QUEST®
For Serial Nos.
850,000 & Higher
Part No. 4500-523 Rev. B
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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
contact Exmark 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
Behind the seat
1. Model and serial number location
Model No.
Serial No.
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Contents
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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
1. 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.
Safe Operating Practices
The following instructions are from ANSI standard
B71.1-2003.
• Operate the machine only in daylight or good
artificial light.
• 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
on slopes greater than 15 degrees, near drop-offs,
ditches, steep banks or water.
To avoid personal injury or property damage, use
extra care when handling gasoline and other fuels.
They are flammable and the vapors are explosive.
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Safety
• Extinguish all cigarettes, cigars, pipes and other
sources of ignition.
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.
• Maintain or replace safety and instruction decals
as necessary.
• Never store the machine or fuel container inside
where there is an open flame, such as near a water
heater or furnace.
• 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
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.
• 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.
• 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;
2. is sufficiently mature to use caution; and
• If fuel is spilled on clothing, change clothing
immediately.
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.
• 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.
General Service:
• Never run a machine inside a closed area.
• Keep nuts and bolts tight, especially the blade
attachment bolts. Keep equipment in good
condition.
• 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 hands, feet, hair, and loose clothing away
from attachment discharge area, underside of
mower and any moving parts while engine is
running.
• 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.
• Do Not touch equipment or attachment parts
which may be hot from operation. Allow to cool
before attempting to maintain, adjust or service.
• Stop and inspect the equipment if you strike an
object. Repair, if necessary, before restarting.
• 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.
• Never make any adjustments or repairs with the
engine running.
• Grass collection system components are subject
to wear, damage and deterioration, which could
expose moving parts or allow objects to be
thrown. Frequently check components and
• Battery gases can explode. Keep cigarettes, sparks
and flames away from battery.
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Safety
• Use only Exmark approved attachments.
Warranty may be voided if used with unapproved
attachments.
• If loading the machine onto a trailer or truck, use
a single, full-width ramp only. The ramp angle
should not exceed 15 degrees.
Note: The left and right sides of the machine are
determined while sitting in the seat in the normal
operating position
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Safety
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
93-7009
1. Warning–Do Not operate 2. Cutting/dismemberment
the mower with the
discharge deflector up
or removed; keep the
discharge deflector in
place.
hazard of hand or foot,
mower blade–stay away
from moving parts.
109-6008
1. Read the Operator’s
3. Push the machine.
Manual.
2. Rotate the drive release
knob to loosen, slide the
knob, and tighten.
103-6327
All Units Except QST20BE422
1. Choke–on
2. Throttle–fast
3. Continuous variable setting
4. Throttle–slow
109-6014
Traction Drive Belt Routing
106-5517
1. Warning–Do Not touch the hot surface.
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Safety
109-9120
2. Diode
1. Fuse
109-6035
Deck Drive Belt Routing
109-6036
1. Read the Operator’s Manual.
109-9173
4. Neutral
2. Remove the ignition key and read the instructions before
servicing or performing maintenance.
3. Height of cut.
1. Parking brake
2. Fast
3. Slow
5. Reverse
6. Machine Speed
109-6210
1. Read the Operator’s Manual.
2. Cutting/dismemberment hazard, fan and entanglement
hazard, belt–stay away from moving parts.
109-9182
1. Machine speed
2. Fast
3. Slow
4. Neutral
5. Reverse
109-6459
1. Entanglement hazard, belt—Do Not open or remove
safety shields while engine is running, keep shields in
place.
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Safety
110-6691
1. Thrown objects
3. Cutting/dismemberment
of hand or foot–stay
hazard–keep bystanders
a safe distance from the
machine.
away from moving parts.
2. Thrown objects hazard,
mower–keep the
discharge deflector
or collection system in
place.
116-0532
QST20BE422 Unit
1. Choke–on
2. Throttle–fast
3. Continuous variable setting
4. Throttle–slow
116-0531
116-0533
116-0551
116-0581
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Safety
117–2718
PTO Symbols
2. PTO—On
1. PTO—Off
109-8965
1. Warning–read the Operator’s Manual.
5. Tipping hazard–avoid sudden and sharp turns while on
slopes, only mow across slopes less than 15 degrees,
keep a safe distance from water, and only mow up and
down slopes less than 15 degrees.
2. Read the instructions before servicing or performing
maintenance; apply parking brake, remove the ignition key
and disconnect the spark plug wire.
6. Cutting/dismemberment hazard of hand or foot, mower
blade–stay away from moving parts.
3. Thrown object hazard—keep bystanders a safe distance
from the machine, pick up debris before operating, keep
the discharge deflector in place.
7. Crushing/dismemberment hazard of bystanders,
reversing–Do Not carry passengers, look behind and
down when reversing.
4. Loss of traction/control hazard, slopes–loss of
traction/control on slope, disengage the blade control
switch (PTO), proceed off the slope slowly.
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Safety
116-2321
4. Check hydraulic oil level and refer to the Operator’s
1. Read the instructions before servicing or performing
maintenance.
2. Time interval
Manual for further instructions.
5. Check tire pressure.
3. Check oil level.
6. Refer to the Operator’s manual for grease instructions.
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
5. Read the Operator’s Manual.
9. Flush eyes immediately with water
and get medical help fast.
2. No fire, open flames, or smoking
6. Keep bystanders a safe distance
from the battery.
10. Contains lead; do not discard.
3. Caustic liquid/chemical burn hazard 7. Wear eye protection; explosive
gases can cause blindness and
other injuries.
4. Wear eye protection
8. Battery acid can cause blindness or
severe burns.
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Specifications
Specifications
Model Numbers
Serial Nos: 850,000 and Higher
QST20BE422; QST22BE482; QST24BE522; QST22BE482C; QST24BE522C
Systems
engine. (It is not necessary for the operator to be
in the seat to start the engine.)
Engine
• Operator must be in seat when PTO is engaged,
brake is disengaged, or motion control levers are
moved in or engine will stop.
• Engine Specifications: See your Engine Owner’s
Manual
• RPM:
– 20HP
• Engine will stop if either the left, the right, or
both levers are moved from neutral lock position
while brake is engaged.
Full Speed: 3300 ±100 (max) RPM (No Load)
Idle: 1650 (min) RPM
Operator Controls
• Steering and Motion Control:
– 22HP & 24HP
Full Speed: 3650 ±100 (max) RPM (No Load)
Idle: 1650 (min) RPM
Note: Motion control levers are adjustable to
two heights.
Fuel System
• Capacity: 4.0 gal. (15.1 L)
– Separate levers, on each side of the console,
control speed and direction of travel of the
respective drive wheels.
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher; containing no more than 10%
methanol or ethanol.
– Steering is controlled by varying the position
of the levers relative to each other.
• Fuel Filter:
– Moving motion control levers outward (in
slots) locks the drive system in neutral.
Briggs & Stratton P/N 695666
• Fuel Shut-Off Valve: 1/4 turn increments (“ON”,
“OFF”)
• PTO Engagement Switch: Engages electric clutch
(to drive belt) which engages mower blades.
• Parking Brake Lever: Engages parking brake.
Electrical System
• Deck Height Adjustment Pin: Sets cutting height
to desired position.
• Charging System: Flywheel Alternator
• Charging Capacity: 16 amps
• Battery Type: BCI Group U1
• Battery Voltage: 12 Volt
• Deck Lift Assist Lever: Foot pedal that assists
in raising the deck.
• Polarity: Negative Ground
Seat
• Fuses: One 25 amp, one 20 amp; one 15 amp
blade type
• Type: Standard seat with high back, foam padded
with spring suspension and armrests (armrests
are optional on the 42 inch unit).
• Diode: TVS
• Mounting: Hinged to tilt up for access to
hydraulic pumps, battery and other components.
Held in tilted position with lanyard. Adjustable
fore and aft.
Safety Interlock System
• PTO must be disengaged, brake engaged, and
motion control levers out (neutral lock) to start
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Specifications
• Armrests: Standard–foam padded flip-up
adjustable height armrests (optional on the 42
inch unit).
• Blade Size: (3 ea.)
– 42 inch Deck: 21.25 inches (53.9 cm)
– 48 inch Deck: 16.25 inches (41.3 cm)
– 52 inch Deck: 18.00 inches (45.7 cm)
• Seat Safety Switch: Incorporated into the Safety
Interlock System.
• Blade Spindles: Solid steel spindles with no
maintenance bearings.
Hydrostatic Ground Drive System
• Hydrostatic Pumps: Two Hydro Gear ZT2800
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.
• 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.
– 42 inch unit
◊ 0-6.0 mph (9.7 km/hr) forward.
◊ 0-4.0 mph (6.4 km/hr) reverse.
– 48 inch and 52 inch units
◊ 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.
• Deck Depth:
– 42 inch Deck: 5.0 inches (12.7 cm)
– 48 inch Deck: 5.0 inches (12.7 cm)
– 52 inch Deck: 5.0 inches (12.7 cm)
• 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.
• Cutting Height Adjustment: A foot deck lift lever
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.
Tires & Wheels
Drive
Front Caster
• Mulching Kit: Optional.
Pneumatic
(Air-Filled)
Pneumatic
(Air-Filled)
Dimensions
Deck
Size
42 & 48 52
42
2
48 & 52
Quantity
Tread
Size
2
2
2
Overall Width:
Turf Tec Turf Tec Sawtooth Smooth
42 inch
Deck
48 inch
Deck
52 inch
Deck
20 x
20 x
10 x 4
10 x 4
8.00-8
10.00-8
Without
Deck
45.5 inches 45.5 inches 47.0 inches
(116 cm) (116 cm) (119 cm)
Ply
4
4
Rating
Deflector
Up
43.1 inches 48.3 inches 53.0 inches
(109 cm) (122 cm) (135 cm)
Pressure 13 psi
13 psi
20 psi
13 psi
(90 kPa) (90 kPa) (138 kPa) (90 kPa)
Deflector
Down
54.2 inches 59.4 inches 64.2 inches
(138 cm) (151 cm) (163 cm)
Cutting Deck
Overall Length:
• Cutting Width:
– 42 inch Deck: 42 inches (107 cm)
– 48 inch Deck: 48 inches (122 cm)
– 52 inch Deck: 52 inches (132 cm)
• Discharge: Side
All Units
73.4 inches (186 cm)
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Product Overview
Overall Height:
Product Overview
All Units
41.8 inches (106 cm)
Tread Width: (Center to Center of
Tires, Widthwise)
42 inch
Deck
48 inch
Deck
52 inch
Deck
Drive
Wheels
36.0 inches 36.0 inches 36.8 inches
(91 cm) (91 cm) (93 cm)
Caster
Wheels
27.9 inches 33.5 inches 33.5 inches
(71 cm) (85 cm) (85 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. Engine
9. Seat
48.9 inches (124 cm)
3. Height of cut foot lever 10. Armrest
4. Discharge deflector
11. Motion control levers
Curb Weight:
5. Height of cut adjustment 12. Park brake
6. Rear drive wheel
7. Control panel
13. Footrest
14. Washout fitting
42 inch Deck
48 inch Deck
52 inch Deck
630 lb (286 kg)
645 lb (293 kg)
660 lb (299 kg)
Torque Requirements
Bolt Location
Torque
Spindle Pulley Nut
75-85 ft-lb (102-115 N-m)
32-42 ft-lb (43-57 N-m)
Blade Mounting Bolt
(lubricate with anti-seize)
Engine Mounting Bolts
27-33 ft-lb (37-45 N-m)
27-33 ft-lb (37-45 N-m)
Anti-Scalp Roller Nyloc
Nut
Wheel Lug Nuts
70-90 ft-lb (95-122 N-m)
50-55 ft-lb (68-75 N-m)
Clutch Mounting Bolt
(secured with threadlocker)
Spark Plug
15 ft-lb (20 N-m)
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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
Located on control panel.
Push the blade control switch to “Off ” to disengage
the blades.
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/Choke 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 into the detent is
full throttle (see Figure 4).
The choke is used to aid in starting a cold engine.
Do Not run a warm engine with the choke in the
“ON” position. Moving the lever forward beyond
the detent will put the choke in the “ON” position
and moving the lever to the detent will put the choke
in the “OFF” position.
Motion Control Levers
Figure 4
The motion control levers located on each side of
1. Throttle/Choke lever
2. Hour meter
3. Blade control switch
(power take-off)
4. Ignition switch
The motion control levers are speed sensitive controls
of independent wheel motors. Moving a lever
forward or backward turns the wheel on the same side
forward or in reverse; wheel speed is proportional to
the amount the lever is moved. Moving the control
levers outward from the center position locks them
in the neutral position. Always position the motion
control levers into the neutral position and engage
the park brake lever when you stop the machine or
leave it unattended. The unit must be tied down and
brake engaged when transporting.
Note: Brake must be engaged, motion control levers
out (neutral lock position) 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
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Operation
Parking Brake Lever
DANGER
Located on left side of the console (Figure 3).
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.
The brake lever engages a parking brake on the drive
wheels.
Pull the lever up and rearward to engage the brake.
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.
Push the lever forward and down to disengage the
brake.
Height-of-Cut Foot Lever
• Reduce speed and use extreme caution on
slopes.
The height of cut lever allows the operator to lower
and raise 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. Only adjust the height of cut
while machine is not moving.
• When mowing slopes, gradually work from
lower to higher areas on the incline.
• Avoid sudden turns or rapid speed changes.
• Turn up, into an incline when changing
directions on slopes. Turning down the slope
reduces traction.
• Attachments change the handling
characteristics of the machine. Use extra
caution when using attachments with the
machine.
Hour Meter
Located on the control panel.
The hour meter is connected to a pressure switch
installed in the engine block and it records the number
of hours that the engine has run ( Figure 4). If the
ignition switch is left on without engine running, hour
meter will not run. The hour meter is standard on the
48 and 52 inch units and optional for the 42 inch unit.
Note: This switch is not a low oil sensor and will not
alert the operator if the engine oil is low.
Operating Instructions
Think Safety First
Figure 5
Note: Determine the left and right sides of the
machine from the normal operating position.
1. Water
2. Danger Zone–Use walk behind mower and/or hand
trimmer on slopes greater than 15 degrees, near
drop-offs and water.
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.
Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for
automotive use (87 pump octane minimum).
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Operation
Important: Never use methanol, gasoline
containing methanol, gasohol containing more
than 10% ethanol, premium gasoline, or white
gas because the fuel system could be damaged.
Do Not mix oil with gasoline.
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.
DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.
• Always place gasoline containers on the
ground away from your vehicle before filling.
• Do Not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the loss
of any static charge.
A fire or explosion from gasoline can burn you,
others, and cause property damage.
• Fill the fuel tank outdoors on level ground, in
an open area, when the engine is cold. Wipe
up any gasoline that spills.
• When practical, remove gas-powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
• 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.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a
gasoline dispenser nozzle.
• If a gasoline dispenser nozzle must be used,
keep the nozzle in contact with the rim of the
fuel tank or container opening at all times
until fueling is complete.
• Never smoke when handling gasoline, and
stay away from an open flame or where
gasoline fumes may be ignited by spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never
buy more than a 30-day supply of gasoline.
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.
• Do Not operate without entire exhaust system
in place and in proper working condition.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Keep away from eyes and skin.
• Never siphon by mouth.
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Operation
Using Stabilizer/Conditioner
Use a fuel stabilizer/conditioner in the machine to
provide the following benefits:
• Keeps gasoline fresh during storage of 30 days or
less. For longer storage it is recommended that
the fuel tank be drained.
• Cleans the engine while it runs.
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting Add the
correct amount of gas stabilizer/conditioner to
the gas.
Note: A fuel stabilizer/conditioner is most effective
when mixed with fresh gasoline. To minimize the
chance of varnish deposits in the fuel system, use fuel
stabilizer at all times.
Figure 6
3. Gas tank body
1. Gas tank opening
2. Fill to here,
approximately
Gasoline/Alcohol blends
4. Install the fuel tank cap securely. Wipe up any
gasoline that may have spilled.
Gasohol (up to 10 percent ethyl alcohol, 90 percent
unleaded gasoline by volume) is approved for fuel use
by the engine manufacturer. Other gasoline/alcohol
blends are not approved.
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.
Filling the Fuel Tank
1. Shut the engine off and set the motion controls
to the neutral position and engage parking brake.
2. Clean around the fuel tank cap and remove the
cap.
Starting the Engine
3. Add unleaded regular gasoline until the body of
the tank is full but fuel does not fill the neck of
the tank (Figure 6). This space in the neck of the
tank allows gasoline to expand. Do Not fill the
fuel tank completely full.
1. Sit down on the seat and move the motion
controls outward to the neutral position and
engage the parking brake.
2. Disengage the blades by moving the blade control
switch to Off (Figure 7).
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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 8).
Figure 7
5. Run
1. Throttle/Choke lever
2. Blade control
6. Start
switch—Off position
3. Ignition key
4. Off
7. Choke
8. Throttle–fast (detent
position)
Figure 8
1. Throttle–Midway
position
2. Blade control
switch—On position
3. Move the lever forward, beyond the detent, to
engage the choke before starting a cold engine
4. Move throttle to full forward position before
mowing.
Note: A warm or hot engine may not require
choking.
Disengaging the Blades
4. Turn the ignition key to Start to energize the
starter. When the engine starts, release the key
Set throttle to midway position. Push the blade
control switch to Off to disengage 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.
Stopping the Engine
1. Bring the unit to a full stop.
2. Disengage the PTO.
3. Move the motion control levers out to the neutral
lock position.
5. Once the engine starts, move the lever to the
detent position. If the engine stalls or hesitates,
move the lever partially forward for a few seconds.
4. Engage the parking brake.
5. Place the throttle midway between the “SLOW”
and “FAST” positions.
Operating the Blades
6. Allow the engine to run for a minimum of 15
seconds, then turn the ignition switch to the
“OFF” position to stop the engine.
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.
7. Remove the key to prevent children or other
unauthorized persons from starting engine.
8. Close the fuel shut-off valve when the machine
will not be in use for a few days, when
transporting, or when the unit is parked inside
a building.
Engaging the Blades
1. Release pressure on the motion control levers and
place the machine in neutral.
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Operation
Try to start with operator in seat, parking brake
engaged, 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.
The Safety Interlock System
CAUTION
If the safety interlock switches are disconnected
or damaged the machine could operate
unexpectedly causing personal injury.
2. Check kill circuits. Run engine at one-third
throttle, disengage parking brake and raise off
of seat (but do not get off of machine) engine
must initiate shutdown.
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches
before operating the machine.
Run engine at one-third throttle, engage PTO
and raise off of seat (but do not get off of
machine) engine must initiate shutdown.
Understanding the Safety Interlock
System
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.
The safety interlock system is designed to prevent the
engine from starting unless:
• The blades are disengaged.
Again, run engine at one-third throttle, brake
engaged, and move left motion control lever in
- engine must initiate shutdown.
• The motion control levers are in the neutral
position.
• The parking brake is engaged.
Repeat again moving the right lever in, then
moving both levers in - engine must initiate
shutdown whether operator is on seat or not.
The safety interlock system is designed to initiate
engine shutdown when:
• The parking brake is disengaged and the operator
gets off machine.
Note: If machine does not pass any of these tests,
Do Not operate. Contact your authorized EXMARK
SERVICE DEALER.
• The PTO is engaged and the operator gets off
machine.
Important: It is essential that operator safety
mechanisms be connected and in proper
operating condition prior to use for mowing.
•
The parking brake is disengaged and levers are in
and the operator gets off machine.
• The parking brake is engaged and motion control
levers are in.
Driving Forward or Backward
Testing the Safety Interlock System
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.
Test the safety interlock system before you use the
machine each time
1. Check starting circuit. Starter should crank with
parking brake engaged, PTO disengaged and
motion control levers moved out in the neutral
lock position. The operator does not need to be
in the seat to start the engine.
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.
Try to start with operator in seat, parking brake
disengaged, PTO disengaged and motion control
levers in the neutral lock position - starter must
not crank.
• Use caution when making turns.
Try to start with operator in seat, parking brake
engaged, PTO engaged and motion control
levers in the neutral lock position - starter must
not crank.
• Slow the machine down before making sharp
turns.
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Operation
Forward
Stopping the Machine
1. Move the levers to the center, unlocked position.
To stop the machine, move the motion control
levers to neutral and outward to the neutral position,
disengage the blade control switch, move the throttle
lever to between Fast and half throttle, and turn the
ignition key to off. Remember to remove the key
from the ignition switch.
2. To go forward, slowly push the motion control
levers forward (Figure 9).
CAUTION
Children or bystanders may be injured if they
move or attempt to operate the mower while it
is unattended.
Always remove the ignition key and move the
motion control levers outward to the neutral
position and apply the parking brake when
leaving the machine unattended, even if just for a
few minutes.
Adjusting the Height of Cut
1. Raise the deck to the transport position (4.5 inch
(114 mm) cut height) by pushing the foot actuated
lever forward (Figure 10). The transport lever will
automatically engage and will drop into place.
Figure 9
1. Neutral position
2. Center unlock position
3. Backward
4. Forward
To go straight, apply equal pressure to both
motion control levers (Figure 9).
To turn, pull back on the motion control lever
toward the direction you want to turn (Figure 9).
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.
Figure 10
Backward
1. Move the levers to the center, unlocked position.
1. Transport release handle 3. Height adjuster pin
2. Height-of-cut positions
4. Foot actuated
height-of-cut lever
2. To go backward, slowly pull the motion control
levers rearward (Figure 9).
2. Move the deck height adjuster pin to the desired
cut height.
To go straight, apply equal pressure to both
motion control levers (Figure 9).
3. Push the foot lever forward, pull the transport
release handle up and let the deck lower down to
the predetermined cut height by slowly decreasing
foot pressure allowing the foot lever to travel
rearward.
To turn, release the pressure on the motion
control lever toward the direction you want to
To stop, push the motion control levers to neutral.
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Operation
• 48 and 52 Inch Units:
Adjusting the Anti-Scalp
Rollers
It is recommended to change the anti-scalp roller
position when the height of cut has changed.
1. Push the adjustment lever towards the center
of the machine to release the seat adjuster
1. Stop the machine and move the drive levers to
the neutral lock position.
2. Disengage the PTO.
3. Engage the park brake.
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.
6. Adjust the anti-scalp rollers for the normal
operating conditions. Place rollers in one of
the positions shown in Figure 11. Rollers will
maintain 3/4 inches (19 mm) clearance to the
ground to minimize gouging and roller wear or
damage.
Figure 12
1. Adjustment lever
2. Move the seat to the desired position and
release the lever to lock in that position.
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.
• 42 Inch Unit:
1. Tip the seat forward.
2. Loosen the knob.
3. Move the seat to the desired position.
4. Tighten the knob.
5. Tip the seat back to the closed position.
Changing the Seat Ride
Suspension
Figure 11
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.
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.
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.
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Operation
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.
1. Loosen the upper bolt holding the control lever
to the control arm shaft.
Figure 13
3. Nut
2. Loosen the lower bolt just enough to pivot the
control lever fore or aft (Figure 14). Tighten both
bolts to secure the control in the new position.
1. Bolt
2. Spring
4. Additional mounting
holes
3. Repeat the adjustment for the opposite control
lever.
Up to five springs can be secured to the seat box with
a nut and bolt, see Figure 13.
Pushing the Machine by
Hand
Refer to your Parts Manual for spring and hardware
part numbers.
Important: Always push the machine by hand.
Never tow the machine because damage may
occur.
Adjusting the Motion Control
Levers
To Push the Machine
Adjusting the Height
1. Park the machine on a level surface and disengage
the blade control switch.
The motion control levers can be adjusted higher or
lower for maximum operator comfort.
2. Move the motion control levers outward to
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
1. Remove the hardware holding the control lever to
the control arm shaft (Figure 14).
3. Locate the bypass release knobs on either side of
the engine deck (Figure 15).
Figure 14
1. Nut
2. Control lever
3. Control arm shaft
4. Washer
5. Bolt
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Operation
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.
• 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).
Figure 15
1. Front of the machine.
5. Lever position for
pushing the machine
2. Rotate bypass release
knob counterclockwise
3. Lever position for
operating the machine.
6. Rotate bypass release
knob clockwise
7. Release lever
Transporting
4. Pull lever in this direction
Transporting a Unit
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.
4. Loosen the knob by turning counterclockwise.
Then pull the release lever on the underside of
machine (Figure 15) towards the back of the
machine and retighten the knob to hold the
release lever back in the released state. Repeat this
on each side of the machine.
5. Release the parking brake. The machine is now
able to be pushed by hand.
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
Loosen the bypass knob, push the release levers
forward, and retighten the knob to engage the drive
Side Discharge
The mower has a hinged discharge deflector that
disperses clippings to the side and down toward the
turf.
Do Not drive a unit on a public street or roadway.
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Operation
Operating Tips
WARNING
Loading a unit on a trailer or truck increases
the possibility of backward tip-over. Backward
tip-over could cause serious injury or death.
Fast Throttle Setting
For best mowing and maximum air circulation,
operate the engine at the Fast position. Air is required
to thoroughly cut grass clippings, so Do Not set the
height-of-cut so low as to totally surround the mower
by uncut grass. Always try to have one side of the
mower free from uncut grass, which allows air to be
drawn into the mower.
• Use extreme caution when operating a unit
on a ramp.
• Use only a single, full width ramp; Do Not
use individual ramps for each side of the unit.
• If individual ramps must be used, use enough
ramps to create an unbroken ramp surface
wider than the unit.
Cutting a Lawn for the First Time
• Do Not exceed a 15° angle between ramp and
ground or between ramp and trailer or truck.
Cut grass slightly longer than normal to ensure that
the cutting height of the mower does not scalp any
uneven ground. However, the cutting height used in
the past is generally the best one to use. When cutting
grass longer than six inches tall, you may want to cut
the lawn twice to ensure an acceptable quality of cut.
• Avoid sudden acceleration while driving unit
up a ramp to avoid tipping backward.
• Avoid sudden deceleration while backing unit
down a ramp to avoid tipping backward.
Loading a Unit
Cut 1/3 of the Grass Blade
Use extreme caution when loading units on trailers or
trucks. One full width ramp that is wide enough to
extend beyond the rear tires is recommended instead
of individual ramps for each side of the unit. The
lower rear section of the tractor frame extends back
between the rear wheels and serves as a stop for
tipping backward. Having a full width ramp provides
a surface for the frame members to contact if the
unit starts to tip backward. If it is not possible to use
one full width ramp, use enough individual ramps to
simulate a full width continuous ramp.
It is best to cut only about 1/3 of the grass blade.
Cutting more than that is not recommended unless
grass is sparse, or it is late fall when grass grows more
slowly.
Mowing Direction
Alternate mowing direction to keep the grass standing
straight. This also helps disperse clippings which
enhances decomposition and fertilization.
Mow at Correct Intervals
Ramp should be long enough so that the angles
between the ramp and the ground and the ramp and
the trailer or truck Do Not exceed 15°. A steeper
angle may cause mower deck components to get
caught as the unit moves from ramp to trailer or
truck. Steeper angles may also cause the unit to tip
backward. If loading on or near a slope, position
the trailer or truck so it is on the down side of the
slope and the ramp extends up the slope. This will
minimize the ramp angle. The trailer or truck should
be as level as possible.
Normally, mow every four days. But remember,
grass grows at different rates at different times. So to
maintain the same cutting height, which is a good
practice, mow more often in early spring. As the
grass growth rate slows in mid summer, mow less
frequently. If you cannot mow for an extended
period, first mow at a high cutting height; then mow
again two days later at a lower height setting.
Cutting Speed
To improve cut quality, use a slower ground speed.
Important: Do Not attempt to turn the unit
while on the ramp, you may lose control and
drive off the side.
Avoid Cutting Too Low
Avoid sudden acceleration when driving up a ramp
and sudden deceleration when backing down a ramp.
Both maneuvers can cause the unit to tip backward.
If the cutting width of the mower is wider than the
mower you previously used, raise the cutting height
to ensure that uneven turf is not cut too short.
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Operation
Long Grass
If the grass is ever allowed to grow slightly longer
than normal, or if it contains a high degree of
moisture, raise the cutting height higher than usual
and cut the grass at this setting. Then cut the grass
again using the lower, normal setting.
When Stopping
If the machine’s forward motion must be stopped
while mowing, a clump of grass clippings may drop
onto your lawn. To avoid this, move onto a previously
cut area with the blades engaged.
Keep the Underside of the Mower
Clean
Clean clippings and dirt from the underside of the
mower after each use. If grass and dirt build up inside
the mower, cutting quality will eventually become
unsatisfactory.
Blade Maintenance
Maintain a sharp blade throughout the cutting season
because a sharp blade cuts cleanly without tearing or
shredding the grass blades. Tearing and shredding
turns grass brown at the edges, which slows growth
and increases the chance of disease. Check the
cutter blades daily for sharpness, and for any wear or
damage. File down any nicks and sharpen the blades
as necessary. If a blade is damaged or worn, replace
it immediately with a genuine Exmark replacement
blade. Only Exmark blades are to be used with this
unit. No other blades are approved.
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Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could seriously
injure you or other bystanders.
Removing standard original equipment parts,
or using non-Exmark replacement 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.
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, and blades 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
• Change the hydraulic filter.
After the first 100 hours
• Check the safety interlock system.
• Check the air intake and cooling areas, clean as necessary.
• Check the oil level before starting or after every 8 hours.
• Check the hydraulic oil level in the expansion tank.
• Check the mower blades.
Before each use or daily
• Clean the mower housing.
• Grease all lubrication points.
• Check the air cleaner for dirt, looseness, or damage. (May need more often under extremely
dusty or dirty conditions.)
• Service the air cleaner. (May need more often under extremely dusty or dirty conditions.)
• Check the tire pressure.
• Check the belts.
Every 25 hours
Every 100 hours
• Replace the paper element. (More often under extremely dusty, dirty conditions.)
• Replace the air cleaner element.
• Change the engine oil and filter.
• Clean the blower housing. More often under dirty conditions.
• Replace the fuel filter.
• Service the spark plug.
Every 200 hours
Every 500 hours
• Change the hydraulic filter (Every 250 hours if using Mobil 1 15W50)
• Replace the spark plug.
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Maintenance
Maintenance Service
Interval
Maintenance Procedure
• Charge the battery and disconnect the battery cables.
• Perform all maintenance procedures before storage.
• Paint any chipped surfaces.
Before storage
Monthly
• Check the battery charge.
Important: Refer to your Engine Operator’s Manual for additional maintenance procedures.
Premaintenance
Procedures
Periodic Maintenance
Lubrication
Raising the Seat
Greasing the Bearings
Make sure the motion control levers are locked in
the neutral position. Lift the seat forward until the
lanyard is tight. The following components can be
accessed by raising the seat:
Service Interval: Every 25 hours/Monthly
(whichever comes first)
Grease Type: NGLI grade #2 multi-purpose gun
grease.
• Auxiliary 12V Plug (12V accessory up to 15 amp)
Grease the front caster wheels (Figure 17).
• Fuses
• Battery cables
G007184
Accessing the Battery
The battery is located under the seat. To access, raise
1
Figure 17
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 the
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
Figure 16
1. Auxiliary 12V Plug
2. Battery
3. Seat
3. Clean the grease fittings (Figure 17) with a rag.
Make sure to scrape any paint off of the front of
the fitting(s).
4. Wipe up any excess grease.
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Maintenance
Servicing Paper Element
Engine Maintenance
Service Interval: Every 25 hours/Monthly
(whichever comes first)
(May need more often
Servicing the Air Cleaner
Service Interval: Every 25 hours/Monthly
(whichever comes first)
(May need more often
under extremely dusty or
dirty conditions.)
Every 100 hours/Yearly
(whichever comes
first)—Replace the air
cleaner element.
under extremely dusty or
dirty conditions.)
Every 100 hours/Yearly
(whichever comes
first)—Replace the paper
element. (More often
under extremely dusty,
dirty conditions.)
1. Remove the air cleaner cover (Figure 18).
2. Remove the air cleaner element with the integral
rubber seal.
3. Remove the foam sleeve from the element.
4. Gently tap the pleated side of the paper element
to dislodge dirt. Do Not wash the paper element
or use pressurized air, as this will damage the
element. Replace a dirty, bent, or damaged
element. Handle new elements carefully; Do Not
use if the rubber seal or foam sleeve is damaged.
This engine is equipped with a replaceable, high
density paper air cleaner element. Check the air
cleaner daily or before starting the engine. Check for
a buildup of dirt and debris around the air cleaner
system. Keep this area clean. Also check for loose or
damaged components. Replace all bent or damaged
air cleaner components.
5. Wash the foam sleeve in warm water and allow to
dry. Reinstall over the paper element.
Note: Operating the engine with loose or damaged
air cleaner components could allow unfiltered air into
the engine causing premature wear and failure.
6. Clean all air cleaner components of any
accumulated dirt or foreign material. Prevent any
dirt from entering the carburetor.
Note: Service the air cleaner more often under
extremely dusty, dirty conditions.
7. Install the air cleaner element with the pleated
side “out” and seat the rubber seal onto the edges
of the air cleaner base.
8. Reinstall the air cleaner cover and secure with
the knobs.
Servicing the Engine Oil
Checking the Oil Level
Service Interval: Before each use or daily
1. Park the machine on a level surface, disengage
the blade control switch, stop the engine, engage
parking brake, and remove the key.
2. Make sure the engine is stopped, level, and is cool
so the oil has had time to drain into the sump.
Figure 18
3. To keep dirt, grass clippings, etc., out of
the engine, clean the area around the oil fill
cap/dipstick before removing it.
1. Air cleaner
2. Knobs
3. Air cleaner cover
4. Pull and remove the oil fill cap/dipstick; wipe oil
off. Reinsert the dipstick and push firmly into
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Maintenance
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 drain plug and on the
machine frame. Place a pan underneath machine
directly below the drain hole in the frame as
Figure 19
3. Oil level
1. Oil dipstick
2. Filler tube
5. Remove the dipstick and check the oil level.
The oil level should be up to, but not over, the
“F” mark on the dipstick.
6. If the level is low, add oil of the proper type, up to
the “F” mark on the dipstick. Always check the
level with the dipstick before adding more oil.
Figure 20
1. Oil drain
3. Pan
2. Oil drain plug
Note: To prevent extensive engine wear or
damage, always maintain the proper oil level in
the crankcase. Never operate the engine with the
oil level below the “L” mark or over the “F” mark
on the dipstick.
5. Remove the oil drain plug (Figure 20 ). Remove
the oil fill cap/dipstick (Figure 19).
Changing the Oil and Filter
Service Interval: After the first 5 hours
Every 100 hours/Yearly
(whichever comes first)
thereafter.
Change the oil and filter while the engine is still
warm. The oil will flow more freely and carry away
more impurities. Make sure the engine is level when
filling, checking, or changing the oil.
Figure 21
1. Oil filter
2. Gasket
6. Be sure to allow ample time for complete
drainage.
1. Start the engine and let it run until warm. This
warms the oil so it drains better.
7. Remove the old filter and wipe off the mounting
2. Disengage the blade control switch and move the
motion controls outward to the neutral position
and engage parking brake.
8. When the oil has drained completely, install the
oil drain plug. Tighten the plug to 14 N-m (125
32
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Maintenance
in-lb) torque. Wipe up any excess oil on the frame
Change the Hydraulic
System Filter
Note: Dispose of the used oil at a recycling
center.
Service Interval: After the first 100 hours
Every 500 hours thereafter
(Every 250 hours if using
Mobil 1 15W50)
9. Apply a thin film of clean oil to the rubber gasket
on the new filter.
10. 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 (Figure 21).
1. Stop engine, wait for all moving parts to stop, and
allow engine to cool. Remove key and engage
parking brake.
2. Locate the two filters under the transmissions.
Remove filter guards.
11. Slowly pour approximately 80% of the specified
oil into the filler tube—use oil recommended in
the Engine Owner’s Manual.
3. Carefully clean area around filters. It is important
that no dirt or contamination enter hydraulic
system.
12. Install the oil fill cap/dipstick and push firmly
into place.
13. Check the oil level (Figure 19); refer to Checking
4. Unscrew filters to remove and allow oil to drain
from drive system.
the Oil Level.
14. Slowly add additional oil to bring it to the full
mark. Do Not overfill.
Important: Before reinstalling new filters,
apply a thin coat of Exmark Premium Hydro
oil on the surface of the filters rubber seal.
15. Install the oil fill cap/dipstick and push firmly
into place.
Turn the filters clockwise until rubber seal
contacts the filter adapter then tighten the filter
an additional 3/4 to 1 full turn.
16. Start the engine and check for leaks.
5. Remove the vent plug on each transmission and
fill through expansion reservoir, when oil comes
out of vent reinstall plug.
Checking the Hydraulic Oil
Level
Service Interval: Before each use or daily
Exmark Premium Hydro Oil is recommended.
Refer to the chart for an acceptable alternative:
Check expansion tank and if necessary add Exmark
Premium Hydro oil to the FULL COLD line.
Hydro Oil
Change Interval
500 Hours
Exmark Premium Hydro
Oil (Preferred)
250 Hours
Mobil 1 15W50
Torque plugs to 180 in-lb (244 N-m). Continue to
add oil until it reaches the FULL COLD line on
the expansion reservoir.
Figure 22
1. Engine
2. Expansion tank
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Maintenance
6 times). Check the oil level, and add oil as
required after stopping the engine.
C. It may be necessary to repeat steps A and
B until all the air is completely purged from
the system. When the transaxle operates at
normal noise levels and moves smoothly
forward and reverse at normal speeds, then
the transaxle is considered purged.
Do Not change hydraulic system oil (except for what
can be drained when changing filter), unless it is felt
the oil has been contaminated or been extremely hot.
Changing oil unnecessarily could damage hydraulic
system by introducing contaminates into the system.
Figure 23
3. Left rear tire
1. Oil filter
2. Vent plug
Servicing the Spark Plug
Service Interval: Every 200 hours/Every 2
years (whichever comes
first)
6. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
Every 500 hours—Replace
the spark plug.
CAUTION
Raising the mower for service or maintenance
relying solely on mechanical or hydraulic
jacks could be dangerous. The mechanical or
hydraulic jacks may not be enough support
or may malfunction allowing the unit to fall,
which could cause injury.
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.
Type: Champion XC92YC
Do Not rely solely on mechanical or hydraulic
jacks for support. Use adequate jack stands
or equivalent support.
Champion RC12YC or QC12C may be used if your
area does not require compliance with Canadian
ICES-002, ISO 14982, or EN 55012.
7. Start engine and move throttle control ahead to
1/2 throttle position. Disengage parking brake.
Air Gap: 0.030 inch (0.76 mm)
Removing the Spark Plug
WARNING
1. Disengage the blade control switch, move the
motion controls outward to the park position,
stop the engine, and remove the key.
Engine must be running and drive wheels
must be turning so adjustments can be
performed. Contact with moving parts or hot
surfaces may cause personal injury.
2. Pull the wire off of the spark plug (Figure 24).
Clean around the spark plug to prevent dirt from
falling into the engine and potentially causing
damage.
Keep fingers, hands, and clothing clear of
rotating components and hot surfaces.
A. With the bypass valve open and the engine
running, slowly move the directional control
in both forward and reverse (5 or 6 times).
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.
B. With the bypass valve closed and the engine
running, slowly move the directional control
in both forward and reverse directions (5 to
3. Remove the spark plug and metal washer.
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Maintenance
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.
Figure 24
1. Spark plug and wire location
2. Clean the cooling fins and external surfaces as
necessary.
3. Make sure the cooling shrouds are reinstalled
Checking the Spark Plug
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.
1. Look at the center of the spark plug (Figure 25).
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.
Fuel System Maintenance
Important: Never clean the spark plug.
Always replace the spark plug when it has a
black coating, worn electrodes, an oily film,
or cracks.
Replacing the Fuel Filter
Service Interval: Every 100 hours/Yearly
(whichever comes first)
2. Check the gap between the center and side
electrodes (Figure 25). Bend the side electrode if
the gap is not correct.
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.
• Perform any fuel related maintenance when
the engine is cold. Do this outdoors in an
open area. Wipe up any gasoline that spills.
• Never smoke when draining gasoline, and
stay away from an open flame or where a
spark may ignite the gasoline fumes.
Figure 25
1. Side electrode
2. Center electrode
insulator
3. Air gap (not to scale)
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.
Installing the Spark Plug
2. Move the motion control levers outward to the
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
1. Install the spark plug. Make sure that the air gap
is set correctly.
2. Tighten the spark plug to 15 ft-lb (20 N-m).
3. Push the wire onto the spark plug (Figure 24).
3. The fuel filter is in the fuel line between the tank
and engine.
35
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Maintenance
Charging the Battery
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.
• When removing or installing the battery, Do
Not allow the battery terminals to touch any
metal parts of the machine.
• Do Not allow metal tools to short between
the battery terminals and metal parts of the
machine.
Figure 26
1. Fuel tank
6. Hose clamps
2. Fuel shut off valve—off
7. Fuel line to engine
3. Fuel shut off valve
4. Fuel shut off valve—on
5. Fuel line from tank
8. Filter
9. Flow direction arrow
DANGER
Charging or jump starting the battery may
produce explosive gases. Battery gases can
explode causing serious injury.
4. Turn fuel shut off valve 90° to “off ” position.
5. Squeeze the ends of the hose clamps together and
slide them away from the filter (Figure 26).
• Keep sparks, flames, or cigarettes away from
battery.
6. Remove the filter from the fuel lines.
• Ventilate when charging or using battery in
an enclosed space.
7. Install a new filter with the flow direction arrow
coming from the fuel tank and pointing to the
engine. Move the hose clamps close to the filter
(Figure 26) to secure it in place.
• Make sure venting path of battery is always
open once battery is filled with acid.
• Always shield eyes and face from battery.
8. Turn fuel shut off valve back to “on” position.
DANGER
Electrical System
Maintenance
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
• Wear safety glasses to shield eyes, and rubber
gloves to protect skin and clothing when
handling electrolyte.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
• Do Not swallow electrolyte.
compounds, chemicals known to the State of
California to cause cancer and reproductive
harm. Wash hands after handling.
• In the event of an accident, flush with water
and call a doctor immediately.
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Maintenance
CAUTION
WARNING
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
Incorrect battery cable routing could damage
the machine and cables causing sparks.
Sparks can cause the battery gasses to
explode, resulting in personal injury.
• Always disconnect the negative (black)
battery cable before disconnecting the
positive (red) cable.
Be sure ignition switch is in the “OFF” position
before charging the battery.
• Always connect the positive (red) battery
cable before connecting the negative
(black) cable.
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
neutral position, engage parking brake stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
5. Slide the rubber cover up the positive (red) cable.
Disconnect the positive (red) cable from the
battery post. Retain all fasteners.
6. Remove the battery strap (Figure 27) and lift the
battery from the battery tray.
3. Raise the seat.
4. Disconnect the negative (black) ground cable
from the battery post (Figure 27). Retain all
fasteners.
Checking the Battery Charge
1. Remove the battery from the chassis; refer to
Removing the Battery.
2. Allowing batteries to stand for an extended period
without recharging them will result in reduced
performance and service life. To preserve
optimum battery performance and life, recharge
batteries in storage when the open circuit voltage
drops to 12.4 volts.
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.
Figure 27
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).
1. Negative battery post
2. Bolt, washer, and nut
3. Terminal boot
4. Positive battery post
5. Battery strap
6. Battery
Voltage
Reading
Percent
Charge
Maximum Charging
Charger
Settings
Interval
12.6 or
greater
100%
No
Charging
Required
16 volts/7
amps
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Maintenance
Voltage
Reading
Percent
Charge
Maximum Charging
CAUTION
Charger
Settings
Interval
30 Minutes
1 Hour
Connecting the jumper cables incorrectly
(wrong polarity) can immediately damage the
electrical system.
12.4 – 12.6 75–100%
12.2 – 12.4 50–75%
16 volts/7
amps
Be certain of battery terminal polarity and
jumper cable polarity when hooking up
batteries.
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
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).
14.4 volts/4
amps
11.7 or less 0%
6 Hours or
More
14.4 volts/2
amps
WARNING
Batteries contain acid and produce explosive
gases.
Recommended Jump Starting
Procedure
• Shield the eyes and face from the batteries
at all times.
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.
• Do Not lean over the batteries.
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.
CAUTION
Corrosion or loose connections can cause
unwanted electrical voltage spikes at anytime
during the jump starting procedure.
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 28.
Do Not attempt to jump start with loose or
corroded battery terminals or damage to the
engine may occur.
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.
Figure 28
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.
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
6. Discharged battery
7. Engine block
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Maintenance
4. Connect the other end of the positive cable to the
positive terminal of the booster battery.
5. Connect the black negative (–) cable to the other
terminal (negative) of the booster battery.
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).
Installing the Battery
1. Position the battery in the tray with the terminal
posts toward the operating position (Figure 27).
2. Install the positive (red) battery cable to the
positive (+) battery terminal using the fasteners
removed previously.
Figure 29
4. Charge–20 amp
1. Cover
2. Relay
3. Auxilliary–15 amp
5. Main–25 amp
6. Diode
3. Install the negative battery cable to the negative
(-) battery terminal using the fasteners removed
previously.
2. Remove cover as shown in Figure 29.
4. Slide the red terminal boot onto the positive (red)
battery post.
3. To replace a fuse, pull out on the fuse to remove it
5. Secure the battery with the strap (Figure 27).
Drive System Maintenance
Checking the Tire Pressure
Service Interval: Every 25 hours/Monthly
(whichever comes first)
Servicing the Fuses and
Relay
The electrical system is protected by fuses. It requires
no maintenance; however, if a fuse blows, check
the component/circuit for a malfunction or short.
There is also a replaceable relay/s next to the fuse.
Refer to your Parts manual for correct replacement
components.
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 30).
Check the tires when they are cold to get the most
accurate pressure reading.
Fuse Block:
• Main fuse: 25 amp fuse, blade-type
• Charge Circuit: 20 amp fuse, blade-type
• Auxiliary circuit: 15 amp fuse, blade-type
• Diode: TVS
Rear Tires: 13 psi (90 kPa)
Front Tires (caster wheels):
• Smooth: 13 psi (90 kPa)
• Sawtooth: 20 psi (138 kPa)
1. Raise the seat to gain access to the fuse holder
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Maintenance
Inspecting the Blades
1. Inspect the cutting edges (Figure 31). If the edges
are not sharp or have nicks, remove and sharpen
the blades; refer to Sharpening the Blades.
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 31), immediately install
a new blade.
Figure 30
1. Valve stem
Mower Maintenance
Servicing the Cutting Blades
Service Interval: Before each use or daily
Figure 31
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.
1. Cutting edge
2. Curved area
3. Wear/slot forming
Checking for Bent Blades
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.
1. Rotate the blades until the ends face forward and
backward (Figure 32 and Figure 33). Measure
from a level surface to the cutting edge, of the
blades. Note this dimension.
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.
• Inspect the blade periodically for wear or
damage.
• Replace a worn or damaged blade.
Figure 32
48 and 52 Inch Deck
Before Inspecting or Servicing the
Blades
1. Blades front to rear
2. Measure here
Park the machine on a level surface, disengage the
blade control switch, and move the motion control
levers outward to the neutral position and engage
parking brake. Stop the engine, remove the key, and
disconnect the spark plug wire(s) from the spark
plug(s).
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Maintenance
(Figure 34). 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.
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.
Figure 33
42 Inch Deck
1. Blades front to rear
2. Measure here
Hold the blade end using a rag or thickly-padded
glove (or place a wrench on the top sheave nut).
Remove the blade bolt and washer assembly, washer,
and blade from the spindle shaft (Figure 34).
2. Rotate the opposite ends of the blades forward.
3. Measure from a level surface to the cutting edge
of the blades at the same position as in step 1.
The difference between the dimensions obtained
in steps 1 and 3 must not exceed 1/8 inch (3
mm). If this dimension exceeds 1/8 inch (3 mm),
the blade is bent and must be replaced. Refer
to Removing the Blades and Installing the
Blades.
WARNING
A blade that is bent or damaged could break
apart and could seriously injure or kill you or
bystanders.
Figure 34
• Always replace bent or damaged blade with
a new blade.
1. Blade
2. Washer
3. Bolt and washer assembly. Apply lubricant to
threads—torque to 32-42 ft-lb (43-57 N-m).
• Never file or create sharp notches in the
edges or surfaces of blade.
Checking for Loose Blades or
Damaged Spring Disc Washers
Sharpening the Blades
1. Use a file to sharpen the cutting edge at both ends
of the blade (Figure 35). Maintain the original
angle. The blade retains its balance if the same
amount of material is removed from both cutting
edges.
1. Place a wrench on the blade bolt and torque to
32-42 ft lb (43-57 N-m).
2. With the wrench still on the blade bolt, hold the
blade spindle stationary and using a rag or thickly
padded glove, try to rotate the blade. If the blade
rotates relative to the spindle guard without
further tightening the blade bolt, the spring
disc washer has been flattened or damaged and
the bolt and washer assembly must be replaced
41
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Maintenance
Mower Belt Maintenance
Inspecting the Belts
Service Interval: Every 25 hours/Monthly
(whichever comes first)
Figure 35
1. Sharpen at original angle
Check the belts for cracks, frayed edges, burn marks,
or any other damage. Replace damaged belts.
2. Check the balance of the blade by putting it on a
blade balancer (Figure 36). 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 36).
Repeat this procedure until the blade is balanced.
Replacing the Mower Belt
Squealing when the belt is rotating, blades slipping
when cutting grass, frayed belt edges, burn marks,
and cracks are signs of a worn mower belt. Replace
the mower belt if any of these conditions are evident.
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
Figure 36
1. Blade
2. Balancer
3. Set the height-of-cut at 1-1/2 inch (38 mm).
4. For 48 and 52 inch decks only, remove the belt
covers over the outside spindles.
Installing the Blades
1. Install the blade onto the spindle shaft (Figure 34).
5. Grasp both belt strands going to the clutch. Pull
them to the rear of the machine and slip the belt
off the clutch pulley as shown in Figure 37 and
Important: The curved part of the blade
must be pointing upward toward the inside of
the mower to ensure proper cutting.
2. Hold the blade end using a rag or thickly-padded
glove (or place a wrench on the top sheave nut).
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.
WARNING
The spring is under tension when installed
and can cause personal injury.
Be careful when removing the belt.
3. Torque the blade bolt to 32-42 ft-lb (43-57 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.
Always install the original Exmark blades,
washers and blade bolts as shown.
42
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Maintenance
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
3. Check the air pressure of all four tires. If needed,
adjust to the recommended inflation; refer to
Checking the Tire Pressure in Drive System
Maintenance section. If either one is out of range
then follow adjustment procedure.
Figure 37
4. Carefully rotate the blades side to side.
48 and 52 Inch Decks
5. Measure between the outside cutting edges and
the flat surface (Figure 39 and Figure 40). If both
measurements are not within 3/16 inch (5 mm),
an adjustment is required; continue with this
procedure.
1. Outside puley
2. Spring
3. Idler pulley
4. Mower belt
5. Engine pulley
6. Pull belt strands in this
direction.
Figure 38
42 Inch Deck
Figure 39
48 and 52 Inch Decks
1. Outside puley
2. Spring
4. Mower belt
5. Engine pulley
1. Blades side to side
2. Measure here
3. Idler pulley
6. Pull belt strands in this
direction.
6. Route the new belt around the mower pulleys.
7. Grasp both belt strands going to the clutch. Pull
them to the rear of the machine and slip the belt
onto the clutch pulley.
8. For 48 and 52 inch decks only, install the belt
covers over the outside spindles.
Leveling the Mower Deck
The mower blades must be level from side to side.
Check the side-to-side level any time you install the
mower or when you see an uneven cut on your lawn.
Figure 40
42 Inch Deck
1. Blades side to side 2. Measure here
43
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Maintenance
6. Set anti-scalp rollers to top holes or remove
completely for this adjustment.
4. Check the air pressure of all four tires. If needed,
adjust to the recommended inflation; refer to
Checking the Tire Pressure in Drive System
Maintenance section.
7. Set the height-of-cut lever to the 3 inch (76 mm)
position. Place two “B” thick blocks (see Block
Height and Rake Table) under the rear edge of the
cutting deck skirt; one on each side of the cutting
deck. Place two “A” thick blocks under each side
of the front edge of the deck, but not under the
anti-scalp roller brackets.
5. Check and adjust the side-to-side blade level if you
have not checked the setting; refer to Leveling
the Mower.
6. Set the height-of-cut lever to the 3 inch (76 mm)
position. Place two “B” thick blocks (see Block
Height and Rake Table in Leveling the Mower
Deck) under the rear edge of the cutting deck
skirt; one on each side of the cutting deck. Place
two “A” thick blocks (see Block Height and Rake
Table in Leveling the Mower Deck) under each
side of the front edge of the deck, but not under
the anti-scalp roller brackets.
Block Height and Rake Table
Deck Front Block Rear Block
Rake “R”
Size
Height “A”
Height “B”
42
2.19 inches
(5.6 cm)
2.44 inches
(6.2 cm)
1/8–3/8 inch
(3.2–9.5 mm)
48 & 2.31 inches
52
(5.9 cm)
2.50 inches
(6.4 cm)
1/16–5/16 inch
(1.6–7.9 mm)
7. Loosen the leveling adjust locking nuts (item 4)
on all four corners so that the deck is sitting
securely on all four blocks. Make sure that the
deck hangers are all the way down (at the top of
the slot) and the deck lift foot lever is pushed back
against the stop, then tighten the four leveling
adjust locking nuts (Figure 41).
8. Carefully rotate the blades side to side (Figure 39
9. Loosen the leveling adjust locking nuts (item 4)
on all four corners so that the deck is sitting
securely on all four blocks. Make sure that the
deck hangers are all the way down (at the top of
the slot) and the deck lift foot lever is pushed back
against the stop, then tighten the four leveling
adjust locking nuts
10. Recheck that blocks fit just snugly under the deck
skirt. Make sure all attachment bolts are tight
11. Continue leveling the deck by checking the
front-to-rear blade slope; refer to Adjusting the
Front-to-Rear Blade Slope.
12. Recheck blades for levelness and repeat deck
leveling procedure if necessary.
Adjusting the Blade Slope
1. Check the front-to-rear blade level any time you
install the mower. If the front blade tip is not “R”
(see Block Height and Rake Table in Leveling the
Mower Deck) lower than the rear blade tip, adjust
the blade level using the following instructions:
2. Park the machine on a level surface and disengage
the blade control switch.
Figure 41
1. Deck lift arm
3. Deck hanger
2. Float retaining nut
4. Leveling adjust locking
nut
3. Move the motion control levers outward to
the neutral position, engage the parking brake,
stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
8. Carefully rotate the blades so they are facing front
to rear (Figure 42 and Figure 43).
44
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Maintenance
9. Measure from the tip of the front blade to the
flat surface and the tip of the rear blade to the
flat surface (Figure 42 and Figure 43). If the front
blade tip is not “R” (see Block Height and Rake
Table in Leveling the Mower Deck) lower than
the rear blade tip, adjust the front deck hanger.
Replacing the Discharge
Deflector
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.
Never operate the lawn mower unless you install
a mulch plate, discharge deflector, or grass
collection system.
1. Locate items shown in Figure 44.
Figure 42
48 and 52 Inch Decks
1. Blades front to rear
2. Measure here
Figure 44
Figure 43
42 Inch Deck
1. Rod
2. Spring
4. Mower deck
5. Discharge deflector
bracket
3. Discharge deflector
6. Assembled view
1. Blades front to rear
2. Measure here
10. When the front-to-rear blade slope is correct
check the side-to-side level of the mower again;
refer to Leveling the Mower.
2. Slide the rod out of the short stand-off, spring,
and discharge deflector. Remove the damaged or
worn discharge deflector.
3. Install new discharge deflector.
4. Orient the spring so that the short leg points
towards the discharge deflector and the longer leg
points towards the deck as shown in Figure 44.
Place spring on rod and slide rod, straight end,
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Maintenance
through the front discharge deflector bracket,
discharge deflector, and rear deflector bracket.
Adjustments
5. Make sure that the spring and rod are installed
so that the rod is retained from sliding out
by the front bracket and the spring holds the
discharge deflector in the down position. Refer to
(Figure 44) for proper orientation.
Tracking Adjustment
If the machine turns right or left when handles are
pushed forward together, adjust the tracking plate on
the side opposite the direction of turn (see Figure 45).
Loosen the hardware that holds the tracking plate.
Move the plate back until the unit drives straight.
Tighten the hardware to lock the tracking plate in
place. Readjust handles if necessary.
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.
Figure 45
1. Control arm shaft
2. Tracking plate nut
3. Tracking plate
Brake Linkage Adjustment
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to
neutral position, engage parking brake, stop the
engine, remove the key and wait for all moving
parts to stop before leaving the operating position.
3. Setup the machine to be pushed by hand
(see Pushing the Machine by Hand in the
Operation section).
4. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.
5. Engage/disengage the brake and check each drive
tire to make sure each brake engages/disengages.
46
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Maintenance
6. If adjustment is necessary, loosen the jam nut
from the yoke on the side that needs adjustment.
Remove the hairpin and clevis pin (see Figure 46).
Cleaning
Washing the Underside of
the Mower
Service Interval: Before each use or daily
After each use, wash the underside of the mower to
prevent grass buildup for improved mulch action and
clipping dispersal.
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
Figure 46
1. Hairpin
2. Clevis pin
3. Yoke
4. Jam nut
3. Attach the hose coupling to the end of the mower
washout fitting, and turn the water on high
• Adjusting the Brake to Engage: Shorten the
linkage by turning the yoke clockwise.
• Adjusting the Brake to Disengage:
Lengthen the linkage by turning the yoke
counterclockwise.
Note: Spread petroleum jelly on the washout
fitting O-ring to make the coupling slide on easier
and protect the O-ring.
7. Reinstall the clevis pin and hair pin and tighten
down the jam nut. Repeat step 5 and readjust if
necessary.
8. When adjustment is complete, remove the jack
stands or equivalent support and lower the
machine.
9. Place the machine into operating position
(see Pushing the Machine by Hand in the
Operation section).
Figure 47
4. Lower the mower to the lowest height-of-cut.
5. Sit on the seat and start the engine. Engage the
blade control switch and let the mower run for
one to three minutes.
6. Disengage the blade control switch, stop the
engine, and remove the ignition key. Wait for all
moving parts to stop.
7. Turn the water off and remove the coupling from
the washout fitting.
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Maintenance
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.
WARNING
A broken or missing washout fitting could
expose you and others to thrown objects or
blade contact. Contact with blade or thrown
debris can cause injury or death.
• Replace broken or missing washout fitting
immediately, before using mower again.
• Plug any hole(s) in mower with bolts and
locknuts.
• Never put your hands or feet under the
mower or through openings in the mower.
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Storage
D. Restart the engine and run it until it stops.
Storage
Cleaning and Storage
1. Disengage the blade control switch, move the
motion controls outward to the neutral position,
engage parking brake, stop the engine, and
remove the key.
E. Choke the engine. Start and run the engine
until it will not start.
10. Remove the spark plug(s) and check its condition;
refer to Servicing the Spark Plug in 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).
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.
11. Clean any dirt and chaff from the top of the
mower.
Important: You can wash the machine with
mild detergent and water. Do Not pressure
wash the machine. Avoid excessive use of
water, especially near the control panel,
engine, hydraulic pumps, and motors.
12. Scrape any heavy buildup of grass and dirt from
the underside of the mower, then wash the mower
with a garden hose.
3. Service the air cleaner; refer to Servicing the Air
Cleaner in Engine Maintenance section.
13. Check the condition of the drive and mower belts.
14. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is worn or
damaged.
4. Grease and oil the machine; refer to Lubrication
section.
5. Change the crankcase oil and filter; refer
to Servicing the Engine Oil in Engine
Maintenance section.
15. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
16. 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.
6. Check the tire pressure; refer to Checking the
Tire Pressure in Drive System Maintenance
section.
7. Charge the battery; refer to Servicing the
Battery in Electrical System Maintenance section.
8. Check the condition of the blades; refer to
Servicing the Cutting Blades in Mower
Maintenance section.
9. Prepare the machine for storage when non-use
occurs over 30 days. Prepare the machine for
storage as follows.
A. 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.
B. Run the engine to distribute the conditioned
fuel through the fuel system (5 minutes).
C. Stop the engine and turn the fuel shut off
valve 90° to the “off ” position.
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Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be
caused by an empty fuel tank.
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors DO Not pull on the wires to separate the connectors.
Problem
The engine overheats.
Possible Cause
Corrective Action
1. Reduce ground speed.
1. The engine load is excessive.
2. The oil level in the crankcase is low.
2. Add oil to the crankcase.
3. The cooling fins and air passages under
the engine blower housing are plugged.
3. Remove the obstruction from the cooling
fins and air passages.
4. The air cleaner is dirty.
5. Dirt, water, or stale fuel is in fuel system.
4. Clean or replace the air cleaner element.
5. Contact an Authorized Service Dealer.
The starter does not crank
1. The blade control switch is engaged.
1. Move the blade control switch to
Disengaged.
2. The motion control levers are not in the
park position.
2. Move the motion control levers outward
to the park position.
3. The operator is not seated.
3. Sit on the seat.
4. Battery does not have a full charge.
4. Charge the battery. See Check
Battery Charge and Recommended
Jump Starting Procedure sections in
Maintenance.
5. The electrical connections are corroded
or loose.
5. Check the electrical connections for good
contact.
6. A fuse is blown.
6. Replace the fuse.
7. A relay or switch is damaged.
7. Contact an Authorized Service Dealer.
Engine will not start, starts hard, or fails to
keep running
1. Fuel tank is empty.
1. Fill the fuel tank.
2. The choke is not on.
3. The air cleaner is dirty.
4. The spark plug wire(s) is loose or
disconnected.
2. Move the choke lever to On.
3. Clean or replace the air cleaner element.
4. Install the wire(s) on the spark plug.
5. The spark plug(s) is pitted, fouled, or the
gap is incorrect.
5. Install a new, correctly gapped spark
plug(s).
6. There is dirt in fuel filter.
6. Replace the fuel filter.
7. Dirt, water, or stale fuel is in the fuel
system.
7. Contact an Authorized Service Dealer.
8. There is incorrect fuel in the fuel tank.
8. Drain the tank and replace the fuel with
the proper type.
9. The oil level in the crankcase is low.
9. Add oil to the crankcase.
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Troubleshooting
Problem
Engine loses power
Possible Cause
Corrective Action
1. Engine load is excessive.
1. Reduce the ground speed.
2. Air cleaner is dirty.
3. Oil level in the crankcase is low.
2. Clean or replace the air cleaner element.
3. Add oil to the crankcase.
4. Cooling fins and air passages for the
engine are plugged.
4. Remove the obstructions from the cooling
fins and air passages.
5. The spark plug(s) is pitted, fouled, or the
gap is incorrect.
5. Install a new, correctly gapped spark
plug(s).
6. Vent hole in the fuel cap is closed.
7. Dirt in fuel filter.
6. Open the vent in the fuel cap.
7. Replace the fuel filter.
8. Dirt, water, or stale fuel is in the fuel
system.
8. Contact an Authorized Service Dealer.
9. There is incorrect fuel in the fuel tank.
9. 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. Deck belt is worn, loose or broken.
4. Deck belt is off pulley.
3. Install new deck belt.
4. Install deck pulley and check the idler
pulley, idler arm and spring for correct
position and function.
5. The mower belt is worn, loose, or broken. 5. Install a new mower belt.
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Schematics
Schematics
Electrical Diagram
E N G I N E
L T B L U E
B R O W N
D K G R E E N
O R A N G E
P I N K
P I N K
R E D
D K B L U E
V I O L E T
D K G R E E N
P I N K
B L A C K
B L A C K
B R O W N
B R O W N
G R E E N
4
5
3
2
1
G009785
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Schematics
Electrical Logic Schematic
. G R D E K E N
. G R D E K E N
W O N R B
W O N R B
R E D
V I O L E T
O R A N G E
O R A N G E
V I O L E T
R E D
N W O R B
. G R D E K E N
O R A N G E
O R A N G E
P I N K
P I N K
V I O L E T
R E D
R E D
. B L U D E K
. B L U D E K
O R A N G E
V I O L E T
. G R D E K E N
. G R D E K E N
. G R D E K E N
C A K B L
P I N K
P I N K
P I N K
C A K B L
C A K B L
W O N R B
W O N R B
W O N R B
W H I T E
W O
W O
Y E L L
Y E L L
Y A G R
G009777
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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*
3-Year, 3rd Year Covered by Exmark
* Please refer to the manufacturer’s warranty statement that is
included in the literature packet. The manufacturer provides a 2 year
warranty. Exmark Warranty Company extends coverage for
warrantable engine items as defined by the manufacturer’s original
warranty during the 3rd year of warranty.
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.
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.
Such damages include but are not limited to:
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.
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other extraordinary
repair charges or charges relating to repairs or replacements
outside of normal business hours at the place of business of the
authorized Exmark Service Dealer.
• Rental of like or similar replacement equipment during the period
of any warranty, repair or replacement work.
• Any telephone or telegram charges or travel charges.
• Loss or damage to person or property other than that covered by
the terms of this warranty.
Warranty Exception
• Air Cooled Gas Engines
Warranty Period
90 days
Items and Conditions Not Covered
This warranty does not cover the following:
• Pickup and delivery charges to and from any authorized Exmark
Service Dealer beyond first warrantable service.
• Any damage or deterioration due to normal use, wear and tear, or
exposure.
• Cost of regular maintenance service or parts, such as filters, fuel,
lubricants, tune-up parts, and adjustments.
• Any claims for lost revenue, lost profit or additional cost as a result
of a claim of breach of warranty.
• Attorney's fees.
• Any product or part which has been altered or misused or required
replacement or repair due to normal wear, accidents, or lack of
proper maintenance.
• Any repairs necessary due to use of parts, accessories or supplies,
including gasoline, oil or lubricants, incompatible with the turf
equipment or other than as recommended in the operator's manual
or other operational instructions provided by Exmark.
No Claim of breach of warranty shall be cause for cancellation or
rescission of the contract of sale of any Exmark mower.
All implied warranties of merchantability (that the product is fit
for ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
There are no other express warranties except for engine and special
emission system coverage.
All warranty work must be performed by an authorized Exmark
Service Dealer using Exmark approved replacement parts.
This warranty gives you specific legal rights, and you may also have
other rights which vary from state to state.
G4500-428_B
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Notes:
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Notes:
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Service Record
Date:
Description of Work Done:
Service Done By:
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SEE EXMARK’S COMPLETE LINE OF 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
ROLL OVER PROTECTION SYSTEM (ROPS)
SUN SHADE
TRASH CONTAINER
LIGHT KIT
TURF STRIPER
12V POWER PORT
ULTRA VAC COLLECTION SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
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
Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Date Purchased
Engine Model No. and Spec. No.
Engine Serial No. (E/No)
Model No.
Serial No.
©2010 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
Part No. 4500-523 Rev. B
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
All Rights Reserved
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