside of
the engine cylinder head fins and blower housing.
Important: Do not store
stabilizer/conditioned gasoline over
30 days.
Important: You can wash the machine with
mild detergent and water. Do not pressure
wash the machine. Avoid excessive use of
water, especially near the control panel, under
the seat, around the engine, hydraulic pumps,
and motors.
11. Remove the spark plug(s) and check its condition;
refer to Servicing the Spark Plug in the Engine
Maintenance section. With the spark plug(s)
removed from the engine, pour two tablespoons
of engine oil into the spark plug hole. Use the
starter to crank the engine and distribute the oil
inside the cylinder. Install the spark plug(s). Do
not install the wire on the spark plug(s).
3. Service the air cleaner; refer to Servicing the Air
Cleaner in the Engine Maintenance section.
4. Grease and oil the machine; refer to the
Lubrication section.
12. Clean any dirt and chaff from the top of the
mower.
5. Change the crankcase oil and filter; refer
to Servicing the Engine Oil in the Engine
Maintenance section.
13. Scrape any heavy buildup of grass and dirt from
the underside of the mower, then wash the mower
with a garden hose.
6. Check the tire pressure; refer to Checking the
Tire Pressure in the Drive System Maintenance
section.
14. Check the condition of the drive and mower belts.
15. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is worn or
damaged.
7. Charge the battery; refer to Servicing the Battery
in the Electrical System Maintenance section.
16. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
8. Check the condition of the blades; refer to
Servicing the Cutting Blades in the Mower
Maintenance section.
17. Store the machine in a clean, dry garage or storage
area. Remove the key from the ignition switch and
keep it in a memorable place. Cover the machine
to protect it and keep it clean.
9. Prepare the machine for storage when non-use
occurs over 30 days. Prepare the machine for
storage as follows.
10. Add a petroleum based stabilizer/conditioner
to the fuel in the tank. Follow the mixing
instructions from the stabilizer manufacturer. Do
not use an alcohol based stabilizer (ethanol or
methanol).
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh gasoline and used
at all times.
Run the engine to distribute the conditioned fuel
through the fuel system (5 minutes).
53
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Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be
caused by an empty fuel tank.
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors DO Not pull on the wires to separate the connectors.
Problem
The engine overheats.
Possible Cause
Corrective Action
1. Reduce ground speed.
1. The engine load is excessive.
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.
5. Dirt, water, or stale fuel is in fuel system.
4. Clean or replace the air cleaner element.
5. Contact an Authorized Service Dealer.
The starter does not crank
1. The blade control switch is engaged.
1. Move the blade control switch to
Disengaged.
2. The motion control levers are not in the
park position.
2. Move the motion control levers outward
to the park position.
3. The operator is not seated.
3. Sit on the seat.
4. Battery does not have a full charge.
4. Charge the battery. See Check
Battery Charge and Recommended
Jump Starting Procedure sections in
Maintenance.
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.
7. A relay or switch is damaged.
7. Contact an Authorized Service Dealer.
Engine will not start, starts hard, or fails to
keep running
1. Fuel tank is empty.
1. Fill the fuel tank.
2. The choke is not on.
3. The air cleaner is dirty.
4. The spark plug wire(s) is loose or
disconnected.
2. Move the choke lever to On.
3. Clean or replace the air cleaner element.
4. Install the wire(s) on the spark plug.
5. The spark plug(s) is pitted, fouled, or the
gap is incorrect.
5. Install a new, correctly gapped spark
plug(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 with
the proper type.
9. The oil level in the crankcase is low.
9. Add oil to the crankcase.
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Troubleshooting
Problem
Engine loses power
Possible Cause
Corrective Action
1. Engine load is excessive.
1. Reduce the ground speed.
2. Air cleaner is dirty.
3. Oil level in the crankcase is low.
2. Clean or replace the air cleaner element.
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. 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 with
the proper type.
The machine does not drive.
Abnormal vibration
1. The drive belts are worn, loose, or broken. 1. Contact an Authorized Service Dealer.
2. The drive belts are off of the pulleys.
3. The drive is in bypass mode.
2. Contact an Authorized Service Dealer.
3. Take machine out of bypass mode. Refer
to Pushing the Machine by Hand
section.
1. Engine mounting bolts are loose.
1. Tighten the engine mounting bolts.
2. Tighten the appropriate pulley.
2. Loose engine pulley, idler pulley, or blade
pulley.
3. Engine pulley is damaged.
4. Cutting blade(s) is/are bent or unbalanced.
5. Blade is loose.
3. Contact an Authorized Service Dealer.
4. Install new cutting blade(s).
5. Tighten the blade mounting bolt and
inspect the blade spring disc washer for
damage (See Servicing the Cutting
Blades section).
6. Blade spindle is bent.
1. Blade(s) not sharp.
6. Contact an Authorized Service Dealer.
Uneven cutting height.
1. Sharpen the blade(s).
2. Install new cutting blade(s).
2. Cutting blade(s) is/are bent.
3. A blade is loose.
3. Tighten the blade mounting bolt and
inspect the blade spring disc washer for
damage (See Servicing the Cutting
Blades section).
4. Mower deck is not level.
4. Level mower deck from side-to-side and
front-to-rear.
5. An anti-scalp wheel is not set correctly
6. Underside of mower is dirty.
7. Tire pressure in drive tires not correct.
8. Blade spindle bent.
5. Adjust the anti-scalp wheel height.
6. Clean the underside of the mower.
7. Adjust tire pressure.
8. Contact an Authorized Service Dealer.
Blades do not rotate.
1. Drive belt is worn, loose or broken.
2. Drive belt is off pulley.
1. Install new drive belt.
2. Install drive belt and check adjusting
shafts and belt guides for correct position.
3. The mower belt is worn, loose, or broken. 3. Install a new mower belt.
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Schematics
Electrical Logic Schematic
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Exmark Quest Turf Equipment
3-Year Limited Consumer Warranty
(30-Day Limited Commercial Warranty)
Consumer Warranty Conditions and Products Covered
Instructions for Obtaining Warranty Service
The product must be registered with original proof of purchase by an
Exmark Service Dealer before obtaining any warranty service.
Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty Company,
pursuant to an agreement between them, jointly warrant on the terms
and conditions herein, that we will repair, replace or adjust any part
on these products and found by us (in the exercise of our reasonable
discretion) to be defective in factory materials or workmanship for a
period of three years for residential usage of Exmark Quest turf
equipment.
Contact any Exmark Service Dealer to arrange service at their
dealership. To locate a dealer convenient to you, access our website at
402-223-6375.
If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:
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 Customer Service Department
The Exmark Warranty Company
2101 Ashland Avenue
Beatrice, NE 68310
402-223-6375 or
This warranty applies to Exmark Quest turf equipment sold in the
U.S. or Canada. This warranty may only be assigned or transferred to
a second (or third) owner by an authorized Exmark dealer. The
warranty period commences upon the date of the original retail
purchase.
Owner’s Responsibilities
Warranty Exceptions
• Bags, Belts and Tires
• Battery
Warranty Period
90 days
1 Year Prorated
*
If your product requires warranty service it must be returned to an
authorized Exmark service dealer within the warranty period. This
warranty extends only to turf equipment operated under normal
conditions. You must read the operator’s manual. You must also
properly service and maintain your Exmark product as described in
the operator’s manual. Such routine maintenance, whether performed
by a dealer or by you, is at your expense.
• Engine
* Please refer to the manufacturer’s warranty statement that is
included in the literature packet.
This warranty only includes the cost of parts and labor. For the first
warrantable service repair, Exmark will cover up to $45 for
associated pick-up and delivery charges to and from any authorized
Exmark Service Dealer. Additional transportation charges may apply,
contact your Dealer for details.
General Conditions
The sole liability of Exmark and Exmark Warranty Company with
respect to this warranty shall be repair or replacement of defective
components as set forth herein. Neither Exmark nor Exmark
Warranty Company shall be liable for any incidental or
consequential loss or damage.
Limited Warranty for Commercial Use
Exmark Quest turf equipment used for commercial, institutional, or
rental use are warranted against defects in materials or workmanship
for a period of 30 days from the date of original purchase.
Such damages include but are not limited to:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other extraordinary
repair charges or charges relating to repairs or replacements
outside of normal business hours at the place of business of the
authorized Exmark Service Dealer.
Warranty Exception
• Engines
Warranty Period
*
* Please refer to the manufacturer’s warranty statement that is
included in the literature packet.
• 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.
Items and Conditions Not Covered
This warranty does not cover the following:
• Pickup and delivery charges to and from any authorized Exmark
Service Dealer beyond first warrantable service.
• Any damage or deterioration due to normal use, wear and tear, or
exposure.
• Cost of regular maintenance service or parts, such as filters, fuel,
lubricants, tune-up parts, and adjustments.
• Any product or part which has been altered or misused or required
replacement or repair due to normal wear, accidents, or lack of
proper maintenance.
No Claim of breach of warranty shall be cause for cancellation or
rescission of the contract of sale of any Exmark mower.
• 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.
All implied warranties of merchantability (that the product is fit
for ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.
There are no other express warranties except for engine and special
emission system coverage.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
All warranty work must be performed by an authorized Exmark
Service Dealer using Exmark approved replacement parts.
This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
G4500-750_A
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Notes:
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Notes:
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Service Record
Date:
Description of Work Done:
Service Done By:
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Figure 62
This page may be copied for personal use.
1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope indicator to determine the
degree of slope of hills before operating. Do Not operate this machine on a slope greater than 15 degrees. Fold
along the appropriate line to match the recommended slope.
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.
3. Example of how to compare slope with folded edge.
63
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EXMARK ACCESSORIES AND OPTIONS*
MID-MOUNT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
FULL SUSPENSION SEAT
DECK LIFT ASSIST KIT
HITCH KIT
OPERATOR CONTROLLED DISCHARGE
SUN SHADE
TRASH CONTAINER
TURF STRIPER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
12V POWER PORT
MICRO-MULCH SYSTEM
OUT-FRONT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
DUAL-TAIL WHEEL
SNOW BLADE
SNOWBLOWER
FLOOR PAN EXTENDER
HITCH KIT
SUN SHADE
TRASH CONTAINER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
WEATHER CAB
MICRO-MULCH SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
TURF STRIPER
STANDON
MICRO-MULCH SYSTEM
*Some accessories and options not available for some models.
Place Model No. and Serial No.
Date Purchased
Label Here (Included in the Literature
Pack) or Fill in Below
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Model No.
Serial No.
©2011 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
Part No. 4501-191 Rev. A
Printed in the USA
All Rights Reserved
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