Exmark Lawn Mower 4501 191 RevA User Guide

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.  
Figure 1 identifies the location of the model and serial  
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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Contents  
Torque Requirements .....................................16  
Periodic Maintenance ........................................31  
Fuel System Maintenance ...............................35  
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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  
(Figure 2), which signals a hazard that may cause  
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.  
6
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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  
8
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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  
9
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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  
10  
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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  
11  
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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  
12  
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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.  
13  
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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  
14  
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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)  
15  
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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)  
16  
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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  
power to the mower blades (see Figure 4).  
Note: Become familiar with all of the controls in  
Figure 3 and Figure 4 before you start the engine and  
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”,  
“RUN” and “START” ( Figure 4). Insert key into  
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  
full throttle (see Figure 4).  
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  
the seat (Figure 3).  
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  
(Figure 3).  
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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  
from the seated position (Figure 3). When the lever  
is moved forward, away from the operator the deck  
is raised from the ground and when moved back,  
towards the operator it is lowered toward the ground.  
• 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.  
Located on the left side of the machine (see Figure 5).  
• 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  
fill the neck of the tank (Figure 7). This space  
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  
switch to Off (Figure 8).  
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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  
position, to engage the blades (Figure 9).  
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  
before starting a cold engine (Figure 8).  
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  
(Figure 8).  
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  
(Figure 8).  
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  
levers forward (Figure 10).  
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  
(Figure 10 and Figure 11).  
3. Front of unit  
To go straight, apply equal pressure to both  
motion control levers (Figure 10 and Figure 11).  
The farther you move the motion control levers  
in either direction, the faster the machine will  
move in that direction.  
To stop, pull the motion control levers to neutral.  
Backward  
1. Move the levers to the center, unlocked position.  
2. To go backward, slowly pull the motion control  
levers rearward (Figure 10 and Figure 12).  
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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  
height-of-cut foot lever forward (Figure 13). The  
transport lever will automatically engage and will  
drop into place.  
Figure 12  
Figure 13  
To go straight, apply equal pressure to both  
motion control levers (Figure 10 and Figure 12).  
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  
turn (Figure 10 and Figure 12).  
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  
the positions shown in Figure 15. Rollers will  
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  
track (Figure 17).  
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  
control lever fore or aft (Figure 19). Tighten both  
bolts to secure the control in the new position.  
Up to five springs can be secured to the seat box with  
a nut and bolt, see Figure 18.  
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  
the control arm shaft (Figure 19).  
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  
Figure 20. Ensure this is done for each lever.  
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  
Figure 20. Ensure this is done for each lever.  
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.  
29  
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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  
Grease the front caster wheels (Figure 21).  
• 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.  
3. Clean the grease fittings shown in Figure 22 with  
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  
the air cleaner assembly to the engine (Figure 23).  
Servicing the Engine Oil  
Checking the Oil Level  
Service Interval: Before each use or daily  
3. Loosen the hose clamp and remove the paper  
element (Figure 23).  
1. Park the machine on a level surface, disengage  
the blade control switch, stop the engine, engage  
parking brake, and remove the key.  
32  
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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  
screw it in (Figure 24).  
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  
pack, onto the oil drain valve (Figure 25). Remove  
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  
the frame (Figure 25).  
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  
14. Check the oil level (Figure 24); refer to Checking  
the Oil Level section.  
1. Look at the center of the spark plug (Figure 27).  
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  
electrodes (Figure 27). Bend the side electrode if  
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.  
2. Pull the wire off of the spark plug (Figure 26).  
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).  
3. Push the wire onto the spark plug (Figure 26).  
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  
slide them away from the filter (Figure 28).  
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  
(Figure 28) to secure it in place.  
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  
(Figure 28) connected to a tee fitting on the vent line  
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  
from the battery post (Figure 29). Retain all  
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.  
6. Remove the battery strap (Figure 29) and lift the  
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  
posts toward the operating position (Figure 29).  
• 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  
the starter or solenoid as shown in Figure 30.  
5. Secure the battery with the strap (Figure 29).  
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  
harness and fuse block (Figure 31).  
Figure 32  
1. Valve stem  
3. To replace a fuse, pull out on the fuse to remove  
it (Figure 31).  
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.  
Check the pressure at the valve stem (Figure 32).  
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  
39  
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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  
place (Figure 36).  
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  
drive system (Figure 37). Remove three screws  
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.  
40  
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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  
8. Install the transaxle guard. Refer to Figure 36 for  
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  
1. Inspect the cutting edges (Figure 39). If the edges  
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  
this area (item 3 in Figure 39), immediately install  
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  
(Figure 44). Refer to Removing the Blades and  
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  
blade from the spindle shaft (Figure 44).  
• 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  
of the blade (Figure 45). Maintain the original  
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  
blade balancer (Figure 46). If the blade stays in a  
horizontal position, the blade is balanced and can  
be used. If the blade is not balanced, file some  
metal off the end of the sail area only (Figure 46).  
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  
1. Install the blade onto the spindle shaft (Figure 44).  
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  
to side (Figure 47 and Figure 48).  
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  
the flat surface (Figure 47 and Figure 48). If both  
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  
(Figure 50). Use the notches on the welded  
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  
position and leave it slightly loose (Figure 49).  
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  
the new position (Figure 50). Tighten the rear  
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  
surface (Figure 51 and Figure 52). If the front  
blade tip is not 1/16-5/16 inch (1.6-7.9 mm) lower  
than the rear blade tip, adjust the front 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  
(Figure 53).  
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  
to rear (Figure 51 and Figure 52).  
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  
than the rear blade tip (Figure 51 and Figure 52).  
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  
(Figure 54). Carefully lower the front of the  
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  
the ground (Figure 55).  
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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  
belt off of the pulleys (Figure 56 and Figure 57).  
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  
mower pulleys (Figure 57).  
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 and Figure 57).  
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  
hanger brackets over the rear lift rod (Figure 55).  
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Maintenance  
6. Attach the front support rod to the mower deck  
with the clevis pin and hairpin cotter (Figure 54).  
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  
deflector (Figure 59). Remove the damaged or  
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  
1. Locate items shown in Figure 58.  
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 60).  
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  
brackets on the deck as shown in Figure 59.  
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  
bracket (Figure 60).  
51  
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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  
(Figure 61).  
• 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.  
54  
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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.  
55  
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Schematics  
Schematics  
Electrical Diagram  
56  
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Schematics  
Electrical Logic Schematic  
57  
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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  
58  
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Notes:  
59  
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Notes:  
60  
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Service Record  
Date:  
Description of Work Done:  
Service Done By:  
61  
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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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