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Exmark 4500-450 Lawn Mower User Manual

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2. gt c O O 2 a For Serial Nos 790 000 amp Higher AWARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancet birth defects or other reproductive harm Important This engine is not equipped with a spark arrester muffler It is a violation of California Public Resource Code Section 4442 to use operate the engine on any forest covered brush covered or grass covered land Other states or federal areas may have similar laws This spark ignition system complies with Canadian ICES 002 ISO 14982 EN 55012 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 Replacements may be ordered through the engine manufacturet For models with stated engine horsepowet the gross horsepowet 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 2009 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 Exmar
3. 15 Operat us aderit ae EEEE EEA 16 16 Operating Instructions eco edo Dp ro Re 17 Recommended Gasoline au oo ooo dd 18 Checking the Engine Oil Level etes I9 Starting the Engine 19 Operating the Blades satis ate dent 20 Stopping the so iere RUNE 20 The Safety Interlock 21 Driving Forward or Backwatd 21 Stopping the Machine 22 Adjusting the Height of Cut eee 22 Adjusting the Anti Scalp Rollers 23 Positioning the Seat ancien 23 Changing the Seat Ride Suspension 24 Adjusting the Motion Control Levers 24 Pushing the Machine by Hand 24 Side Dischakge ies uoti ee 25 PATS PORE Lie rep cappa 25 1 amp 26 Maintenance 28 Recommended Maintenance Schedule s 28 Premaintenance Procedures pe 29 Raising the Seat scene este 29 Accessing the Datteky 29 Periodic Maintenance eoe HD He EN 29 ox redd epe op a 29 Engine dai 30 Servicing the Engine Oil o deiectis 31 Checking the Hydraulic Oil Level 32 Change the Hydraulic System Filter 33 Servicing the Spark Plug o entire 33 Cleaning the Blower Housing
4. 8 JvNSIS TI 105 41703907 1 Old 19 15 1HVIS uvis a A Je 6 l r 5 AYIM CAMIA SHOLO3NNOO va Y 9 of 2 5 FE 5 R 5 iB 2 3 EI bl t 2 2 8 5 2 MOTISA z NOWOW MOTTA 8 z 2 t 9 v 131014 3108102 s 137014 5 z z E E MMH ivaa 2 on E H z ME v ovis a 13101 2 189v219 errs HOLIMS 1 85 H UMS Old 2 8 Javas 5 1 1 AHOSS399V 1 SNOLO3NNOO VNIWH3L HO IMS STWNIWYAL stitute 14913 1 2 ANON 340 7 DIV 504 50 Schematics Electrical Logic Schematic 11022071 15
5. 36 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 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 5 Slide the rubber cover up the positive red cable Disconnect the positive red cable from the battery post Retain all fasteners 6 Remove the battery strap Figure 28 and lift the battety from the battery tray Charging the Battery 1 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 To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery should be fully charged before putting away for winter storage 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 cables are disconnected and the battery charger used for charging the battery has an
6. 1 Rotate the blades until the ends face forward and backward Figure 33 and Figure 34 Measure from a level surface to the cutting edge of the blades Note this dimension Maintenance Cap 2p 6010291 2 Figure 33 48 and 52 Inch Deck 1 Blades front to rear 2 Measure here 2 4 9 1 2 2 VO 2 Figure 34 42 Inch Deck 1 Blades front to rear 2 Measure here 2 Rotate the opposite ends of the blades forward 3 Measure from a level surface to the cutting edge of the blades at the same position as in step 1 The difference between the dimensions obtained in steps 1 and 3 must not exceed 1 8 inch 3 mm If this dimension exceeds 1 8 inch 3 mm the blade is bent and must be replaced Refer to Removing the Blades and Installing the Blades 39 A WARNING A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders Always replace bent or damaged blade with a new blade Never file or create sharp notches in the edges or surfaces of blade Checking for Loose Blades or Damaged Spring Disc Washers 1 Place a wrench on the blade bolt and torque to 32 42 ft Ib 43 57 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 witho
7. 34 Fuel System Maintenance 35 Electrical System Maintenance 35 Charging the 36 Servicing the Fuses and Relay 37 Drive System Maintenance esse 38 Checking the Tire Pressure 38 Mower Maiitenance soc eta ea ron 38 Servicing the Cutting Blades 38 Mower Belt Maintenance 40 Leveling the Mower Deck snas 41 Adjusting the Blade Slope 42 Replacing the Discharge Deflector 44 JACI OSEERLGHIES 45 Tracking 45 45 Washing Underside of the Mowet 45 S OPIE C usto tps 47 Cleaning and Stora Ges ono docete latte 47 DW er bo ca iius 48 dunt En 50 Safety 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 1 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 Standar
8. HONIWHSL 1 6 of 1 WNIWH3L 4 S 4 HOLIMS NOILINDI 51 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 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 Bags Belts and Tires Battery Engine Warranty Period 90 days 1 Year Prorated 3 Year 3rd Year Covered by Exmark Please refer to the manufacturer s warranty statement that is included in the literature packet The manufacturer provides a 2 year
9. following instructions Park the machine on a level surface and disengage the blade control switch Move the motion control levers outward to the neutral position engage the parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Check the air pressure of all four tires If needed adjust to the recommended inflation refer to Checking the Tire Pressure in Drive System Maintenance section Check and adjust the side to side blade level if you have not checked the setting refer to Leveling the Mower Set the height of cut lever to the 3 inch 76 mm position Place two B thick blocks see Block Height and Rake Table in Leveling the Mower Deck under the rear edge of the cutting deck skirt one on each side of the cutting deck Place 42 Maintenance two thick blocks see Block Height and Rake Table in Leveling the Mower Deck under each side of the front edge of the deck but not under the anti scalp roller brackets Loosen the leveling adjust locking nuts item 4 on all four corners so that the deck is sitting securely on all four blocks Make sure that the deck hangers are all the way down at the top of the slot and the deck lift foot lever is pushed back against the stop then tighten the four leveling adjust locking nuts Figure 43 G007204 Figure 43 1 Deck lift arm 2 Float retaining nut 3 Deck hanger 4 Lev
10. he air cleaner is dirty he spark plug wire s is loose 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 48 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 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 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
11. key to Off Also remove the key and pull the wire off the spark plug s Figure 15 1 Front of the machine 5 Transporting Lever position for pushing the machine Rotate bypass release knob clockwise Release lever Rotate bypass release 6 knob counterclockwise 3 Lever position for 7 operating the machine Pull lever in this direction Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer or truck with straps chains cable or ropes Be sure that the trailer or truck has all necessary lighting and marking as required by law Secure a trailer with a safety chain A CAUTION This unit does not have proper turn signals lights reflective markings 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 4 Loosen the knob by turning counterclockwise Then pull the release lever on the underside of machine Figure 15 towards the back of the machine and retighten the knob to hold the release lever back in the released state Repeat this on each side of the machine Release the parking brake The machine is now able to be pushed by hand To Operate the Machine
12. 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 The Exmark turf equipment including any defective part must be returned to an authorized Exmark service dealer within the warranty period This warranty extends only to turf equipment operated under normal conditions You must read the operator s manual You must also properly service and maintain your Exmark product as described in the operator s manual Such routine maintenance whether performed by a dealer or by you is at your expense General Conditi
13. the fuel in the tank Follow the mixing instructions from the stabilizer manufacturer Do Not use an alcohol based stabilizer ethanol or methanol Note A fuel stabilizer conditioner is most effective when mixed with fresh gasoline and used at all times B Run the engine to distribute the conditioned fuel through the fuel system 5 minutes Stop the engine and turn the fuel shut off valve 90 to the off position 10 11 12 13 14 15 16 47 D Restart the engine and run it until it stops E Choke the engine Start and run the engine until it will not start Remove the spark plug s and check its condition refer to Servicing the Spark Plug in Engine Maintenance section With the spark plug s removed from the engine pour two tablespoons of engine oil into the spark plug hole Use the starter to crank the engine and distribute the oil inside the cylinder Install the spark plug s Do Not install the wire on the spark plug s Clean any dirt and chaff from the top 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 g
14. 1 G000503 55 SEE EXMARK S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM ROPS DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB GRASS CATCHER TURF STRIPER MICRO MULCH SYSTEM STANDON Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchased Engine Model No and Spec No Model No Engine Serial No E No Serial No 2009 Exmark Mfg Inc Part No 4500 450 Rev A Industrial Park Box 808 402 223 6300 Cle Beatrice NE 68310 Fax 402 223 5489 All Rights Reserved Printed in the USA www exmark com
15. 13 psi 90 kPa 90 kPa 138 kPa 90 kPa Cutting Deck Cutting Width 42inch Deck 42 inches 107 cm 48 inch Deck 48 inches 122 cm 52 inch Deck 52 inches 132 cm Discharge Side Blade Size 3 ea 42 inch Deck 21 25 inches 53 9 cm 48 inch Deck 16 25 inches 41 3 cm 52 inch Deck 18 00 inches 45 7 cm e Blade Spindles Solid steel spindles with no maintenance bearings e 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 42inch Deck 5 0 inches 12 7 cm 48 inch Deck 5 0 inches 12 7 cm 52 inch Deck 5 0 inches 12 7 cm Cutting Height Adjustment A foot deck lift lever is used to adjust the cutting height from 1 1 2 inch 3 8 cm to 4 1 2 inches 11 4 cm in 1 2 inch 1 3 cm increments e Mulching Kit Optional Dimensions Overall Width 42 inch 48 inch 52 inch Deck Deck Deck Without 45 5 inches 45 5 inches 47 0 inches Deck 116 116 cm 119 cm Deflector 43 1 inches 48 3 inches 53 0 inches Up 109 cm 122 cm 135 cm Deflector 54 2 inches 59 4 inches 64 2 inches Down 138 cm 151 cm 163 cm Overall Length 73 4 inche
16. Loosen the bypass knob push the release levers forward and retighten the knob to engage the drive system Figure 15 Side Discharge The mower has a hinged discharge deflector that disperses clippings to the side and down toward the turf Do Not drive a unit on a public street or roadway 25 Operation A 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 If individual ramps must be used use enough ramps to create 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 ba
17. arage 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 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 he operator is not seated he battery is dead he electrical connections ate corroded ot loose A fuse is blown A relay or switch is damaged Fuel tank is empty he choke is not on
18. ately 4 Install the fuel tank cap securely 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 Starting the Engine 1 Sit down on the seat and move the motion controls outward to the neutral position and engage the parking brake Disengage the blades by moving the blade control switch to Off Figure 7 19 Operation 6009776 Figure 7 1 Throttle Choke lever 5 Run 2 Blade control 6 Start switch Off position 3 Ignition key 7 Choke 4 Off 8 Throttle fast detent position 3 Move the lever forward beyond the detent to engage the choke before starting a cold engine Figure 7 Note A warm or hot engine may not require choking Turn the ignition key to Start to energize the starter When the engine starts release the key Figure 7 Important Do Not engage the starter for more than 5 seconds at a time If the engine fails to start allow a 60 second cool down period between attempts Failure to follow these instructions can burn out the starter motor Once the engine starts move the lever to the detent position If the engine stalls or hesitates move the lever partially forward for a few seconds Operating the Blades The blade control switch represented by a power take off PTO symbol engages and dis
19. aterial 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 tutns Look behind and to the side before changing directions Nevet leave a running machine unattended Always turn off blades engage parking brake stop engine and remove key before dismounting Turn off blades when not mowing Stop the engine wait for all parts to come to a complete stop engage parking brake and remove key before cleaning the machine removing the grass or unclogging the deflector Operate the machine only in daylight or good artificial light Do Not operate the machine while under the influence of alcohol or drugs Watch for traffic when operating near or crossing roadways Use extra care when loading or unloading the machine into a trailer or truck Always weat 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 t
20. before leaving the operating position 3 Clean the grease fittings Figure 17 and Figure 18 with a rag Make sure to scrape any paint off of the front of the fitting s Maintenance 109 6016 G010242 Figure 18 Located on the back of the seat Check hydraulic oil level and refer to Operator s manual for further instructions Check tire pressure 1 Read the instructions 5 before servicing or performing maintenance 2 Grease idler pivot All 6 units 3 Time interval hours 7 Grease idler pivot 48 and 52 inch only 4 Check oil level 4 Connect a grease gun to each fitting Figure 17 and Figure 18 Pump grease into the fittings until gtease begins to ooze out of the bearings 5 Wipe up any excess grease Engine Maintenance Servicing the Air Cleaner Service Interval Every 25 hours Monthly whichever comes first May need more often under extremely dusty or dirty conditions Every 100 hours Yearly whichever comes first Replace the paper element More often under extremely dusty dirty conditions This engine is equipped with a replaceable high density paper air cleaner element Check the air cleaner daily or before starting the engine Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace all bent or damaged air cleaner components Note Operating th
21. ck System A CAUTION If 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 e The motion control levers ate 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 The parking brake is engaged and motion control levers in 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 parking brake engaged PTO disengaged and motion control levers moved out in the neutral lock position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in sea
22. ckward 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 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 air 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 cuttin
23. d 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 G009775 1 Figure 4 3 Blade control switch power take off Ignition switch 1 Throttle Choke lever 2 Hour meter 4 Note Brake must be engaged motion control levers out neutral lock position and PTO switch OFF to start engine It is not necessary for the operator to be in the seat to start the engine Turning the key to the Off position will stop the engine however always remove the key when leaving the machine to prevent someone from accidentally starting the engine 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 Choke Lever Located on control panel The throttle is used to control engine speed Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed Moving the throttle forward into the detent is full throttle see Figure 4 The choke
24. 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 Recommended Maintenance Schedule s Maintenance Service Maintenance Procedure Interval After the first 5 hours Change the engine oil After the first 250 hours Change the hydraulic filter heck the safety interlock system heck the air intake and cooling areas clean as necessary heck the oil level before starting or after every 8 hours heck the hydraulic oil level in the expansion tank heck the mower blades ean the mower housing Before each use or daily rease all lubrication points heck the air cleaner for dirt looseness or damage May need more often under extremely usty or dirty conditions ervice the air cleaner May need more often under extremely dusty or dirty conditions heck the tire pressure heck the belts Every 25 hours Replace the paper element More often under extremely dusty dirty conditions Replace the air cleaner element Every 100 hours Change the engine oil and filter Clean the blower housing More often under dirty conditions Replace the fuel filter Every 200 hours Service the spark plug Evers 500 the hydraulic filter Every 250 hours
25. ds 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 ot 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 clear 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 wire etc which could be picked up and thrown by the blade Be sure the area is clear of other people before mowing Stop the machine if anyone enters the area Never carry passengers Do Not mow in reverse unless absolutely necessary Always look down and behind before and while backing up Be aware of the mower discharge direction and Do Not point it at anyone Avoid discharging m
26. e 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 G007186 Figure 19 1 Air cleaner 3 Air cleaner cover 2 Knobs Servicing Paper Element Service Interval Every 25 hours Monthly whichever comes first May need more often under extremely dusty or dirty conditions Every 100 hours Yearly whichever comes first Replace the air cleaner element 1 Remove the air cleaner cover Figure 19 2 Remove the air cleaner element with the integral rubber seal Maintenance 3 Remove the foam sleeve from the element Gently tap the pleated side of the paper element to dislodge dirt Do Not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element Handle new elements carefully Do Not use if the rubber seal or foam sleeve is damaged 5 Wash the foam sleeve in warm water and allow to dry Reinstall over the paper element 6 Clean all air cleaner components of any accumulated dirt or foreign matetial Prevent any dirt from entering the carburetor 7 Install the air cleaner element with the pleated side out and seat the rubber seal onto the edges of the air cleaner base 8 Reinstall the air cleaner cover and secure with the knobs Servicing the Engi
27. e motion control levers to neutral and outward to the neutral position disengage the blade control switch move the throttle lever to between Fast and half throttle and turn the ignition key to off Remember to remove the key from the ignition switch A CAUTION Children or bystanders may be injured if they move or attempt to operate the mower while it is unattended Always remove the ignition key and move the motion control levers outward to the neutral position and apply the parking brake when leaving the machine unattended even if just for a few minutes Adjusting the Height of Cut 1 Raise the deck to the transport position 4 5 inch 114 mm cut height by pushing the foot actuated lever forward Figure 10 The transport lever will automatically engage and will drop into place 22 Operation G009781 Figure 10 1 Transportrelease handle 3 Height adjuster pin 2 Height of cut positions 4 Foot actuated height of cut lever 2 Move the deck height adjuster pin to the desired cut height 3 Push the foot lever forward pull the transport release handle up and let the deck lower down to the predetermined cut height by slowly decreasing foot pressure allowing the foot lever to travel rearward Adjusting the Anti Scalp Rollers It is recommended to change the anti scalp roller position when the height of cut has changed 1 Stop the machine and move the drive levers to the neutral lock posi
28. ed belt edges burn marks and cracks are signs of a worn mower belt Replace the mower belt if any of these conditions are evident 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to the neutral position engage parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Set the height of cut at 1 1 2 inch 38 mm For 48 and 52 inch decks only remove the belt covets over the outside spindles 5 Grasp both belt strands going to the clutch Pull them to the rear of the machine and slip the belt Maintenance off the clutch pulley as shown in Figure 38 and 7 Grasp both belt strands going to the clutch Pull Figure 39 them to the rear of the machine and slip the belt onto the clutch pulley A WARNING 8 For 48 and 52 inch decks only install the belt covers over the outside spindles The spring is under tension when installed and can cause personal injury Leveling the Mower Deck The mower blades must be level from side to side Check the side to side level any time you install the mower or when you see an uneven cut on your lawn Be careful when removing the belt 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to the neutral position engage parking brake stop the engine remove the key and wait f
29. eling adjust locking nut 8 Carefully rotate the blades so they are facing front to rear Figure 44 and Figure 45 Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat surface Figure 44 and Figure 45 If the front blade tip is not see Block Height and Rake Table in Leveling the Mower Deck lower than the rear blade tip adjust the front deck hanger J2 2p Figure 44 48 and 52 Inch Decks 2 G010291 1 Blades front to rear 2 Measure here Ae 2 ep E up 2 ce 2 0 2D 2 Figure 45 42 Inch Deck 1 Blades front to rear 2 Measure here 10 When the front to rear blade slope is correct check the side to side level of the mower again refer to Leveling the Mower 43 Maintenance Replacing the Discharge through the front discharge deflector bracket Deflector discharge deflector and rear deflector bracket 5 Make sure that the spring and rod are installed GER so that the rod is retained from sliding out by the front bracket and the spring holds the discharge deflector in the down position Refer to An d disch i ld all uncovered discharge opening could allow O the lawn mower to throw objects the operators or bystander s direction and result Important The discharge deflector must be in serious injury Also contact with the blade spring loaded
30. engages 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 8 6009779 Figure 8 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 7 Stopping the Engine 1 Bring the unit to a full stop Disengage the PTO 3 Move the motion control levers out to the neutral lock position Engage the parking brake 5 Place the throttle midway between the SLOW and FAST positions 6 Allow the engine to run for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine 7 Remove the key to prevent children or other unauthorized persons from starting engine 8 Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building 20 Operation The Safety Interlo
31. g 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 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 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 26 Operation 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 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 g
32. gap is incorrect Vent hole in the fuel cap is closed Dirt in fuel filter Dirt watet 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 Deck belt is worn loose or broken Deck belt is off pulley The mower belt is worn loose or broken 49 Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Install a new correctly gapped spark plug s Open the vent in the fuel cap 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 en
33. gine 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 rear Adjust the anti scalp wheel height Clean the underside of the mower Adjust tire pressure Contact an Authorized Service Dealer Install new drive belt Install drive belt and check adjusting shafts and belt guides for correct position Install new deck belt Install deck pulley and check the idler pulley idler arm and spring for correct position and function Install a new mower belt Schematics Schematics Electrical Diagram O13NDVW 13n4 HOLIMS 10 v Cf e Salossa2ov Lr mmm Momma 32018 asn4 8VXSA HOLIMS NOLLINDI
34. ground Do Not mow near drop offs ditches steep banks ot 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 Keep children out of the mowing area and under the watchful care of another responsible adult not the operator Be alert and turn the machine off if children enter the area Before and while backing or changing direction look behind down and side to side for small children e Never carry children even with the 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 e 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 recommendat
35. hat is not included in the ANSI standards 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 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 attachment 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 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 93 7009 1 Warning Do Not operate 2 Cutting dismemberment the mower with the hazard of hand or foot discharge deflector up mower blade
36. ich 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 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 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 the neutral position and engage parking brake Stop the engine remove the key and disconnect the spark plug wire s from the spark plug s Inspecting the Blades 1 Inspect the cutting edges Figure 32 If the edges are not sharp or have nicks remove and sharpen the blades refer to Sharpening the Blades 2 Inspect the blades especially the curved area If you notice any damage wear or a slot forming in this area item 3 in Figure 32 immediately install a new blade V po 4 ee 2 lt Figure 32 1 Cutting edge 2 Curved area 3 Wear slot forming Checking for Bent Blades
37. if using Mobil 1 15W50 Replace the spark plug 28 Maintenance Maintenance Service Interval Before storage Monthly Maintenance Procedure Charge the battery and disconnect the battery cables Perform all maintenance procedures before storage Paint any chipped surfaces Check the battery charge Important Refer to your Engine Operator s Manual for additional maintenance procedures Premaintenance Procedures Raising the Seat Make sure the motion control levers are locked in the neutral position Lift the seat forward until the lanyard is tight The following components can be accessed by raising the seat Auxiliary 12V Plug 12V accessory up to 15 amp e Fuses Battery cables Accessing the Battery The battery is located under the seat To access raise the seat Figure 16 G007183 Figure 16 1 Auxiliary 12V Plug 3 Seat 2 Battery Periodic Maintenance Lubrication Greasing the Bearings Service Interval Every 25 hours Monthly whichever comes first Grease Type NGLI grade 2 multi purpose gun grease Grease the front caster wheels Figure 17 G007184 1 Figure 17 1 Front caster tire 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to the neutral position engage parking brake stop the engine remove the key and wait for all moving parts to stop
38. in the down position Lift the could occur deflector up to test that it snaps to the full Never operate the lawn mower unless you down position install a mulch plate discharge deflector or grass collection system 1 Locate items shown in Figure 46 6007208 Figure 46 1 Rod 4 Mower deck 2 Spring 5 Discharge deflector bracket 3 Discharge deflector 6 Assembled view 2 Slide the rod out of the short stand off spring and discharge deflector Remove the damaged or worn discharge deflector 3 Install new discharge deflector 4 Orient the spring so that the short leg points towards the discharge deflector and the longer leg points towards the deck as shown in Figure 46 Place spring on rod and slide rod straight end 44 Maintenance Adjustments Tracking Adjustment If the machine turns right or left when handles are pushed forward together adjust the tracking plate on the side opposite the direction of turn see Figure 47 Loosen the hardware that holds the tracking plate Move the plate back until the unit drives straight Tighten the hardware to lock the tracking plate in place Readjust handles if necessary 6009780 Figure 47 1 Control arm shaft 3 Tracking plate 2 Tracking plate nut Cleaning Washing the Underside of the Mower Service Interval Before each use or daily After each use wash the underside of the mower to prevent grass buildup for im
39. ion 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 ot 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 tefuel the machine indoots Never store the machine or fuel container inside where there is an open flame such as near a water heater or 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 de
40. is used to aid in starting a cold engine Do Not run a warm engine with the choke in the ON position Moving the lever forward beyond the detent will put the choke in the ON position and moving the lever to the detent will put the choke in the OFF position Motion Control Levers 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 locks them in the neutral position Always position the motion control levers into the neutral position and engage the park brake lever when you stop the machine or leave it unattended The unit must be tied down and brake engaged when transporting 16 Operation Parking Brake Lever A DANGER Located on left side of the console Figure 3 z Mowing on wet grass or steep slopes can The brake lever engages a parking brake on the drive cause sliding and loss of control Wheels wheels dropping over edges can cause rollovers which may result in serious injury death or drowning A loss of traction is a loss of Push the lever forward and down to disengage the steering control brake Pull the lever up and rearward to engage the brake To avoid loss of control and possibility
41. it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Servicing the Spark Plug Service Interval Every 200 hours Every 2 years whichever comes first Every 500 hours Replace the spark plug Maintenance As stated in the maintenance intervals remove the spark plug check condition and reset the gap or replace with a new plug as necessary The spark plug is RFI compliant Equivalent alternate brand plugs can also be used Type Champion 92 Champion RC12YC or QC12C may be used if your area does not requite compliance with Canadian ICES 002 ISO 14982 or EN 55012 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 Pull the wire off of the spark plug Figure 25 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 L 07 G007193 Figure 25 1 Spark plug and wire location Checking the Spark Plug 1 Look at the center
42. k 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 are responsible for operating the product properly and safely 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 Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided G007035 Figure 1 Behind the seat 1 Model and serial number location Model No Serial No Contents tes teg E ERR Lan 3 5 Safety Alert uod Reni edes 5 Safe Operating 5 Safety and Instructional Decals 8 Specifica 13 Model Sati Dees as cec oe o 13 Sy Ste S dd 13 14 Torque Requirements 15 Product Overview
43. lace Thrown objects 110 6691 3 Cutting dismemberment hazard keep bystanders of hand or foot stay a safe distance from the machine Thrown objects hazard mower keep the discharge deflector or collection system in place away from moving parts Engine RPM setting 20 HP Engine 3300 100 RPM 22 HP amp 24 HP Engine 3650 100 RPM 116 0531 116 0531 Tox 116 0532 QST20BE422 Unit Choke on Throttle fast Continuous variable setting Throttle slow Lubricate Blade Bolt threads with copper based antiseize or grease and torque to 32 42 ft Ibs 43 57 N m 116 0533 116 0533 116 0551 116 0581 Safety PTO Symbols 1 PTO Off 2 PTO On 1 Read the instructions before servicing or performing maintenance 2 Time interval 3 Check oil level 109 6016 e s H RIAM 2 e 0 5 em LL T 109 6016 Refer to the Operator s manual for grease instructions Check hydraulic oil level and refer to the Operator s Manual for further instructions Check tire pressure 11 Safety 109 8965 109 8965 1 Warning read the Operator s Manual 5 Tipping hazard avoid sudden and sharp turns while on slopes only mow across slopes less than 15 degrees keep a safe distance from water and only mow up and down slopes less than 15 degrees 2 Read the in
44. lancer Figure 37 If the blade stays in a horizontal position the blade is balanced and can be used If the blade is not balanced file some metal off the end of the sail area only Figure 37 Repeat this procedure until the blade is balanced 1 2 E Figure 37 1 Blade 2 Balancer Installing the Blades 1 Install the blade onto the spindle shaft Figure 35 Important The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting 2 Hold the blade end using a rag or thickly padded glove or place a wrench on the top sheave nut Apply lubricant to the threads of the blade bolt as needed to prevent seizing Copper based anti seize is preferable Grease is an acceptable substitute Install the washer and blade bolt and washer assembly 3 Torque the blade bolt to 32 42 ft lb 43 57 N m A 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 Mower Belt Maintenance Inspecting the Belts Service Interval Every 25 hours Monthly whichever comes first Check the belts for cracks frayed edges burn marks ot any other damage Replace damaged belts Replacing the Mower Belt Squealing when the belt is rotating blades slipping when cutting grass fray
45. lug on each transmission and fill through expansion reservoir when oil comes out of vent reinstall plug Exmark Premium Hydro Oil is recommended Refer to the chart for an acceptable alternative Hydro Oil Change Interval Exmark Premium Hydro 500 Hours Oil Preferred Mobil 1 15W50 250 Hours Torque plugs to 180 in Ib 244 N m Continue to add oil until it reaches the FULL COLD line on the expansion reservoir 33 G007192 Figure 24 1 Oil filter 3 2 Vent plug Left rear tire 6 Raise the tear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely Start engine and move throttle control ahead to 1 2 throttle position Disengage parking brake A With the bypass valve open and the engine running slowly move the directional control in both forward and reverse 5 or 6 times With the bypass valve closed and the engine running slowly move the directional control in both forward and reverse directions 5 to 6 times Check the oil level and add oil as required after stopping the engine It may be necessary to repeat steps A and B until all the air is completely purged from the system When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds then the transaxle is considered purged Do Not change hydraulic system oil except for what can be drained when changing filter unless
46. n RPM 22HP amp 24HP Pull Speed 3650 100 max RPM No Load Idle 1650 min RPM Fuel System Capacity 4 0 gal 15 1 L Type of Fuel Regular unleaded gasoline 87 octane or higher Fuel Filter Briggs amp Stratton P N 695666 Fuel Shut Off Valve 1 4 turn increments OFF 5 Electrical System Charging System Flywheel Alternator Charging Capacity 16 amps Battery Type BCI Group U1 Battery Voltage 12 Volt Polarity Negative Ground Fuses One 25 amp one 20 amp one 15 amp blade type Diode TVS Safety Interlock System PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine It is not necessary for the operator to be in the seat to start the engine 13 Operator must be in seat when PTO is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged Operator Controls Steering and Motion Control Note Motion control levers are adjustable to two heights Separate levers on each side of the console control speed and direction of travel of the respective drive wheels Steering is controlled by varying the position of the levers relative to each other Moving motion control levers outward in slots locks the drive system in neutral PTO Engagement Swi
47. n mower with bolts and locknuts Never put your hands or feet under the mower or through openings in the mower 46 Storage Storage Cleaning and Storage Te Disengage the blade control switch move the motion controls outward to the neutral position engage parking brake 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 water especially near the control panel engine hydraulic pumps and motors Service the air cleaner refer to Servicing the Air Cleaner in Engine Maintenance section Grease and oil the machine refer to Lubrication section Change the crankcase oil and filter refer to Servicing the Engine Oil in Engine Maintenance section Check the tire pressure refer to Checking the Tire Pressure in Drive System Maintenance section Charge the battery refer to Servicing the Battery in Electrical System Maintenance section Check the condition of the blades refer to Servicing the Cutting Blades in Mower Maintenance section Prepare the machine for storage when non use occurs over 30 days Prepare the machine for storage as follows A Add a petroleum based stabilizer conditioner to
48. ne Oil Checking the Oil Level Service Interval Before each use or daily 1 Park the machine on a level surface disengage the blade control switch stop the engine engage parking brake and remove the key 2 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 3 To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap dipstick before removing it 4 Pull and remove the oil fill cap dipstick wipe oil off Reinsert the dipstick and push firmly into place Figure 20 Figure 20 1 Oil dipstick 3 Oil level 2 Filler tube 5 Remove the dipstick and check the oil level The oil level should be up to but not over the mark on the dipstick If the level is low add oil of the proper type up to the F mark on the dipstick Always check the level with the dipstick before adding more oil Note To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the mark on the dipstick Changing the Oil and Filter Service Interval After the first 5 hours Every 100 hours Yearly whichever comes first thereafter Change the oil and filter while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when filling checking or changi
49. ng the oil 1 Start the engine and let it run until warm This watms the oil so it drains better Disengage the blade control switch and move the motion controls outward to the neutral position and engage parking brake 31 Maintenance 3 Stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 4 Clean the area around the drain plug and on the machine frame Place a pan underneath machine directly below the drain hole in the frame as shown in Figure 21 Figure 21 3 1 Oil drain 2 Oil drain plug 5 Remove the oil drain plug Figure 21 Remove the oil fill cap dipstick Figure 20 1 2 E v N G007190 Figure 22 1 Oil filter 2 Gasket 6 Be sure to allow ample time for complete drainage 7 Remove the old filter and wipe off the mounting pad Figure 22 8 When the oil has drained completely install the oil drain plug Tighten the plug to 14 N m 125 in lb torque Wipe up any excess oil on the frame Figure 21 Note Dispose of the used oil at a recycling center 9 Apply thin film of clean oil to the rubber gasket on the new filter 10 Install the replacement oil filter to the mounting pad Turn the oil filter clockwise until the rubber gasket contacts the pad then tighten the filter an additional 1 2 to 3 4 turn Figure 22 11 Slowly pour approximately 80 of the specified oil into
50. o 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 Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine e Choose a low ground speed so you will not have to stop while operating on a slope Do Not mow slopes when grass is wet Slippery conditions reduce traction and could cause sliding and loss of control 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 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
51. of rollover Height of Cut Foot Lever Do Not mow near drop offs or near water The height of cut lever allows the operator to lower Do Not m 1 than 15 and raise the deck from the seated position Figure 3 degrees When the lever is moved forward away from the operator the deck is raised from the ground and Reduce speed and use extreme caution when moved back towards the operator it is lowered on slopes toward the ground Only adjust the height of cut while machine is not moving When mowing slopes gradually work from lower to higher areas on the incline Avoid sudden turns or rapid speed changes Located on the control panel Turn up into an incline when changing directions on slopes Turning down the slope reduces traction Hour Meter The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run Figure 4 If the Attachments change the handling ignition switch is left on without engine running hour characteristics of the machine Use extra meter will not run The hour meter is standard on the caution when using attachments with the 48 and 52 inch units and optional for the 42 inch unit machine Note This switch is not a low oil sensor and will not alert the operator if the engine oil is low Operating Instructions Think Safety First Note Determine the left and right sides of the machine fr
52. of the spark plug Figure 26 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 ot ctacks Check the gap between the center and side electrodes Figure 26 Bend the side electrode if the gap is not correct G006998 Figure 26 1 Side electrode 2 Center electrode insulator 3 Air gap not to scale Installing the Spark Plug 1 Install the spark plug Make sure that the air gap is set correctly 2 Tighten the spark plug to 15 ft lb 20 N m 3 Push the wire onto the spark plug Figure 25 Cleaning the Blower Housing Service Interval Every 100 hours Yearly whichever comes first More often under dirty conditions To ensure proper cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times 1 Remove the blower housing and any other cooling shrouds 2 Clean the cooling fins and external surfaces as necessary 3 Make sure the cooling shrouds are reinstalled Important Operating the engine with a blocked grass screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating 34 Maintenance Fuel System Maintenance Replacing the Fuel Filte
53. om the normal operating position Please carefully read all of the safety instructions and decals in the safety section Knowing this information could help you your family pets or bystanders avoid injury Figure 5 G007037 1 Water 2 Danger Zone Use walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water 3 Safe Zone use the Quest here 17 Operation See inside back cover to determine the approximate slope angle to be mowed Recommended Gasoline Use UNLEADED Regular Gasoline suitable for automotive use 87 pump octane minimum Important Never use methanol gasoline containing methanol or gasohol containing more than 10 ethanol because the fuel system could be damaged Do Not mix oil with gasoline 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 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 inside an enclosed trailer Do Not fill the fuel tank completely full Add gasoline to the fuel tank until the body of the tank is full but fuel does not fill the neck of the tank This empty space in the tank allows gasoline to expand Never smoke when handling gasoline and stay away from an open flame or
54. ons 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 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 las
55. ontrol in the Fast position for best performance Always operate in the Fast full throttle position Operation A 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 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 9 2 5 4 te j a Figure 9 3 Backward 4 Forward 1 Neutral position 2 Center unlock position To go straight apply equal pressure to both motion control levers Figure 9 To turn pull back on the motion control lever toward the direction you want to turn Figure 9 The farther you move the motion control levers in either direction the faster the machine will move in that direction To stop pull the motion control levers to neutral Backward 1 Move the levers to the center unlocked position 2 go backward slowly pull the motion control levers rearward Figure 9 To go straight apply equal pressure to both motion control levers Figure 9 To turn release the pressure on the motion control levet toward the direction you want to turn Figure 9 To stop push the motion control levers to neutral Stopping the Machine To stop the machine move th
56. or all moving parts to stop before leaving the operating position 3 Check the air pressure of all four tires If needed adjust to the recommended inflation refer to Figure 38 Checking the Tire Pressure in Drive System 48 and 52 Inch Decks Maintenance section If either one is out of range then follow adjustment procedure 1 Outside puley 4 Mower belt 2 Spring 5 Engine pulley 4 Carefully rotate the blades side to side 95 den pulley 5 obs DES ns 5 Measure between the outside cutting edges and the flat surface Figure 40 and Figure 41 If both measurements are not within 3 16 inch 5 mm an adjustment is required continue with this procedure lt Ne G010313 Figure 39 eo 42 Inch Deck 1 Outside puley 4 Mower belt Figure 40 2 Spring 5 Engine pulley 48 and 52 Inch Decks 3 Idler pulley 6 Pull belt strands in this direction 1 Blades side to side 2 Measure here 6 Route the new belt around the mower pulleys 41 Maintenance Go10296 2 Figure 41 42 Inch Deck 1 Blades side to side 2 Measure here 6 Setanti scalp rollers to top holes ot remove completely for this adjustment Set the height of cut lever to the 3 inch 76 mm position Place two B thick blocks see Block Height and Rake Table under the rear edge of the cutting deck skirt one on each side of the cutting deck Place two thick block
57. osition 42 nch Unit 23 Operation Tip the seat forward Loosen the knob Move the seat to the desired position Tighten the knob Tip the seat back tot he closed position 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 Qu RIN qm Figure 13 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 13 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 two bolts holding the control lever to the control arm shaft Figure 14 6009782 Figure 14 1 Bolt 4 Control arm shaft 2 Washer 5 Nut 3 Control lever 2 Move the control lever to the next set of holes Secure the lever with the two bolts 3 Repeat the adjustment for the opposite control lever Adjusting the Tilt The motion control levers can be tilted fore or aft for maximum operator comfort 1 Loosen the upper bolt holding the con
58. output of 16 volts and 7 amps or less to avoid damaging the battery see chart below for recommended charger settings Maintenance Maximum Charging 3 Install the negative battery cable to the negative Charger Interval battery terminal using the fasteners removed Settings previously 12 6 16 volts 7 No 4 Slide the red terminal boot onto the positive red greater amps Charging battery post Required 5 Secure the battery with the strap Figure 28 124 126 75 100 16 volts 7 Servicing the Fuses and 12 2 12 4 50 75 16 volts 7 1 Hour Hew Relay 12 0 12 2 25 50 14 4 volts 4 2 Hours The electrical system is protected by fuses It requires amps no maintenance however if a fuse blows check 11 7120 10 25 14 4 volts 4 3 Hours the component circuit for a malfunction or short amps There is also a replaceable relay s next to the fuse Refer to your Parts manual for correct replacement e 2 dk id amps More Fuse Block 4 When the battery is fully charged unplug the charger from the electrical outlet then disconnect the charger leads from the battery Main fuse 25 amp fuse blade type Charge Circuit 20 amp fuse blade type posts Figure 29 e Auxiliary circuit 15 amp fuse blade type Diode TVS 1 Raise the seat to gain access to the fuse holder Figure 30 286 e gt Co 25 a G009784 G007196 Figure 29 1 Negative batte
59. proved mulch action and clipping dispersal 1 N ad Park the machine on a level surface and disengage the blade control switch Move the motion control levers outward to the neutral position engage parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position Attach the hose coupling to the end of the mower washout fitting and turn the water on high Figure 48 Note Spread petroleum jelly on the washout fitting O ring to make the coupling slide on easier and protect the O ring G007277 Figure 48 45 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 run 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 Maintenance Note If the mower is not clean after one washing soak it and let it stand for 30 minutes Then repeat the process 8 Run the mower again for one to three minutes to remove excess water A WARNING A broken missing washout fitting could expose you and others to thrown objects or blade contact Contact with blade or thrown debris can cause injury or death Replace broken or missing washout fitting immediately before using mower again Plug any hole s i
60. r 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 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 2 Move the motion control levers outward to the neutral position engage parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 The fuel filter is in the fuel line between the tank and engine G007194 Figure 27 Fuel tank 6 Hose clamps Fuel shut off valve off 7 Fuelline to engine Fuel shut off valve 8 Filter Fuel shut off valve on 9 Flow direction arrow Fuel line from tank gt 4 Turn fuel shut off valve 90 to off position 5 Squeeze the ends of the hose clamps together and slide them away from the filter Figure 27 6 Remove the filter from the fuel lines 7 Install a new filter with the flow direction arrow coming from the fuel tank and pointing to the engine Mo
61. rass again using the lower normal setting When Stopping If the machine s forward motion must be stopped while mowing a clump of grass clippings may drop onto your lawn To avoid this move onto a previously cut area with the blades engaged Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use If grass and dirt build up inside the mower cutting quality will eventually become unsatisfactory Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades Tearing and shredding turns grass brown at the edges which slows growth and increases the chance of disease Check the cutter blades daily for sharpness and for any wear or damage File down any nicks and sharpen the blades as necessary If a blade is damaged or worn replace it immediately with a genuine Exmark replacement blade Only Exmark blades are to be used with this unit No other blades are approved 27 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
62. ry post 3 Red charger lead 2 Black charger lead 4 Positive battery post Note Do Not run the machine with the battery disconnected electrical damage may occur Installing the Battery ren 1 Cover 4 Charge 20 1 Position the battery in the tray with the terminal 2 Relay 5 Main 25 amp posts toward the operating position Figure 28 3 Auxilliary 15 amp 6 Diode 2 Install the positive red battery cable to the positive battery terminal using the fasteners 2 Remove covet as shown in Figure 30 removed previously 3 To replace a fuse pull out on the fuse to remove it 37 Maintenance 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 31 Check the tires when they are cold to get the most accurate pressure reading Rear Tires 13 psi 90 kPa Front Tires caster wheels Smooth 13 psi 90 kPa e Sawtooth 20 psi 138 kPa aT 9007275 Figure 31 1 Valve stem 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 wh
63. s Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth Operation Using Stabilizer Conditioner Use a fuel stabilizer conditioner in the machine to provide the following benefits Keeps gasoline fresh during storage of 30 days or less For longer storage it is recommended that the fuel tank be drained e Cleans the engine while it runs e Eliminates gum like varnish buildup in the fuel system which causes hard starting Add the correct amount of gas stabilizer conditioner to the gas Note A fuel stabilizer conditioner is most effective when mixed with fresh gasoline To minimize the chance of varnish deposits in the fuel system use fuel stabilizer at all times Gasoline Alcohol blends Gasohol up to 10 percent ethyl alcohol 90 percent unleaded gasoline by volume is approved for fuel use by the engine manufacturer Other gasoline alcohol blends are not approved Filling the Fuel Tank 1 Shut the engine off and set the motion controls to the neutral position and engage parking brake 2 Clean around the fuel tank cap and remove the cap 3 Add unleaded regular gasoline until the body of the tank is full but fuel does not fill the neck of the tank Figure 6 This space in the neck of the tank allows gasoline to expand Do Not fill the fuel tank completely full Figure 6 3 Gas tank body 1 Gas tank opening 2 Fill to here approxim
64. s 186 cm Product Overview Overall Height Product Overview 8 9 10 418 inches 106em ____________ 41 8 inches 106 cm Tread Width Center to Center of Tires Widthwise 42 inch 48 inch 52 inch Deck Deck Deck Drive 36 0 inches 36 0 inches 36 8 inches Wheels 91 cm 91 cm 93 cm Caster 27 9 inches 33 5 inches 33 5 inches Wheels 71 cm 85 cm 85 cm Wheel Base Center of Caster Tire to Center of Drive Tire Front caster wheel 8 Engine 1 2 Antiscalp roller 9 Seat 3 Height of cut foot lever 10 Armrest 4 Discharge deflector 11 Motion control levers Curb Weight 5 Height of cut adjustment 12 Park brake T 6 Rear drive wheel 13 Footrest T Control panel 14 Washout fitting 630 lb 286 kg 645 lb 293 kg 660 lb 299 kg Torque Requirements Spindle Pulley Nut 75 85 ft lb 102 115 N m Blade Mounting Bolt 32 42 ft lb 43 57 N m lubricate with anti seize Engine Mounting Bolts 27 33 ft lb 37 45 N m Anti Scalp Roller Nyloc 27 33 ft lb 37 45 N m Nut Wheel Lug Nuts 70 90 ft lb 95 122 N m Clutch Mounting Bolt 50 55 ft lb 68 75 N m secured with threadlocker Spark Plug 15 ft lb 20 N m 15 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 an
65. s under each side of the front edge of the deck but not under the anti scalp roller brackets Block Height and Rake Table Deck Front Block Rear Block Rake R Size Height A Height 42 2 19 inches 2 44 inches 1 8 3 8 inch 5 6 cm 6 2 cm 3 2 9 5 mm 1 16 5 16 inch 1 6 7 9 mm 48 amp 2 31 inches 2 50 inches 52 5 9 cm 6 4 cm 8 Carefully rotate the blades side to side Figure 40 and Figure 41 9 Loosen the leveling adjust locking nuts item 4 on all four corners so that the deck is sitting securely on all four blocks Make sure that the deck hangers are all the way down at the top of the slot and the deck lift foot lever is pushed back against the stop then tighten the four leveling adjust locking nuts 10 Recheck that blocks fit just snugly under the deck skirt Make sure all attachment bolts are tight 11 Continue leveling the deck by checking the front to rear blade slope refer to Adjusting the Front to Rear Blade Slope 12 Recheck blades for levelness and repeat deck leveling procedure if necessary G007203 Figure 42 1 Deck lift arm 2 Float retaining nut 3 Deck hanger 4 Leveling adjust locking nut Ausg the Blade Slope Check the front to rear blade level any time you install the mower If the front blade tip is not R see Block Height and Rake Table in Leveling the Mowet Deck lower than the rear blade tip adjust the blade level using the
66. stay away or removed keep the from moving parts discharge deflector in place 8 103 6327 All Units Except QST20BE422 Choke on ONS Throttle fast Continuous variable setting Throttle slow Safety decals and instructions are easily visible to the operator and are located near any area of potential danger Replace any decal that is damaged or lost 109 6008 109 6008 1 Read the Operator s 3 Push the machine Manual 2 Rotate the drive release knob to loosen slide the knob and tighten 1 106 5517 Warning Do Not touch the hot surface 109 6014 109 6014 Traction Drive Belt Routing Safety 9 09 601 109 6035 1 Fuse Deck Drive Belt Routing 2 0 51mm 2 5 63mm 3 0 76mm 3 5 90mm 109 6036 109 6036 1 Read the Operator s Manual 2 Remove the ignition key and read the instructions before servicing or performing maintenance 1 Parking brake 3 Height of cut 2 Fast 3 Slow 109 9120 2 Diode 109 9173 109 9173 4 Neutral 5 Reverse 6 Machine Speed 109 6210 Read the Operator s Manual 2 Cutting dismemberment hazard fan and entanglement hazard belt stay away from moving parts 1 Machine speed 1 Entanglement hazard belt Do Not open or remove 3 Slow safety shields while engine is running keep shields in lt el 3H MR 109 9182 4 Neutral 5 Reverse p
67. structions before servicing or performing 6 Cutting dismemberment hazard of hand or foot mower maintenance apply parking brake remove the ignition key blade stay away from moving parts and disconnect the spark plug wire 3 Thrown object hazard keep bystanders a safe distance 7 Crushing dismemberment hazard of bystanders from the machine pick up debris before operating keep reversing Do Not carry passengers look behind and the discharge deflector in place down when reversing 4 Loss of traction control hazard slopes loss of traction control on slope disengage the blade control switch PTO proceed off the slope slowly Pb Pier o Battery Symbols Some or all of these symbols are on your battery 1 Explosion hazard 5 Read the Operator s Manual 9 Flush eyes immediately with water and get medical help fast 2 No fire open flames or smoking 6 Keep bystanders a safe distance 10 Contains lead do not discard from the battery 3 Caustic liquid chemical burn hazard 7 Wear eye protection explosive gases can cause blindness and other injuries 4 Wear eye protection 8 Battery acid can cause blindness or Severe burns 12 Specifications Specifications Model Numbers Serial Nos 790 000 and Higher QST20BE422 QST22BE482 QST24BE522 Systems Engine Engine Specifications See your Engine Owner s Manual RPM 20HP Pull Speed 3300 100 max RPM No Load Idle 1650 mi
68. t parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the left motion control lever in starter must not crank repeat again with the right lever in then with both levers in starter must not crank 2 Check kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must initiate shutdown 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 Again run engine at one third throttle brake engaged and move left motion control lever in engine must initiate shutdown Repeat again moving the right lever in then moving both levers in engine must initiate shutdown whether operator is on seat or not 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 c
69. tch Engages electric clutch to drive belt which engages mower blades Parking Brake Lever Engages parking brake Deck Height Adjustment Pin Sets cutting height to desired position Deck Lift Assist Lever Foot pedal that assists in raising the deck Seat Type Standard seat with high back foam padded with spring suspension and armrests armrests are optional on the 42 inch unit Mounting Hinged to tilt up for access to hydraulic pumps battery and other components Held in tilted position with lanyard Adjustable fore and aft Specifications e Armtests Standard foam padded flip up adjustable height armrests optional on the 42 inch unit e Seat Safety Switch Incorporated into the Safety Interlock System Hydrostatic Ground Drive System e Hydrostatic Pumps Two Hydro Gear ZT2800 Integrated drive systems Hydraulic Oil Type Exmark Premium Hydro oil Speeds 42 inch unit 0 6 0 mph 9 7 km hr forward 0 4 0 mph 6 4 km hr reverse 48 inch and 52 inch units 0 7 0 mph 11 3 km hr forward 0 5 0 mph 8 0 km hr reverse 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 amp Wheels Pneumatic Pneumatic Air Filled Air Filled Deck 42 amp 48 52 42 48 amp 52 Size Size 20 x 20 x 10x4 10x4 8 00 8 10 00 8 Ply 4 4 Rating Pressure 13 psi 13 psi 20 psi
70. the filler tube use oil recommended in the Engine Owner s Manual 12 Install the oil fill cap dipstick and push firmly into place 13 Check the oil level Figure 20 refer to Checking the Oil Level 14 Slowly add additional oil to bring it to the full mark Do Not overfill 15 Install the oil fill cap dipstick and push firmly into place 16 Start the engine and check for leaks Checking the Hydraulic Oil Level Service Interval Before each use or daily Check expansion tank and if necessary add Exmark Premium Hydro oil to the FULL COLD line G007191 Figure 23 1 Engine 2 Expansion tank Maintenance Change the Hydraulic System Filter Service Interval After the first 250 hours Every 500 hours thereafter Every 250 hours if using Mobil 1 15W50 1 Stop engine wait for all moving parts to stop and allow engine to cool Remove key and engage parking brake Locate the two filters under the transmissions Remove filter guards Carefully clean area around filters It is important that no dirt or contamination enter hydraulic system Unscrew filters to remove and allow oil to drain from drive system Important Before reinstalling new filters apply a thin coat of Exmark Premium Hydro oil on the surface of the filters rubber seal Turn the filters clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 3 4 to 1 full turn Remove the vent p
71. tion 2 Disengage the PTO 3 Engage the park brake 4 Stop the engine remove the key and wait for all moving parts to stop 5 After adjusting the height of cut adjust the anti scalp rollers by removing the nyloc nut 6 Adjust the anti scalp rollers for the normal operating conditions Place rollers in one of the positions shown in Figure 11 Rollers will maintain 3 4 inches 19 mm clearance to the ground to minimize gouging and roller wear or damage Note For Maximum Deck Flotation place the rollers one hole position lower Rollers should maintain 1 4 inch 6 35 mm clearance to the ground Do Not adjust rollers to support the deck 1 Y 2 O 2 0 inch 51mm O 2 5 inch 64mm O 3 0 inch 76mm O 3 5 inch 90mm ud Figure 11 For cutting heights above 3 1 2 inches 38 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller mounting bracket 2 Cutting height 7 Torque hardware to 27 33 ft lb 37 45 N m or loss of roller may result Positioning the Seat The seat can move forward and backward Position the seat where you have the best control of the machine and are most comfortable 48 and 52 Inch Units 1 Push the adjustment lever towards the center of the machine to release the seat adjuster track Figure 12 G007180 Figure 12 1 Adjustment lever 2 Move the seat to the desired position and release the lever to lock in that p
72. trol lever to the control arm shaft 2 Loosen the lower bolt just enough to pivot the control lever fore or aft Figure 14 Tighten both bolts to secure the control in the new position 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 To Push the Machine 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to neutral position engage parking brake stop the 24 Operation engine remove the key and wait for all moving parts to stop before leaving the operating position Locate the bypass release knobs on either side of the engine deck Figure 15 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 La 3 rotating mower blade s and thrown debris 4 will cause injury or death 1 N 5 Never remove the discharge deflector t TT 6 from the mower because the discharge ET deflector routes material down toward the turf If the discharge deflector is ever damaged replace it immediately G007182 Never put your hands or feet under the mower Never try to clear discharge area or mower blades unless you move the move 1 the blade control switch to Off and rotate the ignition
73. ts 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 428 52 Service Record Date Description of Work Done Service Done By 53 PREMIUM HYDRO OIL BENEFITS Designed amp manufactured with superior anti wear protection Superior thermal stability Consistent hydro performance Superior shear resistance under heavy loads Field tested amp proven performance Twice the shear stability of SPECIALLY FORMULATED amp competing oils MANUFACTURED FOR SUPERIOR P CR CORMANCE IN ALL EXMARK Enhanced control performance DRAULIC DRIVE SYSTEMS Specially formulated for any 1 US Quart 946 ML 32 FL oz Exmark hydraulic system NOW AVAILABLE FOR PURCHASE Part No 109 9828 54 This is a5 slope No Slope Example Compare slope with a tree building fence post pole etc ry Align this edge with a vertical surface u it 1 1 i y aa 1 ii D RE i We FEST Vig TAY adhe d 1 i w t mp TUN Ay m drm it ME mhi IPIS h m TETTE nara
74. ut further tightening the blade bolt the spring disc washer has been flattened or damaged and the bolt and washer assembly must be replaced Figure 35 Refer to Removing the Blades and Installing the Blades 3 Once the blade has been removed inspect the spring disc washer If the washer appears to be damaged the washer surface has been marred or flattened the bolt and washer assembly must be replaced Removing the Blades The blades must be replaced if a solid object is hit if the blade is out of balance or the blade is bent To ensure optimum performance and continued safety conformance of the machine use genuine Exmark replacement blades Replacement blades made by other manufacturers may result in an unsafe machine Hold the blade end using a rag or thickly padded glove or place a wrench on the top sheave nut Remove the blade bolt and washer assembly washer and blade from the spindle shaft Figure 35 Maintenance Figure 35 1 Blade 2 Washer 3 Bolt and washer assembly Apply lubricant to threads torque to 32 42 ft lb 43 57 N m Sharpening the Blades 1 Use a file to sharpen the cutting edge at both ends of the blade Figure 36 Maintain the original angle The blade retains its balance if the same amount of material is removed from both cutting edges 1 a G007276 Figure 36 Sharpen at original angle 2 Check the balance of the blade by putting it on a blade ba
75. ve the hose clamps close to the filter Figure 27 to secure it in place 8 Turn fuel shut off valve back to position Electrical System Maintenance 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 35 Maintenance Charging the Battery Removing the Battery A WARNING Battery terminals metal tools could short against metal machine components causing sparks Sparks can cause the battery gasses to explode resulting in personal injury When removing or installing the battery Do Not allow the battery terminals to touch any metal parts of the machine Do Not allow metal tools to short between the battery terminals and metal parts of the machine Park the machine on a level surface and disengage the blade control switch Move the motion control levers outward to the neutral position engage parking brake stop the engine remove the key and wait for all moving parts to stop before leaving the operating position 3 Raise the seat 1 2 3 Disconnect the negative black ground cable from the battery post Figure 28 Retain all fasteners G009783 Figure 28 4 Positive battery post 5 Battery strap 6 Battery Negative battery post Bolt washer and nut Terminal boot
76. vice 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 or 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 check 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 Use only 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 t
77. warranty Exmark Warranty Company extends coverage for warrantable engine items as defined by the manufacturer s original warranty during the 3rd year of warranty This warranty only includes the cost of parts and labor 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 Air Cooled Gas Engines 90 days Items and Conditions Not Covered This warranty does not cover the following Pickup and delivery charges to and from any authorized Exmark Service Dealer beyond first warrantable service Any damage or deterioration due to normal use wear and tear or exposure Cost of regular maintenance service or parts such as filters fuel lubricants tune up parts and adjustments Any 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
78. 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 A 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 on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge 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 If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete A 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 vapor

Exmark 4500-450 Lawn Mower User Manual

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