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Exmark 4501-191 Rev.A Lawn Mower User Manual

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2. Figure 30 Positive cable on discharged battery Positive cable on booster battery Negative cable on the booster battery Negative cable on the engine block Booster battery Discharged battery Engine block Connect the other end of the positive cable to the positive terminal of the booster battery Connect the black negative cable to the other terminal negative of the booster battery MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE NOT TO THE NEGATIVE POST AWAY FROM THE BATTERY STAND BACK 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 Position the battery in the tray with the terminal posts toward the operating position Figure 29 Install the positive red battery cable to the positive battery terminal using the fasteners removed previously Install the negative battery cable to the negative battery terminal using the fasteners removed previously Slide the red terminal boot onto the positive red battery post Secure the battery with the strap Figure 29 Maintenance Servicing the Fuses Service Interval As required The electrical system is protected by fuses It requires no maintenance however if a fuse blows check the component circuit for a malfunction or shott Fuse Main F 1 30 amp blade type Charge Circuit
3. Tee fitting vent line In line fuel filter Flow direction arrow Fuel line to engine Hose clamp Emissions filter Open port 5 6 7 Fuel line from tank 8 4 Squeeze the ends of the hose clamps together slide them away from the filter Figure 28 5 Remove the filter from the fuel lines 6 Install a new filter with the flow direction arrow coming from the fuel tank and pointing to the engine Move the hose clamps close to the filter Figure 28 to secure it in place Servicing the Emissions Filter Service Interval Yearly The machine is equipped with a emissions filter Figure 28 connected to a tee fitting on the vent line coming from the gas tank The filter has an open port by design The filter should be inspected regularly Replace the filter if the filter is dirty or clogged 35 Maintenance Electrical System Maintenance A WARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Charging the Battery Removing the Battery WARNING Battery terminals or metal tools could short against metal machine components causing spatks Sparks can cause the battery gasses to explode resulting in personal injury When removing or installing the battery Do Not allow the battery terminals t
4. HY EMS M N na M A9 3009 310100 QIoN310S N9 AM3LIV8 440 AGL NO QION310S f8 34 a Old v 1 M3l4vIS zZ 0103105 A9 OIA y z 4 vas NI 4 N 440 sumoH o MS YAS MS Old 3574 2118 YMS ps ZMS gt ig SNOILO3NNOO 3NI9N3 l HOLIMS JO 5 H SNOLLO3NNOO HOLIMS A33 LMS 5 V i 4 9 NOLLO3NNOO ON QN3931 HOLIMS A35 5 84 8 LYVIS NO 330 G014644 57 Exmark Quest Turf Equipment 3 Year Limited Consumer Warranty 30 Day Limited Commercial Warranty Consumer Warranty Conditions and Products Covered Exmark Mfg Co Inc and its affiliate Exmark Warranty Company pursuant to an agreement between them jointly warrant on the terms and conditions herein that we will repair replace or adjust any part 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 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 This warranty applies
5. May need more often under extremely dusty or dirty conditions Check the air cleaner daily or before starting the engine Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace all bent or damaged air cleaner components Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Note Service the air cleaner more often under extremely dusty dirty conditions 1 Park the machine level surface disengage the blade control switch move the motion control levers to the brake position stop the engine and remove the key 2 Clean around the air cleaner cover to prevent dirt from getting into the engine and causing damage Lift the cover and remove the hose clamp securing the air cleaner assembly to the engine Figure 23 3 Loosen the hose clamp and remove the paper element Figure 23 Figure 23 1 Cover 3 Hose clamp 2 Paper element Cleaning the Element Service Interval Every 100 hours Service the paper element more often in dusty dirty conditions Every 200 hours Yearly whichever comes first Replace the paper element more often in dusty dirty conditions 1 Lightly tap the element on a flat surface to remove dust and dirt Inspect the element for tears an oily film and damage to the seal Importa
6. Place the throttle midway between the SLOW and FAST positions 5 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 6 Remove the key to prevent children or other unauthorized persons from starting engine 21 Operation The Safety Interlock System A CAUTION If the safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury Do not tamper with the interlock switches Check the operation of the interlock switches daily and replace any damaged switches before operating the machine Understanding the Safety Interlock System The safety interlock system is designed to prevent the engine from starting unless The blades are disengaged The motion control levers are in the neutral position The parking brake is engaged The safety interlock system is designed to initiate engine shutdown when The parking brake is disengaged and the operator gets off machine The PTO is engaged and the operator gets off machine The parking brake is disengaged and levers are in and the operator gets off machine Testing the Safety Interlock System Test the safety interlock system before you use the machine each time 1 Check starting circuit Starter should crank with the PTO disengaged and motion control levers moved out in the parking brake position The
7. and turn the water on high Figure 61 Note Spread petroleum jelly on the washout fitting O ring to make the coupling slide on easier and protect the O ring G003934 Figure 61 1 Washout fitting 3 O ring 2 Hose 4 Coupling 4 Lower the mower to the lowest height of cut Sit on the seat and start the engine Engage the blade control switch and let the mower tun for one to three minutes Disengage the blade control switch stop the engine and remove the ignition key Wait for all moving parts to stop Turn the water off and remove the coupling from the washout fitting Note If the mower is not clean after one washing soak it and let it stand for 30 minutes Then repeat the process Run the mower again for one to three minutes to remove excess water A 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 missing washout fitting immediately before using mower again Never put your hands or feet under the mower or through openings in the mower Clean Engine and Exhaust System Area Service Interval Before each use or daily May be required more often in dry or dirty conditions CAUTION Excessive debris around engine cooling air intake and exhaust system area can cause engine exhaust area and hydraulic system to overheat which can create a fire hazard Cl
8. release the key Figure 8 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 motot Once the engine starts gradually push down the choke control as the engine warms If the engine stalls or hesitates slightly pull the control up for a few seconds Operating the Blades The blade control switch represented by a power take off PTO symbol engages and disengages power to the mower blades This switch controls power to any attachments that draw power from the engine including the mower deck and cutting blades Engaging the Blades 1 Release pressure on the motion control levers and place the machine in neutral 2 Move the throttle midway to the Fast position Note Always engage the blades with the throttle in the midway position 3 Pull out on the blade control switch to the On position to engage the blades Figure 9 G015095 Figure 9 1 Throttle Midway position 2 Blade control switch On position 4 Move throttle to full forward position before mowing Disengaging the Blades Set throttle to midway position Push the blade control switch to Off to disengage the blades Figure 8 the Engine Bring the unit to a full stop 2 Disengage the blades 3 Move the motion control levers out to engage the parking brake 4
9. reta ete Qao zr Transportno ec Gomes TINO 27 Operatino Lips 28 ir M 30 Recommended Maintenance Schedule s 30 Prenaintenance Procedures 31 tlie S edt ocean nth trip Pon tu RORIS 31 Periodic Maintenance 31 hin 31 Engine Maintenances 32 Servicing the Engine CIL boe eas 32 Servicing the Spark Plog eee irren 34 Cleaning the Blower Housing ete 25 Fuel System Maintenance 35 Servicing the Emissions Filter 35 Electrical System Maintenance 36 Charging the 36 Drive System Maintenance aste 39 Checking the Tire Pressure lt 39 Checking the Hydraulic Oil Level 39 Changing the Hydraulic System Filter and S M 40 Mower Maintenance oed epe trop 42 Servicing the Cutting Blades 42 Leveling the Mower Deck 45 Mower Belt Maintenance aset 48 Replacing the Discharge Deflector 50 Tfi Go 22 Washing the Underside of the Mower 52 Clean Engine and Exhaust System oE L NUR 52 53 Cleaning and e ae 53 54 Schematics 56 Sa
10. E 3 0 inch 76mm Figure 15 50 Inch Deck For cutting heights above 3 1 2 inches 90 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller 2 Outting height mounting bracket G015097 7 Torque hardware to 27 33 ft lb 37 45 N m or Figure 17 loss of toller may result 1 Adjustment lever Positioning the Seat The seat can move forwatd and backward Position the seat where you have the best control of the machine and are most comfortable 42 Inch Unit 2 Move the seat to the desired position and release the lever to lock in that position 25 Operation Changing the Seat Ride Suspension The number of seat springs can be changed to maximize rider comfort More springs should be used with heavier operators and on rough terrain Fewer springs should be used with lighter operators and when mowing smooth well established lawns Always keep the number of springs on the left and right side the same when adding and removing springs 6015098 4 Figure 18 1 Bolt 3 Nut 2 Spring 4 Additional mounting holes Up to five springs can be secured to the seat box with a nut and bolt see Figure 18 Refer to your Parts Manual for spring and hardware part numbers Adjusting the Motion Control Levers Adjusting the Height The motion control levers can be adjusted higher or lower for maximum operator comfort 1 Remove the hardware holding
11. F2 25 amp blade type 1 Remove the four screws securing the control panel to the machine Retain all fasteners 2 Lift the control pane up to access the main wiring harness and fuse block Figure 31 3 replace a fuse pull out on the fuse to remove it Figure 31 A Ys NUS 37 frm NS E 1 Main 30 amp 2 Charge circuit 25 amp 4 Return the control panel to its original position Use the four screws removed previously to secure the panel to the machine Drive System Maintenance Checking the Tire Pressure Service Interval Every 25 hours Monthly whichever comes first Maintain the air pressure in the front and rear tires as specified Uneven tire pressure can cause uneven cut Check the pressure at the valve stem Figure 32 Check the tires when they are cold to get the most accurate pressure reading Rear Tires 13 psi 90 kPa 39 Front Tires caster wheels Ribbed 13 psi 90 kPa Smooth 20 psi 138 kPa G007275 Figure 32 1 Valve stem Releasing the Electric Brake Service Interval As required The electric brake can be release by manually rotating the link arms forward Once the electric brake is energized the brake will reset release the brake G015000 Figure 33 1 Brake link arm on the electric brake control module Locate the shaft on the electric brake where the brake link arms are connected 1 2 Rotate the s
12. Important Refer to your Engine Operator s Manual for additional maintenance procedures Premaintenance Periodic Maintenance Procedures Lubrication Raising the Seat Make sute the motion control levets are locked in the park position Lift the seat forward Greasing the Bearings Service Interval Every 25 hours Monthly whichever comes first The following components can be accessed by raising heset Grease Type NGLI grade 2 multi purpose gun grease e Serial plate Grease the front caster wheels Figure 21 Service decal Seat adjustment bolts Fuel filter G007184 Battery and battery cables 1 Figure 21 1 Front caster tire 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to engage parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Clean the grease fittings shown in Figure 22 with tag Make sure to scrape any paint off of the front of the fitting s 31 Maintenance Figure 22 Located on the seat pan 1 Read the instructions before servicing or performing maintenance 2 Check tire pressure every 25 operating hours 3 Grease every 25 operating hours 4 Engine 4 Wipe up any excess grease Engine Maintenance Servicing the Air Cleaner Service Interval Every 25 hours Monthly whichever comes first
13. No E No Serial No 2011 Exmark Mfg Co Inc Part No 4501 191 Rev A Industrial Park Box 808 Printed in the USA Cf Beatrice NE 68310 8 Rights Reserved www exmark com
14. an unbroken ramp surface wider than the unit Do Not exceed a 15 angle between ramp and ground or between ramp and trailer or truck 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 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 sutface 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 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 Important Do Not attempt to turn the unit
15. areas on the incline e 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 G007037 Figure 6 1 Water 2 Danger Zone Use walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water Safe Zone use the Quest here injuty See inside back cover to determine the approximate slope angle to be mowed 18 Operation Recommended Gasoline Fill fuel tank on level ground See Fuel Recommendations in the Specifications section for additional gasoline information Do Not add oil to gasoline Do Not overfill fuel tank Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system A DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A fire 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 Never refill the fuel tank or drain the machine indoors or inside an enclosed trailer Do Not fill the fuel tank completely full Add ga
16. before making sharp turns Forward 1 Move the levers to the center unlocked position 2 To go forward slowly push the motion control levers forward Figure 10 22 Operation N Figure 10 Parking brake position 4 Forward engaged Center unlock position 5 Backward neutral Front of unit To go straight apply equal pressure to both motion control levers Figure 10 and Figure 11 23 Z G008952 To turn pull back on the motion control lever toward the direction you want to turn Figure 10 and Figure 11 The farther you move the motion control levers in either direction the faster the machine will move in that direction To stop pull the motion control levers to neutral Backward 1 Move the levers to the center unlocked position 2 To go backward slowly pull the motion control levers rearward Figure 10 and Figure 12 Operation eta E ET S C K at A 29 6008953 Figure 12 To go straight apply equal pressure to both motion control levers Figure 10 and Figure 12 To turn release the pressure on the motion control lever toward the direction you want to turn Figure 10 and Figure 12 To stop push the motion control levers to neutral Stopping the Machine To stop the machine move the motion control levers to neutral disengage the blade control switch move th
17. complete 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 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 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 e Cleans the engine while it runs e Eliminates gum like varnish buildup in the fuel system which causes hard starting Add the Operation correct amount of gas stabilizer conditioner to the gas Note A fuel stabilizer conditioner is most effective when mixed with fresh gasoline minimize the chance of varnish deposits in the fuel system use fuel stabilizer at all times Filling the Fuel Tank Make sure the engine is shut off and the motion controls are in the park position Tank maximum capacity is 2 9 gallons Important Do Not overfill fuel tank Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows the fuel to expand Overfilling may result in fuel leakage or damage to the engine or emission system 1 Shut the engine off and move the motion controls outward to engage park
18. cutting height which is a good practice mow more often in early spring As the grass growth rate slows in mid summer mow less frequently If you cannot mow for an extended period first mow at a high cutting height then mow again two days later at a lower height setting Cutting Speed To improve cut quality use a slower ground speed Avoid Cutting Too Low If the cutting width of the mower is wider than the mower you previously used raise the cutting height to ensure that uneven turf is not cut too short 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 incre
19. engine with the oil level below the ADD mark or over the FULL mark on the dipstick Changing the Oil and Filter Service Interval After the first 5 hours Every 100 hours Yearly whichever comes first thereafter 33 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 1 Start the engine and let it run until warm This warms the oil so it drains better 2 Disengage the blade control switch and move the motion controls outward to the parking brake position 3 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 4 Clean the area around the oil drain valve and on the machine frame 5 Install the oil drain hose located in the literature pack onto the oil drain valve Figure 25 Remove the oil fill cap dipstick G015104 Figure 25 1 Oil filter 4 Oil drain hose Oil fill cap dipstick 5 Pan on Oil drain valve 6 Place a pan under the open end of the hose 7 Open the drain valve by turning hex end counterclockwise Be sure to allow ample time for complete drainage 8 Remove the old filter and wipe off the mounting pad 9 When the oil has drained completely close the oil drain valve by rotating it clockwise and remove Maintenance and retain the hose Wipe up any excess
20. high securing the filter guard and guard enough to allow drive wheels to turn freely 40 Maintenance Figure 37 Right side shown 1 Transaxle drive 4 Screws 2 Oil filter 5 Vent plug 3 Filter guard 5 Carefully clean area around filters It is important that no dirt or contamination enter hydraulic system 6 Place a container below the filter to catch the oil that drains when the filter and vent plugs are removed 7 Locate and remove the vent plug on each transmission 8 Unscrew the filter to remove and allow oil to drain from drive system Repeat this procedure for both filters 41 Installing the Hydraulic System Filters G008748 Figure 38 Apply a thin coat of oil on the surface of the rubber seal of each filter Turn the filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 3 4 to 1 full turn Repeat for the other filter Install the filter guards over each filter as previously removed Use the three screws to secure the filter guards Verify the vent plugs are removed before adding the oil Slowly pour the specified oil through expansion reservoir until oil comes out of one of the vent plug holes Stop and install that vent plug Torque the plug to 180 in lb 20 3 N m Continue to add oil through the expansion reservoir until oil comes out of the remaining vent plug hole on th
21. is not balanced file some metal off the end of the sail area only Figure 46 Repeat this procedure until the blade is balanced A N Figure 46 G007201 1 Blade 2 Balancer Installing the Blades 1 Install the blade onto the spindle shaft Figure 44 Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting 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 Torque the blade bolt to 35 65 ft lb 47 88 N m WARNING Incorrect installation of the blade or components used to retain the blade cause the blade to come loose and could seriously injure or kill you or bystanders Always install the original Exmark blades washets and blade bolts as shown Leveling the Mower Deck Check to ensure the mower deck is level any time you install the mower or when you see an uneven cut on your lawn The mower deck must be checked for bent blades prior to leveling any bent blades must be removed and replaced Refer to the Checking for Bent Blades procedure before continuing The mower deck must be leveled side to side first then the front to rear slope can be adjusted Requirements The ma
22. operating near or crossing roadways Use extra care when loading or unloading the machine into a trailer or truck Always wear eye protection when operating the mowet 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 Safety safely enough to protect themselves and others from serious injury 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 Do Not mow slopes greater than 15 degrees e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine e Choose 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 e Reduce speed and use extreme caution on slopes Do Not make sudden turns or rapid speed changes e Remove mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles Avoid sudden starts when mowing uphill because
23. operator does not need to be in the seat to start the engine Try to start with operator in seat PTO disengaged and motion control levers in the parking brake position starter must not crank Try to start with operator in seat PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank Check kill circuits Run engine at one third throttle engage PTO and raise off of seat but do not get off of machine engine must initiate shutdown 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 Note If machine does not pass any of these tests Do Not operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm revolutions per minute Place the throttle control in the Fast position for best performance Always operate in the Fast full throttle position 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 Use caution when making turns Slow the machine down
24. page be copied for personal use The maximum slope you can safely operate the machine on is 15 degrees Use the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope Align this edge with a vertical surface a tree building fence pole etc Example of how to compare slope with folded edge 63 EXMARK ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT SUN SHADE DECK LIFT ASSIST KIT TRASH CONTAINER HITCH KIT TURF STRIPER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM LIGHT KIT 12V POWER PORT MICRO MULCH SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB WALK BEHIND ACCESSORIES AND OPTIONS GRASS CATCHER MICRO MULCH SYSTEM TURF STRIPER STANDON Some accessories and options not available for some models Place Model No and Serial No Date Purchased Label Here Included in the Literature Pack or Fill in Below Engine Model No and Spec No Model No Engine Serial
25. stop before leaving the operating position 3 Raise the seat 4 Disconnect the negative black ground cable from the battery post Figure 29 Retain all fastenets 36 Maintenance 1 2 Bolt washer and nut 5 3 Terminal boot G009783 Figure 29 Negative battery post 4 Positive battery post Battery strap 6 Battery A WARNING Incorrect battery cable routing could damage the machine and cables causing sparks Sparks can cause the battery gasses to explode resulting in personal injury e Always disconnect the negative black battery cable before disconnecting the positive red cable Always connect the positive red battery cable before connecting the negative black cable Slide the rubber cover up the positive red cable Disconnect the positive red cable from the battery post Retain all fasteners Remove the battery strap Figure 29 and lift the battery from the battery tray Checking the Battery Charge 1 2 Remove the battery from the chassis refer to Removing the Battery Allowing batteries to stand for an extended period without recharging them will result in reduced performance and service life preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts 37 12 6 100 greater Note To prevent damage due to freezing battery should be fully charged before putting away for
26. such as filters fuel lubricants tune up parts and adjustments Any product or part which has been altered or misused or required replacement or repair due to normal wear accidents or lack of proper maintenance Any repairs necessary due to use of parts accessories or supplies including gasoline oil or lubricants incompatible with the turf equipment or other than as recommended in the operator s manual or other operational instructions provided by Exmark There are no other express warranties except for engine and special emission system coverage All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark Service Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at their dealership To locate a dealer convenient to you access our website at www exmark com U S or Canada customers may also call 402 223 6375 If for any reason you are dissatisfied with the Service Dealer s analysis or with the assistance provided contact us at Exmark Customer Service Department The Exmark Warranty Company 2101 Ashland Avenue Beatrice NE 68310 402 223 6375 or service exmark com Owner s Responsibilities If your product requires warranty service it must be returned to an authorized Exmark service de
27. the blade to the flat surface here Park the machine on a level surface and disengage the blade control switch Move the motion control levers outward to the park position stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Set the height of cut lever to middle position Note Check and adjust the side to side blade level if you have not checked the setting refer to Side to Side Leveling Carefully rotate the blades so they are facing front to rear Figure 51 and Figure 52 Figure 51 42 Inch Decks Blades front to rear 1 0009659 Figure 52 50 Inch Decks Blades front to rear 2 Outside cutting edges 3 Measure from the tip of the blade to the flat surface here 5 1 Measure from the of the front blade to the flat surface and the tip of the rear blade to the flat surface Figure 51 and Figure 52 If the front blade tip is not 1 16 5 16 inch 1 6 7 9 mm lower than the rear blade tip adjust the front locknut To adjust the front to rear blade slope rotate the adjustment nut in the front of the mower Figure 53 ir BM wees C Lo E 7 SS 0014634 Figure 53 Adjusting rod 3 Lock nut 2 Adjusting block d 47 To raise the front of the mower tighten the adjustment nut To lower the front of
28. the control lever to the control arm shaft Figure 19 G015099 Figure 19 1 Control arm shaft 3 Washer 2 Control lever 4 Bolt 2 Move the conttol lever to the next set of holes Secute the levet with the hardware 3 Repeat the adjustment for the opposite control levet 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 2 Loosen the lower bolt just enough to pivot the control lever fore or aft Figure 19 Tighten both bolts to secure the control in the new position 3 Repeat the adjustment for the opposite control lever Pushing the Machine by Hand Important Always push the machine by hand Never tow the machine because damage may occur This machine has an electric brake mechanism and to push the machine the ignition key needs to be in the Run position The battery needs to be charged and functioning for the electric brake to be disengage To Push the Machine 1 Park the machine on a level surface and disengage the blade control switch 26 Operation 2 Move the motion control levers outward to park position stop the engine and wait for all moving parts to stop before leaving the operating position 3 Locate the bypass levers on the frame on both sides of the engine 4 Move the bypass levers forward through the key hole and down to lock them in p
29. the mower loosen the adjustment nut After adjustment check the front to rear slope again Continue adjusting the nut until the front Maintenance blade tip is 1 16 5 16 inch 1 6 7 9 mm lower than the rear blade tip Figure 51 and Figure 52 9 When the front to rear blade slope is correct check the side to side level of the mower again refer to Leveling the Mower from Side to Side Removing the Mower Service Interval As required 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to the park position stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Lower the height of cut lever to the lowest position 4 Remove the hairpin cotter from the front support rod and remove the rod from the deck bracket Figure 54 Carefully lower the front of the mower deck to the ground 6014635 Figure 54 1 Front support rod 3 Deck bracket 2 Locking nut 5 Lift the mower deck and hanger brackets clear of the rear lift rod and lower the mower carefully to the ground Figure 55 G005077 Figure 55 1 Mower deck 3 Rear lift rod 2 Hanger bracket 6 Slide the mower deck rearward to remove the mower belt from the engine pulley 7 Slide the mower deck out from underneath the machine Note Retain all parts f
30. the mower may tip backwards e 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 Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Use extreme care with grass collection systems or other attachments These can change the stability of the machine and cause loss of control Do Not try to stabilize the machine by putting your foot on the ground Do Not mow near drop offs ditches steep banks water Wheels dropping over edges can cause rollovers which may result in serious injury death ot drowning Use a walk behind mower and or a hand trimmer on slopes greater than 15 degrees near drop offs ditches steep banks or water Children Tragic accidents can occur if the operator is not alert to the presence of children Children are often attracted to the machine and the mowing activity Never assume that children will remain where you last saw them e Keep children out of the mowing area and under the watchful care of another responsible adult not the operator e Be alert and turn the machine off if children enter the area Before and while backing or changing direction look behind down and side to side for small children Never carry children even with the
31. winter storage Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table below and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery cable is disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Percent Charge Maximum Charging No Charging Required 16 volts 7 amps 12 4 12 6 75 100 16 volts 7 30 Minutes amps 122 124 50 75 16 volts 7 1 Hour amps 12 0 12 2 25 50 14 4 volts 4 2 Hours amps 11 7 12 0 0 25 14 4 volts 4 3 Hours amps 11 7 or less 0 14 4 volts 2 6 Hours ot amps More Recommended Jump Starting Procedure 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 necessaty CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine may occur Maintenance 4 DANGER Jump starting a weak battery that is cracked frozen has low electrolyte level or an open shorted battery cell can c
32. 2 inch unit Two Hydro Gear 272100 Integrated drive systems 50 inch E Series unit Two Hydro Gear ZT2200 Integrated drive systems 50 inch S Series unit Two Hydro Gear Z 12800 Integrated drive systems Hydraulic Oil Type Exmark Premium Hydro Oil Speeds 0 7 0 mph 11 3 km hr forward 0 5 0 mph 8 0 km hr reverse Drive wheel releases located on left and right sides of engine deck allow machine to be moved when the engine is not running and brake is off Tires and Wheels ae Premium Premium Master 90 kPa 90 kPa 90 kPa SS 410 350 x 4 13 x 5 6 Pressure 20 psi 13 psi 138 kPa 90 kPa Cutting Deck Cutting Width 42inch Deck 42 inches 107 cm 50 inch Deck 50 inches 127 cm Discharge Side Blade Size 42 inch Deck 21 60 inches 54 9 cm Qty 2 50 inch Deck 17 50 inches 44 5 cm Qty 3 Blade Spindles Solid steel spindles with no maintenance bearings Deck Drive Electric clutch mounted on vertical engine shaft Blades are driven by one belt w self tensioning idler direct from the engine Deck Full floating deck is attached to out front support frame Maximum turf protection is provided with anti scalp rollers Deck design allows for bagging mulching or side discharge Deck Depth 42 inch Deck 4 0 inches 10 2 cm 50 inch Deck 4 0 inches 10 2 cm Cutting Height Adjustment A hand deck lift lever with foot assist
33. 5462 120 5462 42 Inch Model 1 Fast 3 Slow 2 Continuous variable setting 4 Choke Safety 120 2239 Warning read the Operator s Manual Warning read the instructions before servicing or performing maintenance move the motion control levers to the park brake position remove the ignition key and disconnect the spark plug wire Cutting dismemberment hazard mower blade entanglement hazard belt stay away from moving parts keep all guards and shields in place Thrown object hazard keep bystanders a safe distance from the machine pick up debris before operating keep deflector in place 5 Warning do not use split ramps use a full ramps when transporting machine Loss of traction control hazard slopes ioss of traction control on a slope disengage the blade control switch PTO proceed off the slope slowly 6 7 Crushing dismemberment hazard of bystanders reversing crushing dismemberment hazard of bystanders do not carry passengers look behind and down when reversing 8 Tipping hazard do not mow slopes greater than 15 degrees avoid sudden and sharp turns while on slopes o 2 d Battery Symbols Some or all of these symbols are on your battery Explosion hazard No fire open flames or smoking 5 Read the Operator s Manual 6 Keep bystanders a safe distance 9 Flush eyes immediately with water and get medical help fast 10 Contains l
34. EDITT MUL LES Ji QUEST 312 000 000 amp Higher Part No 4501 191 Rev A For Serial Nos A WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Important The engine in this product is not equipped with a spark arrester muffler It is a violation of California Public Resource Code CPRC Section 4442 to use or operate this engine on any forest covered brush covered ot gtass covered land as defined in CPRC 4126 Other states or federal areas may have similar laws To acquire a spark arrester for your unit see your Engine Service Dealer This spark ignition system complies with the Canadian standard ICES 002 A WARNING Removing standard original equipment parts and accessories may alter the warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury death Making unauthorized changes to the engine or fuel system may violate EPA and CARB regulations Replace all parts including but not limited to tires belts blades and fuel system components with original Exmark parts The enclosed Engine Owner s Manual is supplied for information regarding the US Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Replaceme
35. To ensure proper cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times 1 Remove the blower housing and any other cooling shrouds 2 Clean the cooling fins and external surfaces as necessary 3 Make sure the cooling shrouds are reinstalled Important Operating the engine with a blocked grass screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating Fuel System Maintenance Replacing the Fuel Filter Service Interval Every 100 hours Yearly whichever comes first A 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 e 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 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 Move the motion control levers outward to engage parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 The fuel filter is in the fuel line between the tank and engine 6015165 Figure 28
36. When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds then the transaxle 1s considered purged Check the oil level in the expansion reservoir one last time Add the specified oil as until it reaches the FULL COLD line on the expansion reservoir if necessaty Mower Maintenance Servicing the Cutting Blades Service Interval Before each use or daily Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades Tearing and shredding turns grass brown at the edges which slows growth and increases the chance of disease Check the cutter blades daily for sharpness and for any wear damage File down any nicks and sharpen the blades as necessary If a blade is damaged or worn replace it immediately with a genuine Exmark replacement blade For convenient sharpening and replacement you may want to keep extra blades on hand A WARNING A worn damaged blade can break and a piece of the blade could be thrown into the operator s ot bystander s area resulting in serious personal injury or death Inspect the blade periodically for wear or damage Replace a worn ot damaged blade Before Inspecting or Servicing the Blades Park the machine on a level surface disengage the blade control switch and move the motion control levers outward to engage parking brake Stop the engine remove the key and di
37. a new correctly gapped spark plug s Replace the fuel filter Contact an Authorized Service Dealer Drain the tank and replace the fuel with the proper type Add oil to the crankcase Troubleshooting Engine loses power The machine does not drive Abnormal vibration Uneven cutting height Blades do not rotate Engine load is excessive Air cleaner is dirty Oil level in the crankcase is low Cooling fins and ait passages for the engine are plugged The spark plug s is pitted fouled or the gap is incorrect Dirt in fuel filter Dirt water or stale fuel is in the fuel system There is incorrect fuel in the fuel tank The drive belts are worn loose or broken The drive belts are off of the pulleys The drive is in bypass mode Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Cutting blade s is are bent or unbalanced Blade is loose Blade spindle is bent Blade s not sharp Cutting blade s is are bent A blade is loose Mower deck is not level An anti scalp wheel is not set correctly Underside of mower is dirty Tire pressure in drive tires not correct Blade spindle bent Drive belt is worn loose or broken Drive belt is off pulley The mower belt is worn loose or broken 55 Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstruct
38. ace here The variance should be no more 1 Deck 3 Blade than 1 8 inch mm 2 Spindle housing 3 Measure from the tip of the blade to the flat sutface here 43 Maintenance G014973 Figure 43 Opposing blade edge in position for measuring Level surface Second measured distance between blade and surface B 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 A If the difference between A and B is greater than 1 8 inch 3mm replace the blade with a new blade Refer to Removing the Blades and Installing the Blades Note If a bent blade is replaced with a new one and the dimension obtained continues to exceed 1 8 inch 3mm the blade spindle could be bent Contact an Authotized Exmark Dealer for service B If the variance is within constraints move to the next blade Repeat this procedure on each blade Checking for Loose Blades or Damaged Spring Disc Washers 1 Place a wrench on the blade bolt and torque to 35 65 ft lb 47 88 N m 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 bla
39. aler within the warranty period This warranty extends only to turf equipment operated under normal conditions You must read the operator s manual You must also properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense General Conditions The sole liability of Exmark and Exmark Warranty Company with respect to this warranty shall be repair 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 Such damages include but are not limited to Expenses related to gasoline oil or lubricants Travel time overtime after hours time or other extraordinary repair charges or charges relating to repairs or replacements outside of normal business hours at the place of business of the authorized Exmark Service Dealer Rental of like or similar replacement equipment during the period of any warranty repair or replacement work Any telephone or telegram charges or travel charges Loss or damage to person or property other than that covered by the terms of this warranty Any claims for lost revenue lost profit or additional cost as a result of a claim of breach of warranty Attorney s fees No Claim of breach of warranty shall be cause for cancellation or rescission of the contract of sale
40. ases the chance of disease Check the cutter blades daily for sharpness and for any wear or damage File down any nicks and sharpen the blades as necessary If a blade is damaged or worn replace it immediately with a genuine Exmark replacement blade Only Exmark blades are to be used with this unit No other blades are approved 29 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position 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 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 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 A WARNING Removing standard original equipment parts and accessories may alter the warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury or death Making unauthorized changes to the engine or fuel system may violate EPA and CARB regulations Replace all parts including but not limited to tires belts blades and fuel system components with o
41. ause an explosion resulting in serious personal injury Do Not jump start a weak battery if these conditions exist 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 ot labeled for the correct polarity CAUTION Connecting the jumper cables incorrectly wrong polarity can immediately damage the electrical system Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries 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 WARNING Batteries contain acid and produce explosive gases Shield the eyes and face from the batteries at all times 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 Connect the positive cable to the positive terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 30 38 WN D gt 0012785
42. blades off They may fall off and be seriously injured or interfere with safe machine operation Children who have been given rides in the past may suddenly appear in the mowing area for another ride and be run over or backed over by the mower Never allow children to operate the machine Use extra care when approaching blind corners shrubs trees the end of a fence or other objects that may obscure vision Towing Use for towing only if equipped with an Exmark hitch kit Do Not attach towed equipment except at the hitch point 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 Never allow children or others in or on towed equipment On slopes the weight of the towed equipment may cause loss of traction and loss of control Travel slowly and allow extra distance to stop Service Safe Handling of Gasoline To avoid personal injury or property damage use extra care when handling gasoline and other fuels They are flammable and the vapors are explosive Safety Extinguish all cigarettes cigars pipes and other sources of ignition Use only an approved container Never remove the gas cap or add fuel when the engine is running Allow the engine to cool before refueling Never refuel the machine indoors Never store the machine or fuel container inside where there i
43. chine must be on a level surface All four tire must be properly inflated Refer to Checking the Tire Pressure in the Drive System Maintenance section Side to Side Leveling 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to the park position stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Set the height of cut lever to middle position Carefully rotate the blades so that they are all side to side Figure 47 and Figure 48 2 Py CAs 2 De Figure 47 42 Inch Decks 3 4 1 Blades side to side Outside cutting edges 2 Sail area of blade Measure from the tip of the blade to the flat surface here 45 Maintenance 6005278 2 Eo 3 on A 4 UJ LI UJ L4 Figure 48 50 Inch Decks 1 Blades side to side 3 2 Sail area of blade 4 Outside cutting edges Measure from the tip of the blade to the flat surface here 5 Measure between the outside cutting edges and the flat surface Figure 47 and Figure 48 If both measurements are not within 3 16 inch 5 mm an adjustment is required continue with this procedure 6 Support the weight of mower deck by placing wood blocks under the edges of the deck Note Avoid placing the su
44. de bolt the spring disc washer has been flattened or damaged and the bolt and washer assembly must be replaced Figure 44 Refer to Removing the Blades and Installing the Blades 3 Once the blade has been removed inspect the spring disc washer If the washer appears to be damaged the washer surface has been marred ot 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 Hold the blade end using a rag or thickly padded glove Remove the blade bolt curved washer and blade from the spindle shaft Figure 44 G014975 Figure 44 1 Sail area of blade 3 Curved washer 2 Blade 4 Blade bolt Sharpening the Blades 1 Use file to sharpen the cutting edge at both ends of the blade Figure 45 Maintain the original angle The blade retains its balance if the same amount of material is removed from both cutting edges 44 Maintenance 1 Figure 45 G007276 1 Sharpen at original angle 2 Check the balance of the blade by putting it on a blade balancer Figure 46 If the blade stays in a horizontal position the blade is balanced and can be used If the blade
45. duct Write the numbers in the space provided G015046 Figure 1 Under the seat 1 Model and serial number location Model No Serial No Contents 3 SALE 5 Safety Alert side rte 5 Safe Operating 5 Safety and Instructional Decals 9 SUECHICATONS 14 Model Numbers e oo UR 14 wee dae MS 14 DIMENSION Sn s corned T pre Free tt praes 15 Torque Requirements ca saci foresees prat err er trem 16 Product Overview Gao Duda 16 MN 17 c opio cet UT Ne 17 Operating INStrUCHONS 18 Recommended CIasolitie uos ont 19 Checking ihe Engine Oil Level eise 20 Starting the oe Wet ar petite ener 20 Operating the Blades caves m vie M p 21 Stopping the Engineered paetos 21 The Safety Interlock System 22 Driving Forward or Backwatd 22 Stopping the Machine siis 24 Adjusting the Height of Qut aute 24 Adjusting the Anti Scalp Rollers 24 Positioning the 25 Changing the Seat Ride Suspension 26 Adjusting the Motion Control Levers 26 Pushing the Machine by Hand 26 Side
46. e motion control levers outward to engage the parking brake move the throttle lever to between Fast and half throttle and turn the ignition key to off Remember to remove the key from the ignition switch CAUTION Children bystanders may 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 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 moving the deck height adjustment lever inward and pulling up The height can also be adjusted by moving the deck height adjustment lever inward and pushing the height of cut foot lever forward Figure 13 The transport lever will automatically engage and will drop into place G015096 Figure 13 1 Height of cut foot lever Deck height adjustment lever 3 Height of cut positions 4 Transport position 4 5 inch 115 mm 2 Push the foot lever forward pull the deck height adjustment lever handle inward and let the deck lower down to the desired cut height by slowly decreasing foot pressure allowing the foot lever to travel rearward Move the deck height adjustment lever outwatd at the desired height of cut Adjusting the Anti Scalp Rollers It is recommended to change the anti scalp roller position when the heig
47. e second transmission Stop Maintenance and install that vent plug Torque the plug to 180 in Ib 20 3 N m 7 Continue to add oil through the expansion reservoir until it reaches the FULL COLD line on the expansion reservoit 8 Install the transaxle guard Refer to Figure 36 for the correct torque values for the nuts and bolts 9 Proceed to the Bleeding the Hydraulic System section Important Failure to perform the Bleeding the Hydraulic System procedure after changing hydraulic filters and oil can result in irreparable damage to the transaxle drive system Bleeding the Hydraulic System 1 Enter the operator s position Start engine and move throttle control ahead to 1 2 throttle position Disengage parking brake A Move the bypass levers into the pushing the machine position refer to the Pushing the Machine by Hand section in Operation With the bypass valves open and the engine running slowly move the motion control levers in both forward and reverse 5 or 6 times Move the bypass levers into the operating the machine position With the bypass valve closed and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times Stop the engine and check the oil level in the expansion reservoir Add the specified oil as until it reaches the FULL COLD line on the expansion reservoit Repeat step 1 until all the air is completely purged from the system
48. ead do not discard from the battery Caustic liquid chemical burn hazard 7 Wear eye protection explosive gases can cause blindness and other injuries Wear eye protection 8 severe burns Battery acid can cause blindness or Specifications Specifications Model Numbers Serial Nos 312 000 000 and Higher Systems Polarity Negative Ground e Fuses One 30 amp one 25 amp blade type Engine Engine Specifications See your Engine Ownet s Safety Interlock System Manual PTO must be disengaged motion control levers 828 Engine Oil Type Exmark 4 Cycle Premium out brake engaged to start engine It is not Engine Oil necessary for the operator to be in the seat to RPM start the engine Full Speed 3300 100 max RPM No Load Operator must be in seat when PTO is engaged Idle 1650 min RPM ot motion control levers are moved in or engine will stop Fuel System Capacity 3 0 gal 11 4 L Operator Controls Fus Beeommsemdtons Steering and Motion Control For best results use only clean fresh unleaded Note Motion control levers are adjustable to gasoline with an octane rating of 87 or higher two heights R M 2 rating method Separate levers on each side of the console Oxygenated fuel with up to 10 ethanol or control speed and direction of travel of the 15 MTBE by volume is acceptable respective drive wheels Do Not use ethanol blends of gasoline
49. ean all debris from engine and exhaust system area 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debris from rotating engine air intake screen around engine shrouding and exhaust system area 3 Wipe up any excessive grease or oil around the engine and exhaust system area 52 Storage Storage Cleaning and Storage 1 10 Disengage the blade control switch move the motion controls outward to the park position stop the engine and remove the key Remove grass clippings dirt and grime from the external parts of the entire machine especially the engine Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing Important You can wash the machine with mild detergent and water Do not pressure wash the machine Avoid excessive use of watet especially near the control panel under the seat around the engine hydraulic pumps and motots Service the air cleaner refer to Servicing the Air Cleaner in the Engine Maintenance section Grease and oil the machine refer to the Lubrication section Change the crankcase oil and filter refer to Servicing the Engine Oil in the Engine Maintenance section Check the tire pressure refer to Checking the Tire Pressure in the Drive System Maintenance section Charge the battery refer to Servicing the Battery in the Electrical System Maintenance section Check the conditi
50. ent discharge area underside of mower and any moving parts while engine is running Do Not touch equipment or attachment parts which may be hot from operation Allow to cool before attempting to maintain adjust or service Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery Safety Battery gases can explode Keep cigarettes sparks and flames away from battery Use only Exmark approved attachments Warranty may be voided if used with unapproved attachments If loading the machine onto a trailer or truck use a single full width ramp only The ramp angle should not exceed 15 degrees Note The left and right sides of the machine are determined while sitting in the seat in the normal operating position Safety Safety and Instructional Decals Safety decals and instructions easily visible to the operator and are located near any area of XN y potential danger Replace any decal that is damaged or lost 93 7009 1 Warning don t operate the mower with the deflector up or removed keep the deflector in place 2 Cutting dismemberment hazard of hand or foot mower blade stay away from moving parts 105 7015 105 7015 For Models with 42 Inch Decks 1 Belt routing 99 3943 99 3943 For Models with 50 Inch Decks 106 8717 1 Engine 1 Read the instructions befo
51. fety 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 Figure 2 Safety Alert Symbol 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 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 DANGER personal safety instruction Failure to comply with the instruction may result in personal injury or death Safe Operating Practices The following instructions are from ANSI standard B71 1 2003 This product is capable of amputating hands and feet and throwing objects Always follow all safety instructions to avoid serious injury or death General Operation e Read understand and follow all instructions in the operator s manual and on the machine before starting Do Not place hands or feet near rotating parts or under the machine Keep c
52. haft forward to release the brake Checking the Hydraulic Oil Level Service Interval Every 25 hours Maintenance Check expansion reservoir and if necessary add 20W 50 engine oil to the FULL COLD line Figure 35 1 Jacking points 3 Remove the nuts holding the transaxle support in place Figure 36 9017656 Figure 34 1 Expansion reservoir 3 Engine 2 Full Cold line Changing the Hydraulic O System Filter and Oil on a Pm Service Interval After the first 50 hours Every 400 hours thereafter The filter and oil are changed at the same time Do Not reuse oil Once the new filter is installed and oil is added any air in the system must be purged The bleeding process is repeated until the oil remains X if at the FULL COLD line in the reservoir after purging 123 ie Failure to properly perform this procedure can result in irreparable damage to the transaxle 2 1 drive system Figure 36 1 Nut 5 16 inch 27 to 33 3 Transaxle support Removing Hydraulic System Filters 2 Nut 3 8 inch 15 to 19 1 Stop engine wait for all moving parts to stop and ft lb allow engine to cool Remove the key and engage the parking brake 4 Locate the filter and filter guards on each transaxle 2 Raise the rear of machine up and support with drive system Figure 37 Remove three screws jack stands or equivalent support just
53. height adjustment lever outward at the desired height of cut Only adjust the height of cut while the machine is not moving Height of Cut Foot Lever The height of cut foot lever allows the operator to use their leg to assist in lowering and raising the deck from the seated position Figure 3 When the lever is moved forward away from the operator the deck is raised from the ground and when moved back towards the operator it is lowered toward the ground Fuel Window Located on the left side of the machine see Figure 5 The fuel window can be used to verify the presence of fuel in the tank Figure 5 1 Fuel cap 2 Fuel window Operating Instructions Think Safety First Note Determine the left and right sides of the machine from the normal operating position Please carefully read all of the safety instructions and decals in the safety section Knowing this information could help you your family pets or bystanders avoid DANGER Mowing on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning A loss of traction is a loss of steering control To avoid loss of control and possibility of rollover Do Not mow near drop offs or near water Do Not mow slopes greater than 15 degrees Reduce speed and use extreme caution on slopes When mowing slopes gradually work from lower to higher
54. hook and placing tension on the idler pulley and mower belt Figure 56 and Figure 57 G014930 Figure 56 42 Inch Deck Installing the Mower 1 Idler pulley 4 Spring D ene Engine pulley Service Interval As required 3 Outside pulley 6 Spring removal tool 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to the park position stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Slide the mower under the machine 4 Lower the height of cut lever to the lowest position 5 Lift the reat of the mower deck and guide the hanger brackets over the rear lift rod Figure 55 49 Maintenance 6 Attach the front support rod to the mower deck with the clevis pin and hairpin cotter Figure 54 7 Install the mower belt onto the engine pulley refer to Replacing the Mower Belt Replacing the Discharge Deflector A DANGER An uncovered discharge opening could allow the lawn mower to throw objects in the operator s 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 Inspect the discharge deflector for damage before each use Replace any damaged parts before use 42 inch and 50 inch E Series Deck 1 Locate
55. ht of cut has changed 1 Stop the machine and move the drive levers to the neutral position 2 Disengage the PTO 3 Move the motion control levers outwatd to 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 24 Operation the positions shown in Figure 15 Rollers will 1 Tip the seat forward maintain 3 4 inches 19 mm clearance to the ground to minimize gouging and roller wear or damage i 7 Note For Maximum Deck Flotation place the rollers one hole position lower Rollers should maintain 1 4 inch 6 35 mm clearance to 1 ground Do Not adjust rollers to support the Ss 2 Loosen the adjustment bolts JJ 2 3 2 8 T EE D Figure 14 014477 42 Inch Deck Figure 16 1 Adjustment bolt 1 Anti scalp roller mounting bracket 2 Below 2 1 2 inches 64mm cutting height 2 1 2 inches 64mm and above cutting height 3 Move the seat to the desired position and tighten bolts 1 4 Tip the seat back to the closed position We 50 Inch Units 2 1 Push the adjustment lever towards the center of the machine to release the seat adjuster 1 5 inch 38mm track Figure 17 2 0 inch 51mm 2 5 inch 64mm
56. ing brake 2 Clean around the fuel tank cap and remove the cap 3 Add unleaded regular gasoline until the fuel reaches the base of the filler neck and does not fill the neck of the tank Figure 7 This space at the base of the filler neck allows gasoline to expand Do Not fill the fuel tank completely full Overfilling may result in fuel leakage or damage to the engine or emissions system G015093 Figure 7 1 Fuel cap 4 Fill opening 2 Fuel window 5 Base of filler neck DO NOT FILL PAST HERE 3 Empty space for fuel 6 Fuel expansion 4 Install the fuel tank cap securely and tighten until it clicks Wipe up any gasoline that may have spilled Checking the Engine Oil Level Before you start the engine and use the machine check the oil level in the engine crankcase refer to Checking the Oil Level in Engine Maintenance section Starting the Engine 1 Sit down on the seat and move the motion controls outward to engage the parking brake Disengage the blades by moving the blade control switch to Off Figure 8 20 Operation 6015094 Figure 8 1 Ignition key 5 Throttle lever 2 Off 6 Choke control 3 Run 7 Blade control switch Off position 4 Start 3 Pull up on the choke control to engage the choke before starting a cold engine Figure 8 Note A warm or hot engine may not require choking Turn the ignition key to Start to energize the starter When the engine starts
57. ions from the cooling fins and air passages Install a new correctly gapped spark plug s Replace the fuel filter Contact an Authorized Service Dealer Drain the tank and replace the fuel with the proper type Contact an Authorized Service Dealer Contact an Authorized Service Dealer Take machine out of bypass mode Refer to Pushing the Machine by Hand section Tighten the engine mounting bolts Tighten the appropriate pulley Contact an Authorized Service Dealer Install new cutting blade s Tighten the blade mounting bolt and inspect the blade spring disc washer for damage See Servicing the Cutting Blades section Contact an Authorized Service Dealer Sharpen the blade s Install new cutting blade s Tighten the blade mounting bolt and inspect the blade spring disc washer for damage See Servicing the Cutting Blades section Level mower deck from side to side and front to tear Adjust the anti scalp wheel height Clean the underside of the mower Adjust tire pressure Contact an Authorized Service Dealer all new drive belt all drive belt and check adjusting fts and belt guides for correct position all a new mower belt Electrical Diagram Schematics Schematics ov Luvs FER MS Old N39 ayvug ano 8
58. 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 e Mulching Kit Optional Dimensions Overall Width 42inch Deck 50 inch Deck Without Deck 39 0 inches 46 3 inches 99 cm 118 cm Deflector Up 45 3 inches 54 6 inches 115 cm 139 cm Deflector Down 53 8 inches 63 0 inches 137 cm 160 cm Overall Length 42 inch Deck 50 inch Deck 71 8 inches 182 cm 72 9 inches 185 cm Product Overview Overall Height 41 5 inches 105 cm Tread Width Center to Center of Tires Widthwise 42 inch Deck 50 inch Deck Drive Wheels 31 5 inches 37 4 inches 80 cm 95 cm Caster Wheels 29 5 inches 36 9 inches 75 cm 94 cm Wheel Base Center of Caster Tire to Center of Drive Tire 45 6 inches 116 cm Curb Weight 42 inch Deck 50 inch E Series 50 inch S Series Deck Deck 531 Ib 241 kg 614 1b 279 kg 672 Ib 305 kg Torque Requirements Wheel Lug Nuts 70 90 ft lb 95 122 N m Clutch Mounting Bolt 50 60 ft lb 68 81 N m secured with threadlocker Product Overview 10 9 p 8 c 5 774 a KE IH NA 14 XS AS gt RY 75872 77344 a LS 22 Front caster wheel 8 Control panel Anti scalp roller 9 Engine Height of cut foot lever 10 Seat Discharge deflector 11 Fuel tank ak WN Deck height adjustment 12 Armrest lever Washout fitting 13 Motion co
59. items shown in Figure 58 GAN G005192 Figure 58 1 Mower deck 5 Spring 2 Discharge deflector 6 Nut 3 8 inch 3 Discharge deflector 7 Short stand off bracket 4 Rod 2 Remove the nut 3 8 inch from the rod under the mowet 3 Slide the rod out of the short stand off spring and discharge deflector Remove the damaged or worn discharge deflector 50 Replace the discharge deflector Slide rod straight end through the rear discharge deflector bracket Place the spring on the rod with end wires down and between the discharge deflector brackets Slide rod through second discharge deflector bracket Insert rod at front of discharge deflector into short stand off on deck Secure rear end of into the mower with a nut 3 8 inch 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 50 inch S Series Deck 1 Disengage the spring from the notch in the deflector bracket and slide the rod out of the welded deck brackets spring and discharge deflector Figure 59 Remove the damaged or worn discharge deflector Maintenance g017618 Figure 60 1 Rod and spring 3 Rod short end moved assembly installed behind mower bracket 2 Loop end of the spring 4 Short end retained by installed into the notch in mower bracket the deflector bracket 5 Secure the r
60. k components and replace with manufacturers recommended parts when necessary Mower blades are sharp and can cut Wrap the blades or wear gloves and use extra caution when servicing them Check for proper brake operation frequently Adjust and service as required Maintain or replace safety and instruction decals as necessary Useonly genuine Exmark replacement parts to ensure that original standards are maintained 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 Only adults and mature teenagers should operate a mower and even mature teenagers should have adult supervision Be sure a teenaget 1 has read and understands the Operator s Manual and recognizes the risks involved 2 is sufficiently mature to use caution and is of sufficient size and weight to operate the controls comfortably and to manage the mower without taking risks 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 e Park machine level ground Stop the engine wait for all moving parts to stop engage parking brake disconnect spark plug wire s and remove key before performing any service repairs maintenance or adjustments Keep hands feet hair and loose clothing away from attachm
61. lace as shown in Figure 20 Ensure this is done for each lever 5 Move the motion control levers inward to the neutral position and turn the ignition key to the run position Do Not start the machine The machine is now able to be pushed by hand 9017303 Figure 20 Bypass lever location 3 Lever position for pushing the machine 2 Lever position for operating the machine When finished ensure the key has been returned to the Stop position to avoid draining the battery charge If the machine fails to move the electric brake may still be engaged If necessary the electric brake can be released manually Refer to the Releasing the Electric Brake procedure in Drive Maintenance To Operate the Machine Move the bypass levers rearward through the key hole and down to lock them in place as shown in Figure 20 Ensure this is done for each lever Side Discharge The mower has a hinged discharge deflector that disperses clippings to the side and down toward the turf A 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 immedia
62. lear of the discharge opening at all times Allow only responsible adults who are familiar with the instructions to operate the machine Clear the area of objects such as rocks toys wite etc which could be picked up and thrown by the blade Be sure the area is clear of other people before mowing Stop the machine if anyone enters the area Never carry passengers Do Not mow in reverse unless absolutely necessary Always look down and behind before and while backing up Be aware of the mower discharge direction and Do Not point it at anyone Avoid discharging material against a wall or obstruction Material may ricochet back toward the operator Stop the blades when crossing gravel surfaces Do Not operate the mower without either the entire grass collection system or the discharge deflector in place Be alert slow down and use caution when making turns Look behind and to the side before changing directions Never leave a running machine unattended Always turn off blades engage parking brake stop engine and remove key before dismounting Turn off blades when not mowing Stop the engine wait for all parts to come to a complete stop engage patking brake and remove key before cleaning the machine removing the grass ot unclogging the deflector Operate the machine only in daylight or good artificial light Do Not operate the machine while under the influence of alcohol or drugs WAtch for traffic when
63. ll the wire off of the spark plug Figure 26 Clean around the spark plug to prevent dirt from falling into the engine and potentially causing damage 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 3 Remove the spark plug and metal washer OV Figure 26 1 Spark plug and wire location Checking the Spark Plug 1 Look at the center of the spark plug Figure 27 If you see light brown or gray on the insulator the engine is operating properly A black coating on the insulator usually means the air cleaner is dirty Important Never clean the spark plug Always replace the spark plug when it has a black coating worn electrodes an oily film or ctacks 2 Check the gap between the center and side electrodes Figure 27 Bend the side electrode if the gap is not correct G006998 Figure 27 1 Side electrode 3 Air gap not to scale 2 Center electrode insulator Installing the Spark Plug 1 Install the spark plug Make sure that the air gap is set correctly 2 Tighten the spark plug to 16 ft lb 22 N m 3 Push the wire onto the spark plug Figure 26 34 Maintenance Cleaning the Blower Housing Service Interval Every 100 hours Yearly whichever comes first More often under dirty conditions
64. nt Never clean the paper element with pressurized air or liquids such as solvent gas ot kerosene Replace the paper element if it is damaged or cannot be cleaned thoroughly 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 32 Maintenance 1 2 Filler tube Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap dipstick before removing it Remove the oil fill cap dipstick wipe oil off Reinsert the dipstick push into place but Do Not screw it in Figure 24 G015103 Figure 24 Oil dipstick 3 Oil level Remove the dipstick and check the oil level The oil level should be up to but not over the PULL mark on the dipstick If the level is low wipe off the area around the oil fill cap remove cap and add oil to the FULL mark on the dipstick Exmark 4 Cycle Premium Engine Oil is recommended refer to the Engine Owner s manual for an acceptable alternative Always check the level with the dipstick before adding more oil Do Not overfill Note To prevent extensive engine wear damage always maintain the proper oil level in the crankcase Never operate the
65. ntrol levers Rear drive wheel 14 Footrest 16 Operation Operation Controls Note Become familiar with all of the controls in Figure 3 and Figure 4 before you start the engine and operate the machine Ignition Switch Located on control panel The ignition switch is used to start and stop the engine The switch has three positions OFF RUN and START Figure 4 Insert key into switch and rotate clockwise to the ON position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position G015092 Figure 4 1 Ignition switch 3 Choke control 2 Throttle lever 4 Blade control switch power take off Note Brake must be engaged motion control levers out and PTO switch 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 Blade Control Switch Power Take Off Located on the control panel The blade control switch represented by a power take off PTO symbol engages and disengages power to the mower blades see Figure 4 Pull out on the blade control switch to to engage the blades Push the blade control switch to Off to disengage the blades Throttle Lever L
66. nts may be ordered through the engine manufacturer For models with stated engine horsepower the gross horsepower of the engine was laboratory rated by the engine manufacturer in accordance with SAE J1940 As configured to meet safety emission and operating requirements the actual engine horsepower on this class of lawn mower will be significantly lower 2011 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PARTS OVERNIGHT FREE If your Exmark dealer does not have the Exmatk part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA All Rights Reserved Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage You responsible for operating the product properly and safely Exmark parts manuals are available online at http www exmark com You may contact Exmark directly at www Exmark com for product and accessory information or help finding a dealer Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer 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 pro
67. o touch any metal parts of the machine Do Not allow metal tools to short between the battery terminals and metal parts of the machine DANGER Charging or jump starting the battery may produce explosive gases Battery gases can explode causing serious injury Keep spatks flames or cigarettes away from battery e Ventilate when charging or using battery in an enclosed space Make sure venting path of battery is always open once battery is filled with acid Always shield eyes and face from battery DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns e Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte n the event of an accident flush with water and call a doctor immediately A CAUTION 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 Be sure ignition switch is in the OFF position before charging the battery 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to engage parking brake stop the engine remove the key and wait for all moving parts to
68. ocated on control panel The throttle is used to control engine speed Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed Moving the throttle forward until it stops is full throttle see Figure 4 Choke Control The choke is used to aid in starting a cold engine Pulling up on the choke control will put the choke in the ON position and pushing down the control will put the choke in the OFF position Do Not run a warm engine with the choke in the ON position Motion Control Levers and Parking Brake Position The motion control levers located on each side of the seat Figure 3 The motion control levers are speed sensitive controls of independent wheel motors Moving a lever forward or backward turns the wheel on the same side forward or in reverse wheel speed is proportional to the amount the lever is moved Moving the control levers outward from the center position engages the parking brake on the drive wheels Always position the motion control levers into the parking brake position when you stop the machine or leave it unattended The unit must be tied down and brake engaged when transporting Deck Height Adjustment Lever Located below the RH motion control lever Figure 3 17 Operation Pull the lever inward and rearward to raise the cutting deck Allow the handle to move forward to lower the cutting deck Move the deck
69. od and spring assembly by twisting it so the short end of the rod can be placed 5 behind the front bracket welded to the deck Figure 59 igure Ot 4 Rod A Deck brackets Important The grass deflector must be 2 Spring 5 Spring installed over the spring loaded in the down position Lift rod the deflector up to test that it snaps to the 3 Deflector assembly full down position 2 Position the new discharge deflector assembly with the bracket ends between the welded brackets on the deck as shown in Figure 59 3 Install the spring onto the straight end of the rod Position the spring on the rod as shown in so the shorter spring end is coming from under the rod before the bend and going over the rod as it returns from the bend 4 Lift the loop end of the spring and place it into the notch on the deflector assembly bracket Figure 60 51 Maintenance Cleaning Washing the Underside of the Mower Service Interval Before each use or daily Clean the mower housing Wash the underside of the mower after each use 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 Move the motion control levers outward to the park position stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Attach the hose coupling to the end of the mower washout fitting
70. 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 This warranty gives you specific legal rights and you may also have other rights which vary from state to state G4500 750_A 58 Notes 59 Notes 60 Service Record Date Description of Work Done Service Done By 61 MAXIMIZE THE PERFORMANCE OF YOUR EXMARK 4 CYCLE PREMIUM ENGINE OIL PREMIUM HYDRO OIL Part No 116 3373 Part No 109 9828 Both SAE 30 and SAE 10W 30 in one Commercial quality for tough high bottle heat conditions Contains increased levels of zinc and Designed specifically for zero turn phosphorus for better lubricity mower hydraulic systems No Viscosity Index Improvers that tend Superior shear resistance under to shear down in high heat heavy loads Synthetic formulation Gas amp Diesel compatible Anti corrosion additives SL and JASO rated with wet clutch compatibility for other machines EXMARK MAINTENANCE D Available from your local Exmark dealer Find your closest dealer at exmark com 62 6011841 Figure 62 This
71. of the mower Scrape any heavy buildup of grass and dirt from the underside of the mower then wash the mower with a garden hose Check the condition of the drive and mower belts Check and tighten all bolts nuts and screws Repair or replace any part that is worn or damaged Paint all scratched or bare metal surfaces Paint is available from your Authorized Service Dealer 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 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 The engine overheats The starter does not crank Engine will not start starts hard or fails to keep running he engine load is excessive he oil level in the crankcase is low he cooling fins and air passages
72. oil on the frame Figure 25 Note Dispose of the used oil at a recycling center 10 Apply a thin film of clean Exmark 4 Cycle Premium Engine Oil to the rubber gasket on the new filter 11 Install the replacement oil filter to the mounting pad Turn the oil filter clockwise until the rubber gasket contacts the pad then tighten the filter an additional 1 2 to 3 4 turn Slowly pour approximately 80 of the specified oil into the filler tube use oil recommended in the Checking the Oil Level section 12 13 Install the oil fill cap dipstick and push into place but Do Not screw it in Check the oil level Figure 24 refer to Checking the Oil Level section 14 15 Slowly add additional oil to bring it to the full mark Do Not overfill 16 Install the oil fill cap dipstick 17 Start the engine and check for leaks Servicing the Spark Plug Service Interval Every 200 hours Every 2 years whichever comes first Every 500 hours Replace the spark plug As stated in the maintenance intervals remove the spark plug check condition and reset the gap or replace with a new plug as necessary The spark plug is RFI compliant Equivalent alternate brand plugs can also be used Type NGK BPR4ES or equivalent Air Gap 0 030 inch 0 76 mm Removing the Spark Plug 1 Disengage the blade control switch move the motion controls outward to the park position stop the engine and remove the key Pu
73. on of the blades refer to Servicing the Cutting Blades in the Mower Maintenance section Prepare the machine for storage when non use occurs over 30 days Prepare the machine for storage as follows Add a petroleum based stabilizer conditioner to the fuel in the tank Follow the mixing instructions from the stabilizer manufacturer Do not use an alcohol based stabilizer ethanol or methanol Note A fuel stabilizer conditioner is most effective when mixed with fresh gasoline and used at all times Run the engine to distribute the conditioned fuel through the fuel system 5 minutes 11 12 13 14 15 16 17 53 Stop the engine allow it to cool and drain the fuel tank refer to Draining the Fuel Tank in the Fuel System Maintenance section Restart the engine and run it until it stops Choke the engine Start and run the engine until it will not start Dispose of fuel properly Recycle pursuant to local codes Important Do not store stabilizer conditioned gasoline over 30 days Remove the spark plug s and check its condition refer to Servicing the Spark Plug in the Engine Maintenance section With the spark plug s removed from the engine pour two tablespoons of engine oil into the spark plug hole Use the starter to crank the engine and distribute the oil inside the cylinder Install the spark plug s Do not install the wire on the spark plug s Clean any dirt and chaff from the top
74. or future installation Mower Belt Maintenance Inspecting the Belts Service Interval Every 25 hours Monthly whichever comes first Check the belts for cracks frayed edges burn marks or any other damage Replace damaged belts Replacing the Mower Belt Squealing when the belt is rotating blades slipping when cutting grass frayed belt edges burn marks and cracks are signs of a worn mower belt Replace the mower belt if any of these conditions are evident 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to the park position stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Maintenance 3 Set the height of cut at the lowest cutting position 1 1 2 inch 38 mm 4 Using a spring removal tool P N 92 5771 remove the idler spring from the deck hook to remove tension on the idler pulley and roll the belt off of the pulleys Figure 56 and Figure 57 WARNING The spring is under tension when installed and can cause personal injury Be careful when removing the belt 6 G014931 Figure 57 50 Inch Deck 1 Idler pulley 4 Spring 2 Mower belt 5 Engine pulley 3 Outside pulley 6 Spring removal tool 5 Route the new belt around the engine pulley and mower pulleys Figure 57 6 Using a spring removal tool P N 92 5771 install the idler spring over the deck
75. pports under any anti scalp rollers if present on the deck 7 Move to the left side of the machine Remove the side carriage bolt and locking nut from the fixed position and install it into the rear slotted position and leave it slightly loose Figure 49 46 2 Rear locking nut Figure 49 Hanger bracket 4 Side locking nut Slotted adjustment 5 Side carriage bolt position Fixed position 8 Loosen the side locking nut on the hanger bracket just enough to allow the hanger to be adjusted Figure 50 Use the notches on the welded bracket to measure the amount of adjustment Each notch surface is equivalent to 1 16 of an inch Adjust the height of the mower deck to the desired height Figure 50 Hanger bracket 3 Side locking nut 4 Adjustment notches 9 Stop the deck at the adjusted position and tighten the side locking nut on the hanger bracket to hold Maintenance the new position Figure 50 Tighten the rear locking nut on the hanger bracket 10 Continue leveling the deck by checking the front to rear blade slope refer to Adjusting the Front to Rear Blade Slope Adjusting the Front to Rear Blade Slope Check the front to rear blade level any time you install the mower If the front of the mower is more than 5 16 inch 7 9 mm lower than the rear of the mowet adjust the blade level using the following instructions 1 1 2 Measure from the tip of
76. re servicing or performing maintenance Check tire pressure every 25 operating hours Grease every 25 operating hours RON Engine Safety Rage m Po of N i 110 6691 119 8814 1 Thrown object hazard keep bystanders a safe distance 1 Parking position 4 Neutral Tonne macine 2 Fast 5 Reverse 2 Thrown object hazard mower do not operate without the deflector discharge cover or grass collection 3 Slow system in place 3 Cutting dismemberment of hand or foot stay away from moving parts 119 8815 1 5 8 2 0 51mm 1 Parking position 4 Neutral 2 5 63mm 2 Fast 5 Reverse 3 Slow 3 0 76 112 9840 112 9840 1 Read the Operator s 3 Remove the ignition key Manual and read the instructions before servicing or performing maintenance LAP 2 Height of cut 114 1606 114 1606 1 Entanglement hazard belt keep all guards in place 119 8870 50 Inch Model 1 Height of cut 10 Safety 119 8871 PTO Switch Symbols 1 PTO disengage 2 119 8871 42 Inch Model 1 Height of cut 121 2989 121 2989 42 Inch Model 1 Bypass lever position for 2 Bypass lever position for pushing the machine operating the machine Safety 116 4220 amp 116 4220 50 Inch Model 1 Fast 3 Slow 2 Continuous variable setting 4 Choke 120
77. riginal Exmark parts Recommended Maintenance Schedule s Maintenance Service Maintenance Procedure Interval After the first 5 hours After the first 50 hours Change the engine oil Before each use or daily heck the mower blades heck the tire pressure heck the belts Every 25 hours Every 100 hours Every 200 hours Every 400 hours Change the hydraulic system filter and oil Every 500 hours Replace the spark plug ean the Replace the fuel filter Service the spark plug ean the mower housing ean the engine and exhaust system area rease all lubrication points heck the air cleaner for dirt looseness or damage May need more often under extremely 30 Change the hydraulic system filter and oil heck the safety interlock system heck the oil level before starting or after every 8 hours heck the hydraulic oil level in the expansion tank Service the paper element more often in dusty dirty conditions hange the engine oil and filter blower housing More often under dirty conditions Replace the paper element more often in dusty dirty conditions Maintenance Maintenance Service Maintenance Procedure Interval Charge the battery and disconnect the battery cables Before storage Perform all maintenance procedures listed above before storage Paint any chipped surfaces Monthly Check the battery charge Inspect the emissions filter
78. s an open flame such as near a water heater furnace 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 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 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 If fuel is spilled on clothing change clothing immediately Never overfill the fuel tank Replace gas cap and tighten securely General Service Never run a machine inside a closed area Keep nuts and bolts tight especially the blade attachment bolts Keep equipment in good condition Never tamper with safety devices Check their proper operation regularly Keep the machine free of grass leaves ot other debris build up Clean up oil or fuel spillage and fuel soaked debris Allow the machine to cool before storing Stop and inspect the equipment if you strike an object Repair if necessary before restarting Never make any adjustments or repairs with the engine running Grass collection system components are subject to wear damage and deterioration which could expose moving parts or allow objects to be thrown Frequently chec
79. sconnect the spark plug wire s from the spark plug s Inspecting the Blades 1 Inspect the cutting edges Figure 39 If the edges are not sharp or have nicks remove and sharpen the blades refer to Sharpening the Blades 2 Inspect the blades especially the curved area If you notice any damage weat or a slot forming in this area item 3 in Figure 39 immediately install a new blade 42 Maintenance G006530 6014973 Figure 39 1 Cutting edge 3 Wear slot forming 2 Curved area 4 Damage Figure 41 1 Blade in position for measuring 2 Level surface Checking for Bent Blades 3 Measured distance between blade and surface A Note The machine must be on a level surface for the following procedure 4 Rotate the same blade 180 degrees so that the i tti dge i in th ition 1 Raise the mower deck to the highest height of cut M M position also considered the transport position 2 While wearing thickly padded gloves or other adequate hand protection slowly rotate blade to be measure into a position that allows effective measurement of the distance between the cutting edge and the level surface the machine is on G014974 Figure 42 1 Blade side previously measured Measurement position used previously Opposing side of blade being moved into measurement position Figure 40 5 Measure from the tip of the blade to the flat sutf
80. soline 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 e 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 Do Not operate without entire exhaust system in place and in proper working condition 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 Always place gasoline containers the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle Ifa 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
81. such Steering is controlled by varying the position as E15 or E85 with more than 10 ethanol of the levers relative to each other by volume Performance problems and or Moving motion control levers outward in engine damage may result which may not be slots locks the drive system in neutral and covered under warranty applies the parking brake Do Not use gasoline containing methanol PTO Engagement Switch Engages electric clutch Do Not store fuel either in the fuel tank or to drive belt which engages mower blades fuel containers over the winter unless a fuel Deck Height Adjustment Lever Sets cutting stabilizer is used height to desired position Do Not add oil to gasoline Deck Lift Assist Lever Foot pedal that assists in Brel Filtet raising the deck Kawasaki P N 49019 7005 Seat Electrical System E 42 inch unit Standard seat with high back foam padded with spring suspension and armrests Charging System Flywheel Alternator Charging Capacity 15 amps Battery Type 195 CCA 50 inch unit Two tone upholstered seat with Battery Voltage 12 Volt spring suspension and armrests 14 Specifications Mounting Hinged to tilt up for access to battery and other components Adjustable fore and aft e Armrests Standard padded flip up armrests e Seat Safety Switch Incorporated into the Safety Interlock System Hydrostatic Ground Drive System e Hydrostatic Pumps 4
82. tely Never put your hands or feet under the mower Never try to clear discharge area or mower blades unless you move the move the blade control switch to Off and rotate the ignition key to Off Also remove the key and pull the wire off the spark plug s Transporting 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 A 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 Do Not drive a unit on a public street or roadway 27 Operation 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 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 Ifindividual ramps must be used use enough ramps to create
83. 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 Warranty Exceptions Warranty Period Bags Belts and Tires 90 days Battery 1 Year Prorated Engine Please refer to the manufacturer s warranty statement that is included in the literature packet This warranty only includes the cost of parts and labor For the first warrantable service repair Exmark will cover up to 45 for associated pick up and delivery charges to and from any authorized Exmark Service Dealer Additional transportation charges may apply contact your Dealer for details 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 Warranty Exception Warranty Period Engines Please refer to the manufacturer s warranty statement that is included in the literature packet 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
84. under the engine blower housing are plugged The air cleaner is dirty Dirt water or stale fuel is in fuel system The blade control switch is engaged The motion control levers are not in the park position The operator is not seated Battery does not have a full charge The electrical connections ate corroded ot loose A fuse is blown A relay or switch is damaged Fuel tank is empty The choke is not on The air cleaner is dirty The spark plug wite s is loose or disconnected The spark plug s is pitted fouled or the gap is incorrect There is dirt in fuel filter Dirt water or stale fuel is in the fuel system There is incorrect fuel in the fuel tank The oil level in the crankcase is low 54 Reduce ground speed Add oil to the crankcase Remove the obstruction from the cooling fins and air passages Clean or replace the air cleaner element Contact an Authorized Service Dealer Move the blade control switch to Disengaged Move the motion control levers outward to the park position Sit on the seat Charge the battery See Check Battery Charge and Recommended Jump Starting Procedure sections in Maintenance Check the electrical connections for good contact Replace the fuse Contact an Authorized Service Dealer Fill the fuel tank Move the choke lever to On Clean or replace the air cleaner element Install the wire s on the spark plug Install
85. while on the ramp you may lose control and drive off the side 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 Operating Tips Fast Throttle Setting For best mowing and maximum air circulation operate the engine at the Fast position Air is required to thoroughly cut grass clippings so Do Not set the height of cut so low as to totally surround the mower by uncut grass Always try to have one side of the mower free from uncut grass which allows to be drawn into the mower Cutting a Lawn for the First Time Cut grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground However the cutting height used in the past is generally the best one to use When cutting grass longer than six inches tall you may want to cut the lawn twice to ensure an acceptable quality of cut Cut 1 3 of the Grass Blade It is best to cut only about 1 3 of the grass blade Cutting more than that is not recommended unless grass is sparse or it is late fall when grass grows more slowly Mowing Direction Alternate mowing direction to keep the grass standing straight This also helps disperse clippings which enhances decomposition and fertilization Mow at Correct Intervals Normally mow every four days But remember grass grows at different rates at different times So to maintain the same

Exmark 4501-191 Rev.A Lawn Mower User Manual

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