Exmark Quest Lawn Mower Users Manual

Lawn Mower to the manual 5377fd67-82c9-414a-8091-3075a47b8941

2015-02-04

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QUEST

For Serial Nos.
720,000 & Higher
Part No. 4500-338 Rev. A

WARNING
CALIFORNIA
Proposition 65 Warning
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects, or
other reproductive harm.
Important: This engine is not equipped with
a spark arrester muffler. It is a violation of
California Public Resource Code Section 4442 to
use or 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 manufacturer.
For models with stated engine horsepower, the gross
horsepower of the engine was laboratory rated by the
engine manufacturer in accordance with SAE J1940.
As configured to meet safety, emission, and operating
requirements, the actual engine horsepower on this
class of lawn mower will be significantly lower.

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,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.

Figure 1
Behind the seat
1. Model and serial number location

Model No.
Serial No.

Contents

Drive System Maintenance ............................ 39
Checking the Tire Pressure ............................ 39
Mower Maintenance ...................................... 39
Servicing the Cutting Blades .......................... 39
Mower Belt Maintenance ............................... 41
Leveling the Mower Deck .............................. 42
Adjusting the Blade Slope .............................. 42
Removing the Mower Deck ........................... 44
Installing the Mower Deck............................. 44
Replacing the Discharge Deflector ................. 45
Cleaning ........................................................... 46
Washing the Underside of the Mower ............. 46
Storage ................................................................. 47
Cleaning and Storage ..................................... 47
Troubleshooting ................................................... 48
Schematics ........................................................... 50

Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ....................... 8
Specifications ....................................................... 13
Model Numbers ............................................ 13
Systems ......................................................... 13
Dimensions................................................... 14
Torque Requirements .................................... 15
Product Overview ................................................ 15
Operation ............................................................. 16
Controls ........................................................ 16
Operating Instructions .................................. 17
Recommended Gasoline................................ 18
Checking the Engine Oil Level....................... 19
Starting the Engine........................................ 19
Operating the Blades ..................................... 20
Stopping the Engine ...................................... 21
The Safety Interlock System........................... 21
Driving Forward or Backward........................ 22
Stopping the Machine.................................... 23
Tracking Adjustment ..................................... 23
Adjusting the Height of Cut ........................... 23
Adjusting the Anti-Scalp Rollers..................... 24
Positioning the Seat ....................................... 24
Changing the Seat Ride Suspension ................ 24
Adjusting the Motion Control Levers ............. 25
Pushing the Machine by Hand........................ 25
Side Discharge............................................... 26
Transporting ................................................. 26
Operating Tips ............................................. 27
Maintenance ......................................................... 29
Recommended Maintenance Schedule(s) ........... 29
Premaintenance Procedures .............................. 30
Raising the Seat ............................................. 30
Accessing the Battery .................................... 30
Periodic Maintenance ....................................... 30
Lubrication.................................................... 30
Engine Maintenance...................................... 31
Servicing the Engine Oil ................................ 32
Checking the Hydraulic Oil Level ................... 34
Change the Hydraulic System Filter................ 34
Servicing the Spark Plug ................................ 35
Cleaning the Blower Housing......................... 35
Fuel System Maintenance .............................. 36
Electrical System Maintenance....................... 36
Charging the Battery...................................... 37
Servicing the Fuses and Relay......................... 38
4

Safety

• Allow only responsible adults who are familiar
with the instructions to operate the machine.

Safety Alert Symbol

• Clear the area of objects such as rocks, toys, wire,
etc., which could be picked up and thrown by the
blade.

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.

• Be sure the area is clear of other people before
mowing. Stop the machine if anyone enters the
area.
• Never carry passengers.
• Do Not mow in reverse unless absolutely
necessary. Always look down and behind before
and while backing up.

Figure 2

•

1. Safety alert symbol

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.

Be aware of the mower discharge direction and
Do Not point it at anyone. Avoid discharging
material against a wall or obstruction. Material
may ricochet back toward the operator. Stop the
blades when crossing gravel surfaces.

• Do Not operate the mower without either the
entire grass collection system or the discharge
deflector in place.

This machine meets or exceeds the safety
specifications of the American National
Standards Institute B71.1-2003 in effect at the
time of production. However, improper use
or maintenance by the operator or owner can
result in injury. To reduce the potential for
injury, comply with these safety instructions
and always pay attention to the safety alert
symbol, which means CAUTION, WARNING,
or DANGER-"personal safety instruction."
Failure to comply with the instruction may result
in personal injury or death.

• Be alert, slow down and use caution when making
turns. Look behind and to the side before
changing directions.
• Never leave a running machine unattended.
Always turn off blades, engage parking brake,
stop engine, and remove key before dismounting.
• Turn off blades when not mowing. Stop the
engine, wait for all parts to come to a complete
stop, engage parking brake, and remove key
before cleaning the machine, removing the grass
or unclogging the deflector.

Safe Operating Practices

• Operate the machine only in daylight or good
artificial light.

The following instructions are from ANSI standard
B71.1-2003.

• Do Not operate the machine while under the
influence of alcohol or drugs.

This product is capable of amputating hands and
feet and throwing objects. Always follow all safety
instructions to avoid serious injury or death.

• Watch for traffic when operating near or crossing
roadways.
• Use extra care when loading or unloading the
machine into a trailer or truck

General Operation

• Always wear eye protection when operating the
mower.

• Read, understand, and follow all instructions in
the operator’s manual and on the machine before
starting.

• Data indicates that operators, age 60 years and
above, are involved in a large percentage of riding
mower-related injuries. These operators should
evaluate their ability to operate the riding mower

• Do Not place hands or feet near rotating parts or
under the machine. Keep clear of the discharge
opening at all times.
5

Safety
Children

safely enough to protect themselves and others
from serious injury.
• Always follow the recommendations for wheel
weights or counterweights.

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.
• 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.
• 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.

Slope Operation
Slopes are a major factor related to loss of control
and tip-over accidents, which can result in severe
injury or death. Operation on all slopes requires extra
caution. If you cannot back up the slope or if you
feel uneasy on it, Do Not mow it.
• Do Not mow slopes greater than 15 degrees.
• Watch for ditches, holes, rocks, dips, and rises that
change the operating angle, as rough terrain could
overturn the machine.
• 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.
• Reduce speed and use extreme caution on slopes.
• Do Not make sudden turns or rapid speed
changes.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
• Be aware that loss of traction may occur going
downhill. Weight transfer to the front wheels
may cause drive wheels to slip and cause loss of
braking and steering.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• Use extreme care with grass collection systems or
other attachments. These can change the stability
of the machine and cause loss of control.
• Do Not try to stabilize the machine by putting
your foot on the ground.
• Do Not mow near drop-offs, ditches, steep banks
or water. Wheels dropping over edges can cause
rollovers, which may result in serious injury, death
or drowning.
• Use a walk behind mower and/or a hand trimmer
near drop-offs, ditches, steep banks or water.

Towing
• Use for towing only if equipped with an Exmark
hitch kit. Do Not attach towed equipment except
at the hitch point.
• Follow Exmark’s recommendation for weight
limits for towed equipment and towing on slopes.
This information can be found in the hitch kit
instruction sheet and on the decal.
• Never allow children or others in or on towed
equipment.
• On slopes, the weight of the towed equipment
may cause loss of traction and loss of control.
• Travel slowly and allow extra distance to stop.

Service
Safe Handling of Gasoline
To avoid personal injury or property damage, use
extra care when handling gasoline and other fuels.
They are flammable and the vapors are explosive.
6

Safety
• Extinguish all cigarettes, cigars, pipes and other
sources of ignition.
• Use only an approved container.
• Never remove the gas cap or add fuel when the
engine is running. Allow the engine to cool before
refueling.
• Never refuel the machine indoors.
• Never store the machine or fuel container inside
where there 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 device.
• If fuel is spilled on clothing, change clothing
immediately.
• Never overfill the fuel tank. Replace gas cap and
tighten securely.

•

•
•
•

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 that 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.

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

Note: The left and right sides of the machine are
determined while sitting in the seat in the normal
operating position
7

Safety

Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.

93-7009
1. Warning–Do Not operate 2. Cutting/dismemberment
the mower with the
hazard of hand or foot,
discharge deflector up
mower blade–stay away
or removed; keep the
from moving parts.
discharge deflector in
place.

109-6014
Traction Drive Belt Routing

106-5517
1. Warning–Do Not touch the hot surface.

109-6008
1. Read the Operator’s
Manual.
2. Rotate the drive release
knob to loosen, slide the
knob, and tighten.

3. Push the machine.

109-6029
1.
2.
3.
4.

Engine–stop
Engine–run
Engine–start
Power take-off (PTO),
Blade control switch
5. Read the Operator’s
Manual.

6.
7.
8.
9.

Throttle–fast
Choke–on
Throttle–slow
Choke–off

Safety

109-6035
Deck Drive Belt Routing

109-8759
1. Height of cut

109-6036
1. Read the Operator’s Manual.
2. Remove the ignition key and read the instructions before
servicing or performing maintenance.
3. Height of cut.

109-9120
1. Fuse

109-6210
1. Read the Operator’s Manual.
2. Cutting/dismemberment hazard, fan and entanglement
hazard, belt–stay away from moving parts.

109-6459
1. Entanglement hazard, belt—Do Not open or remove
safety shields while engine is running, keep shields in
place.

2. Diode

Safety

110-6691
1. Thrown objects
hazard–keep bystanders
a safe distance from the
machine.
2. Thrown objects hazard,
mower–keep the
discharge deflector
or collection system in
place.

3. Cutting/dismemberment
of hand or foot–stay
away from moving parts.

109-9173
1. Parking brake
2. Fast
3. Slow

4. Neutral
5. Reverse
6. Machine Speed

PTO Symbols
1. PTO—Off

109-9182
1. Machine speed
2. Fast
3. Slow

4. Neutral
5. Reverse

2. PTO—On

Safety

109-6016
1. Read the instructions before servicing or performing
maintenance.
2. Time interval

4. Refer to the Operator’s manual for grease instructions.
5. Check hydraulic oil level and refer to the Operator’s
Manual for further instructions.
6. Check tire pressure.

3. Check oil level.

109-8965
5. Tipping hazard–avoid sudden and sharp turns while on
slopes, only mow across slopes less than 15 degrees,
keep a safe distance from water, and only mow up and
down slopes less than 15 degrees.
2. Read the instructions before servicing or performing
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.
1. Warning–read the Operator’s Manual.

Safety

Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard

5. Read the Operator’s Manual.

2. No fire, open flames, or smoking

6. Keep bystanders a safe distance
from the battery.
7. Wear eye protection; explosive
gases can cause blindness and
other injuries.
8. Battery acid can cause blindness or
severe burns.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

9. Flush eyes immediately with water
and get medical help fast.
10. Contains lead; do not discard.

Specifications

Specifications
Model Numbers
Serial Nos: 720,000 and Higher
QST22BE482; QST23KC482; QST23KC522; QST24BE522

Systems

engine. (It is not necessary for the operator to be
in the seat to start the engine.)

Engine

• Operator must be in seat when PTO is engaged,
brake is disengaged, or motion control levers are
moved in or engine will stop.

• Engine Specifications: See your Engine Owner’s
Manual
• RPM:
Briggs & Stratton: Full Speed: 3650 ±100 (max)
RPM (No Load) Idle: 1650 (min) RPM

• Engine will stop if either the left, the right, or
both levers are moved from neutral lock position
while brake is engaged.

Kohler Command: Full Speed: 3600 ±75 (max)
RPM (No Load) Idle: 1750 (min) RPM

Operator Controls
• Steering and Motion Control:

Fuel System

Note: Motion control levers are adjustable to
two heights.

• Capacity: 4.0 gal. (15.1 L)
• Type of Fuel: Regular unleaded gasoline, 87
octane or higher.
• Fuel Filter:

– Separate levers, on each side of the console,
control speed and direction of travel of the
respective drive wheels.

Briggs & Stratton: Briggs & Stratton P/N 695666

– Steering is controlled by varying the position
of the levers relative to each other.

Kohler Command: Kohler P/N 24 050 10
• Fuel Shut-Off Valve: 1/4 turn increments (“ON”,
“OFF”)

– Moving motion control levers outward (in
slots) locks the drive system in neutral.
• PTO Engagement Switch: Engages electric clutch
(to drive belt) which engages mower blades.

Electrical System
• Charging System: Flywheel Alternator
• Charging Capacity:

• Parking Brake Lever: Engages parking brake.
• Deck Height Adjustment Pin: Sets cutting height
to desired position.

Briggs & Stratton: 16 amps
•
•
•
•
•

Kohler Command: 15 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

• 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.
• Mounting: Hinged to tilt up for access to
hydraulic pumps, battery and other components.
Held in tilted position with lanyard. Adjustable
fore and aft seat track.

Safety Interlock System
• PTO must be disengaged, brake engaged, and
motion control levers out (neutral lock) to start
13

Specifications
• Deck: Full floating deck is attached to out-front
support frame. Maximum turf protection is
provided with three anti-scalp rollers (both deck
sizes).

• Armrests: Standard–foam padded flip-up
adjustable height armrests.
• Seat Safety Switch: Incorporated into the Safety
Interlock System.

Deck design allows for bagging, mulching or side
discharge.

Hydrostatic Ground Drive System
• Hydrostatic Pumps: Two Hydro Gear ZT2800
Integrated drive systems.
• Hydraulic Oil Type: Use Mobil 1 15W-50
Synthetic motor oil.
• Speeds:
– 0-7.0 mph (11.3 km/hr) forward.
– 0-5.0 mph (8.0 km/hr) reverse.
• Drive wheel releases, located on left and right
sides of engine deck, allow machine to be moved
when the engine is not running and brake is off.

• Deck Depth:
– 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.
• Mulching Kit: Optional.

Dimensions

Tires & Wheels
Drive
Pneumatic (Air-Filled)

Overall Width:

Front
Caster

48 inch Deck

52 inch Deck

Pneumatic
(Air-Filled)

Without Deck

45.5 inches
(116 cm)

47.0 inches
(119 cm)

Deflector Up

48.3 inches
(122 cm)

53.0 inches
(135 cm)

Deflector Down

59.4 inches
(151 cm)

64.2 inches
(163 cm)

Deck Size

All Decks

Quantity

Tread

Turf Tec

Smooth

Size

20 x 8.00-8

20 x 10.00-8 10 x 4

Ply Rating

Pressure

13 psi
(90 kPa)

Overall Length:

13 psi
(90 kPa)

Cutting Deck
• Cutting Width:
– 48 inch Deck: 48 inches (122 cm)
– 52 inch Deck: 52 inches (132 cm)
• Discharge: Side
• Blade Size: (3 ea.)
– 48 inch Deck: 16.25 inches (41.3 cm)
– 52 inch Deck: 18.00 inches (45.7 cm)
• Blade Spindles: Solid steel spindles with no
maintenance bearings.
• Deck Drive: Electric clutch mounted on vertical
engine shaft. Blades are driven by one belt
(w/self-tensioning idler) direct from the engine.

48 inch Deck

52 inch Deck

73.4 inches (186 cm)

Overall Height:

48 inch Deck

52 inch Deck

41.8 inches (106 cm)

Product Overview
Tread Width: (Center to Center of
Tires, Widthwise)
48 inch Deck

52 inch Deck

Drive Wheels

36.0 inches
(91 cm)

36.8 inches
(93 cm)

Caster Wheels

33.5 inches
(85 cm)

Product Overview

Wheel Base: (Center of Caster Tire to
Center of Drive Tire)
48 inch Deck

52 inch Deck

48.9 inches (124 cm)

Curb Weight:
48 inch Deck

52 inch Deck

645 lb (293 kg)

660 lb (299 kg)

Figure 3
1.
2.
3.
4.
5.
6.
7.

Torque Requirements
Bolt Location

Torque

Spindle Pulley Nut

95-105 ft-lb (129-142 N-m)

Blade Mounting Bolt
(lubricate with anti-seize)

32-42 ft-lb (43-57 N-m)

Engine Mounting Bolts

27-33 ft-lb (37-45 N-m)

Anti-Scalp Roller Nyloc
Nut

27-33 ft-lb (37-45 N-m)

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)

Front caster wheel
Anti-scalp roller
Height of cut foot lever
Discharge deflector
Height of cut adjustment
Rear drive wheel
Control panel

8.
9.
10.
11.
12.
13.
14.

Engine
Seat
Armrest
Motion control levers
Park brake
Footrest
Washout fitting

Operation

Blade Control Switch (Power
Take-Off)

Controls

Located on the control panel.

Note: Become familiar with all of the controls in
Figure 3 and Figure 4 before you start the engine and
operate the machine.

The blade control switch, represented by a power
take-off (PTO) symbol, engages and disengages
power to the mower blades.

Ignition Switch

Pull out on the blade control switch to “On” to
engage the blades

Located on control panel.

Push the blade control switch to “Off ” to disengage
the blades

The ignition switch is used to start and stop the
engine. The switch has three positions “OFF”,
“RUN” and “START” ( Figure 4). Insert key into
switch and rotate clockwise to the “ON” position.
Rotate clockwise to the next position to engage the
starter (key must be held against spring pressure in
this position).

Choke Control
Located on control panel.
The choke is used to aid in starting a cold engine. Do
Not run a warm engine with the choke in the “ON”
position. Moving the choke lever forward will put the
choke in the “ON” position and moving the choke
lever to the rear will put the choke in the “OFF”
position (Figure 4).

Throttle Control
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).

Figure 4
1. Ignition switch
2. Blade control switch
(power take-off)
3. Hour meter

4. Throttle
5. Choke

Motion Control Levers
The motion control levers located on each side of
the seat (Figure 3).

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.)

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.

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

Operation
Parking Brake Lever

DANGER

Located on left side of the console (Figure 3).

Mowing on wet grass or steep slopes can
cause sliding and loss of control. Wheels
dropping over edges can cause rollovers,
which may result in serious injury, death
or drowning. A loss of traction is a loss of
steering control.

The brake lever engages a parking brake on the drive
wheels.
Pull the lever up and rearward to engage the brake.
Push the lever forward and down to disengage the
brake.

To avoid loss of control and possibility 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
and raise the deck from the seated position (Figure 3).
When the lever is moved forward, away from the
operator the deck is raised from the ground and
when moved back, towards the operator it is lowered
toward the ground. Only adjust the height of cut
while machine is not moving.

• Do not mow slopes greater than 15
degrees.

Hour Meter

• 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.

• Reduce speed and use extreme caution
on slopes.
• When mowing slopes, gradually work
from lower to higher areas on the incline.

The hour meter is connected to a pressure switch
installed in the engine block and it records the number
of hours that the engine has run ( Figure 4). If the
ignition switch is left on without engine running,
hour meter will not run.

• Attachments change the handling
characteristics of the machine. Use extra
caution when using attachments with the
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 from the normal operating position.
Please carefully read all of the safety instructions
and decals in the safety section. Knowing this
information could help you, your family, pets or
bystanders avoid injury.
Figure 5
1. Water
2. Use walk behind mower
and/or hand trimmer
near drop-offs and
water.

3. Safe Zone-use the Quest
here.

Operation
See inside back cover to determine the approximate
slope angle to be mowed.

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.

Recommended Gasoline
Use UNLEADED Regular Gasoline suitable for
automotive use (87 pump octane minimum).

• Always place gasoline containers on the
ground away from your vehicle before
filling.

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.

• Do Not fill gasoline containers inside a
vehicle or on a truck or trailer bed because
interior carpets or plastic truck bed liners
may insulate the container and slow the
loss of any static charge.

DANGER
In certain conditions gasoline is extremely
flammable and vapors are explosive.

• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.

A fire or explosion from gasoline can burn
you, others, and cause property damage.
• Fill the fuel tank outdoors in an open
area, when the engine is cold. Wipe up
any gasoline that spills.

• 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.

• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.

• 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.

• Do Not fill the fuel tank completely full.
Add gasoline to the fuel tank until the
body of the tank is full but fuel does not
fill the neck of the tank. This empty space
in the tank allows gasoline to expand.

WARNING

• Never smoke when handling gasoline,
and stay away from an open flame or
where gasoline fumes may be ignited by
spark.

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.

• 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.

• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.

• Do Not operate without entire exhaust
system in place and in proper working
condition.

• 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.
• Cleans the engine while it runs.
• Eliminates gum-like varnish buildup in the fuel
system, which causes hard starting Add the
correct amount of gas stabilizer/conditioner to
the gas.
Note: A fuel stabilizer/conditioner is most effective
when mixed with fresh gasoline. To minimize the
chance of varnish deposits in the fuel system, use fuel
stabilizer at all times.

Figure 6
1. Gas tank opening
2. Fill to here,
approximately

Gasoline/Alcohol blends

3. Gas tank body

4. Install the fuel tank cap securely. Wipe up any
gasoline that may have spilled.

Gasohol (up to 10 percent ethyl alcohol, 90 percent
unleaded gasoline by volume) is approved for fuel use
by the engine manufacturer. Other gasoline/alcohol
blends are not approved.

Checking the Engine Oil
Level

Filling the Fuel Tank
1. Shut the engine off and set the motion controls
to the neutral position and engage parking brake.

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.

2. Clean around the fuel tank cap and remove the
cap.

Starting the Engine

3. Add unleaded regular gasoline until the body of
the tank is full but fuel does not fill the neck of
the tank (Figure 6). This space in the neck of the
tank allows gasoline to expand. Do not fill the
fuel tank completely full.

1. Sit down on the seat and move the motion
controls outward to the neutral position and
engage the parking brake.
2. Disengage the blades by moving the blade control
switch to Off (Figure 7).

Operation

Figure 7
1. Control panel

2. Blade control
switch—Off position

Figure 9
1. Ignition key—start
position
2. Control panel
3. Choke

3. Move the throttle lever to midway and the choke
lever forward before starting a cold engine
(Figure 8).

4. Start
5. Run
6. Off

5. If the engine stalls or hesitates, move the
choke lever partially forward for a few seconds
(Figure 9).

Note: A warm or hot engine may not require
choking.

Operating the Blades
The blade control switch, represented by a power
take-off (PTO) symbol, engages and disengages
power to the mower blades. This switch controls
power to any attachments that draw power from the
engine, including the mower deck and cutting blades.

Engaging the Blades
1. Release pressure on the motion control levers and
place the machine in neutral.

Figure 8
1. Control panel
2. Choke—on
3. Choke–off

2. Move the throttle midway to the Fast position.

4. Throttle—slow
5. Throttle—fast

Note: Always engage the blades with the throttle
in the midway position.
3. Pull out on the blade control switch to On to
engage the blades (Figure 10).

4. Turn the ignition key to Start to energize the
starter. When the engine starts, release the key
(Figure 9).
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.

Operation

The Safety Interlock System
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.

Figure 10
1. Control panel

2. Blade control
switch—On position

Understanding the Safety Interlock
System

4. Move throttle to full forward position before
mowing.

The safety interlock system is designed to prevent the
engine from starting unless:
• The blades are disengaged.
• The motion control levers are in the neutral
position.
• The parking brake is engaged.

Disengaging the Blades
Set throttle to midway position. Push the blade
control switch to Off to disengage the blades
(Figure 11).

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 are in.

Figure 11
1. Control panel

2. Blade control
switch—Off position

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.

Stopping the Engine
1. Move the throttle lever to between Fast and half
throttle (Figure 9).
2. Disengage the blades by moving the blade control
switch to Off (Figure 11).
3. Turn the ignition key to Off (Figure 9).
4. Pull the wire off of the spark plug(s) to prevent
the possibility of someone accidentally starting
the machine before transporting or storing the
machine.

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.
21

Operation
Try to start with operator in seat, parking brake
engaged, PTO engaged and motion control
levers in the neutral lock position - starter must
not crank.

CAUTION
Machine can spin very rapidly by positioning
one lever too much ahead of the other.
Operator may lose control of the machine,
which may cause damage to the machine
or injury.

Try to start with operator in seat, parking brake
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.

• Use caution when making turns.
• Slow the machine down before making
sharp turns.

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.

Forward
1. Move the levers to the center, unlocked position.
2. To go forward, slowly push the motion control
levers forward (Figure 12).

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

Figure 12
1. Neutral position
2. Center unlock position

The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place
the throttle control in the Fast position for best
performance. Always operate in the Fast (full throttle)
position.

3. Backward
4. Forward

To go straight, apply equal pressure to both
motion control levers (Figure 12).
To turn, pull back on the motion control lever
toward the direction you want to turn (Figure 12).
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.
22

Operation
Backward

CAUTION

1. Move the levers to the center, unlocked position.
2. To go backward, slowly pull the motion control
levers rearward (Figure 12).

Children or bystanders may be injured if they
move or attempt to operate the mower while
it is unattended.

To go straight, apply equal pressure to both
motion control levers (Figure 12).

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.

To turn, release the pressure on the motion
control lever toward the direction you want to
turn (Figure 12).
To stop, push the motion control levers to neutral.

Stopping the Machine

Adjusting the Height of Cut

To stop the machine, move the motion control
levers to neutral and outward to the neutral position,
disengage the blade control switch, move the throttle
lever to between Fast and half throttle, and turn the
ignition key to off. Remember to remove the key
from the ignition switch.

1. Raise the deck to the transport position (4.5 inch
(114 mm) cut height) by pushing the foot actuated
lever forward (Figure 14). The spring loaded
transport pin will automatically engage and will
click into place.

Tracking Adjustment
If the machine turns right or left when handles are
pushed forward together, adjust the stop on the side
opposite the direction of turn (see Figure 13). Loosen
the screws that hold the motion control limiter stop.
Move the stop back until the unit drives straight.
Tighten the screws to lock the stop in place. Readjust
handles if necessary.

Figure 14
1. Push forward
2. Foot actuated
height-of-cut lever
3. Height-of-cut positions

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

Figure 13
1. Control arm shaft
2. Limiter stop screws

4. Height adjuster pin
5. Transport release handle

3. Adjust stop

Operation

Positioning the Seat

the predetermined cut height by slowly decreasing
foot pressure allowing the foot lever to travel
rearward.

The seat can move forward and backward. Position
the seat where you have the best control of the
machine and are most comfortable.

Adjusting the Anti-Scalp
Rollers

1. Push the adjustment lever towards the center of
the machine to release the seat adjuster track
(Figure 16).

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 position.
2. Disengage the PTO.
3. Engage the park brake.
4. Stop the engine, remove the key and wait for all
moving parts to stop.
5. After adjusting the height of cut, adjust the
anti-scalp rollers by removing the nyloc nut.
6. Adjust the anti-scalp rollers for the normal
operating conditions. Place rollers in one of
the positions shown in Figure 15. Rollers will
maintain 3/4 inches (19 mm) clearance to the
ground to minimize gouging and roller wear or
damage.

Figure 16
1. Adjustment lever

2. Move the seat to the desired position and release
the lever to lock in that position.

Note: For Maximum Deck Flotation, place
the rollers one hole position lower. Rollers should
maintain 1/4 inch (6.35 mm) clearance to the
ground. Do Not adjust rollers to support the
deck.

Changing the Seat Ride
Suspension
The number of seat springs can be changed to
maximize rider comfort. More springs should be used
with heavier operators and on rough terrain. Fewer
springs should be used with lighter operators and
when mowing smooth, well established lawns. Always
keep the number of springs on the left and right side
the same when adding and removing springs.

Figure 15
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.
24

Operation
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 control lever
to the control arm shaft.
Figure 17
1. Bolt
2. Spring

2. Loosen the lower bolt just enough to pivot the
control lever fore or aft (Figure 18). Tighten both
bolts to secure the control in the new position.

3. Nut
4. Additional mounting
holes

3. Repeat the adjustment for the opposite control
lever.

Up to five springs can be secured to the seat box with
a nut and bolt, see Figure 17.
Refer to your Parts Manual for spring and hardware
part numbers.

Pushing the Machine by
Hand

Adjusting the Motion Control
Levers

Important: Always push the machine by hand.
Never tow the machine because damage may
occur.

Adjusting the Height

To Push the Machine

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 18).

1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
3. Locate the bypass release knobs on either side of
the engine deck (Figure 19).

Figure 18
1. Control arm shaft
2. Control lever
3. Washer

4. Bolt
5. Slotted holes

Operation

DANGER
Without the discharge deflector, mulch kit,
or entire grass collection system mounted in
place, you and others are exposed to blade
contact and thrown debris. Contact with
rotating mower blade(s) and thrown debris
will cause injury or death.
• Never remove the discharge deflector
from the mower because the discharge
deflector routes material down toward
the turf. If the discharge deflector is ever
damaged, replace it immediately.
• Never put your hands or feet under the
mower.
• Never try to clear discharge area or
mower blades unless you move the move
the blade control switch to Off and rotate
the ignition key to Off. Also remove the
key and pull the wire off the spark plug(s).

Figure 19
1. Front of the machine.
2. Rotate bypass release
knob counterclockwise
3. Lever position for
operating the machine.
4. Pull lever in this direction

5. Lever position for
pushing the machine
6. Rotate bypass release
knob clockwise
7. Release lever

Transporting
Transporting a Unit

4. Loosen the knob by turning counterclockwise.
Then pull the release lever on the underside of
machine (Figure 19) 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.

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.

5. Release the parking brake. The machine is now
able to be pushed by hand.

CAUTION

To Operate the Machine

This unit does not have proper turn
signals, lights, reflective markings, or a
slow moving vehicle emblem. Driving on a
street or roadway without such equipment
is dangerous and can lead to accidents
causing personal injury. Driving on a street
or roadway without such equipment may also
be a violation of State laws and the operator
may be subject to traffic tickets and/or fines.

Loosen the bypass knob, push the release levers
forward, and retighten the knob to engage the drive
system (Figure 19).

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.

Operation
Important: Do Not attempt to turn the unit
while on the ramp, you may lose control and
drive off the side.

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.

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.

• Use extreme caution when operating a
unit on a ramp.

Operating Tips

• Use only a single, full width ramp; Do
Not use individual ramps for each side
of the unit.

Fast Throttle Setting

• Do Not exceed a 15° angle between ramp
and ground or between ramp and trailer
or truck.

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.

• Avoid sudden acceleration while driving
unit up a ramp to avoid tipping backward.

Cutting a Lawn for the First Time

• If individual ramps must be used, use
enough ramps to create an unbroken
ramp surface wider than the unit.

Cut grass slightly longer than normal to ensure that
the cutting height of the mower does not scalp any
uneven ground. However, the cutting height used in
the past is generally the best one to use. When cutting
grass longer than six inches tall, you may want to cut
the lawn twice to ensure an acceptable quality of cut.

• Avoid sudden 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 surface for the frame members to contact if the
unit starts to tip backward. If it is not possible to use
one full width ramp, use enough individual ramps to
simulate a full width continuous ramp.

Cut 1/3 of the Grass Blade
It is best to cut only about 1/3 of the grass blade.
Cutting more than that is not recommended unless
grass is sparse, or it is late fall when grass grows more
slowly.

Mowing Direction
Alternate mowing direction to keep the grass standing
straight. This also helps disperse clippings which
enhances decomposition and fertilization.

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.

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.
27

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 grass
again using the lower, normal setting.

When Stopping
If the machine’s forward motion must be stopped
while mowing, a clump of grass clippings may drop
onto your lawn. To avoid this, move onto a previously
cut area with the blades engaged.

Keep the Underside of the Mower
Clean
Clean clippings and dirt from the underside of the
mower after each use. If grass and dirt build up inside
the mower, cutting quality will eventually become
unsatisfactory.

Blade Maintenance
Maintain a sharp blade throughout the cutting season
because a sharp blade cuts cleanly without tearing or
shredding the grass blades. Tearing and shredding
turns grass brown at the edges, which slows growth
and increases the chance of disease. Check the
cutter blades daily for sharpness, and for any wear or
damage. File down any nicks and sharpen the blades
as necessary. If a blade is damaged or worn, replace
it immediately with a genuine Exmark replacement
blade. Only Exmark blades are to be used with this
unit. No other blades are approved.

Maintenance

Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.

WARNING
While maintenance or adjustments are being made, someone could start the engine. Accidental
starting of the engine could seriously injure you or other bystanders.
Remove the key from the ignition switch, engage parking brake, and pull the wire(s) off the spark
plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally
contact the spark plug(s).

WARNING
The engine can become very hot. Touching a hot engine can cause severe burns.
Allow the engine to cool completely before service or making repairs around the engine area.

Recommended Maintenance Schedule(s)
Maintenance Service
Interval

Maintenance Procedure

After the first 5 hours

• Change the engine oil.

After the first 200 hours

• Change the hydraulic system filter.

Before each use or daily

•
•
•
•
•
•
•

Check the safety interlock system.
Check the air cleaner for dirty, loose, or damage.
Check the air intake and cooling areas, clean as necessary.
Check the oil level before starting or after every 8 hours.
Check the hydraulic oil level in the expansion tank.
Check the mower blades.
Clean the mower housing.

Every 25 hours

•
•
•
•

Grease all lubrication points.
Service the air cleaner. (May need more often under extremely dusty or dirty conditions.)
Check the tire pressure.
Check the belts.

Every 100 hours

•
•
•
•
•

Replace the paper element. (More often under extremely dusty, dirty conditions.)
Replace the air cleaner element.
Change the engine oil and filter.
Clean the blower housing. More often under dirty conditions.
Replace the fuel filter.

Every 200 hours

• Service the spark plug.

Every 500 hours

• Replace the spark plug.

Before storage
Monthly

• Charge the battery and disconnect the battery cables.
• Perform all maintenance procedures before storage.
• Paint any chipped surfaces.
• Check the battery charge.

Maintenance
Important: Refer to your Engine Operator’s Manual for additional maintenance procedures.

Premaintenance
Procedures

Periodic Maintenance
Lubrication

Raising the Seat

Greasing the Bearings

Make sure the motion control levers are locked in
the neutral position. Lift the seat forward until the
lanyard is tight. The following components can be
accessed by raising the seat:

Grease Type: NGLI grade #2 multi-purpose gun
grease.
Grease the front caster pivots and wheels (Figure 21).

• Auxiliary 12V Plug (12V accessory up to 15 amp)
• Fuses
G007184

• Battery cables

Accessing the Battery
The battery is located under the seat. To access, raise
the seat (Figure 20).

1
Figure 21
1. Front caster tire

1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to 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. Clean the grease fittings (Figure 21 and Figure 22)
with a rag. Make sure to scrape any paint off of
the front of the fitting(s).

Figure 20
1. Auxiliary 12V Plug
2. Battery

3. Seat

Maintenance
cleaner daily or before starting the engine. Check for
a buildup of dirt and debris around the air cleaner
system. Keep this area clean. Also check for loose or
damaged components. Replace all bent or damaged
air cleaner components.
Note: Operating the engine with loose or damaged
air cleaner components could allow unfiltered air into
the engine causing premature wear and failure.
Note: Service the air cleaner more often under
extremely dusty, dirty conditions.

Figure 22
Located on the back of the seat.
1. Read the instructions
before servicing or
performing maintenance
2. Grease idler pivots.

3. Time interval.

4. Check oil level.

Figure 23
Briggs & Stratton engine

5. Check hydraulic oil level
and refer to Operator’s
manual for further
instructions.
6. Check tire pressure.

1. Air cleaner
2. Knobs

3. Air cleaner cover

4. Connect a grease gun to each fitting (Figure 21
and Figure 22). Pump grease into the fittings until
grease begins to ooze out of the bearings.
5. Wipe up any excess grease.

Engine Maintenance
Servicing the Air Cleaner
Figure 24
Kohler Command engine

Service Interval: Before each use or daily
Every 100 hours—Replace
the paper element. (More
often under extremely
dusty, dirty conditions.)

1. Air cleaner cover
2. Knob

This engine is equipped with a replaceable, high
density paper air cleaner element. Check the air
31

3. Air cleaner

Maintenance
Servicing Paper Element
Service Interval: Every 25 hours (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 23).
2. Remove the air cleaner element with the integral
rubber seal.
3. 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.

Figure 25
1. Oil dipstick
2. Filler tube

3. Oil level

5. Remove the dipstick and check the oil level.

4. Clean all air cleaner components of any
accumulated dirt or foreign material. Prevent any
dirt from entering the carburetor.

The oil level should be up to, but not over, the
“F” mark on the dipstick.
6. If the level is low, add oil of the proper type, up to
the “F” mark on the dipstick. Always check the
level with the dipstick before adding more oil.

5. Install the air cleaner element with the pleated
side “out” and seat the rubber seal onto the edges
of the air cleaner base.

Note: To prevent extensive engine wear or
damage, always maintain the proper oil level in
the crankcase. Never operate the engine with the
oil level below the “L” mark or over the “F” mark
on the dipstick.

6. Reinstall the air cleaner cover and secure with
the knobs.

Servicing the Engine Oil
Checking the Oil Level

Changing the Oil and Filter

Service Interval: Before each use or daily

Service Interval: After the first 5 hours
Every 100 hours/Yearly
(whichever comes first)
thereafter.

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.

Change the oil and filter while the engine is still
warm. The oil will flow more freely and carry away
more impurities. Make sure the engine is level when
filling, checking, or changing the oil.

3. To keep dirt, grass clippings, etc., out of
the engine, clean the area around the oil fill
cap/dipstick before removing it.

1. Start the engine and let it run until warm. This
warms the oil so it drains better.

4. Pull and remove the oil fill cap/dipstick; wipe oil
off. Reinsert the dipstick and push firmly into
place (Figure 25).

2. Disengage the blade control switch and move the
motion controls outward to the neutral position
and engage parking brake.

Maintenance
3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.

5. Remove the oil drain plug (Figure 26 and
Figure 27). Remove the oil fill cap/dipstick
(Figure 25).

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 26 and Figure 27.

Figure 28
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 28).
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 26 and Figure 27).
Figure 26
Briggs & Stratton engine
1. Oil drain
2. Oil drain plug

Note: Dispose of the used oil at a recycling
center.

3. Pan

9. Apply a thin film of clean oil to the rubber gasket
on the new filter.
10. Install the replacement oil filter to the mounting
pad. Turn the oil filter clockwise until the rubber
gasket contacts the pad, then tighten the filter an
additional 1/2 to 3/4 turn (Figure 28).
11. Slowly pour approximately 80% of the specified
oil into 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 25); refer to Checking
the Oil Level.
14. Slowly add additional oil to bring it to the full
mark. Do Not overfill.

Figure 27
Kohler Command engine
1. Oil drain hose
2. Oil drain plug

15. Install the oil fill cap/dipstick and push firmly
into place.

3. Pan

16. Start the engine and check for leaks.

Maintenance

Checking the Hydraulic Oil
Level

5. Remove the vent plug on each transmission and
fill through expansion reservoir, when oil comes
out of vent reinstall plug. Torque plugs to 180
in-lb (244 N-m). Continue to add oil until it
reaches the FULL COLD line on the expansion
reservoir.

Service Interval: Before each use or daily
Check expansion tank and if necessary add MOBIL 1
15W-50 synthetic motor oil to the FULL COLD line

Figure 30
1. Oil filter
2. Vent plug

Figure 29
1. Engine

3. Left rear tire

2. Expansion tank

6. Raise the rear of machine up and support with
jack stands (or equivalent support) just high
enough to allow drive wheels to turn freely.

Change the Hydraulic
System Filter

7. Start engine and move throttle control ahead to
1/2 throttle position. Disengage parking brake.

Service Interval: After the first 200 hours

A. With the bypass valve open and the engine
running, slowly move the directional control
in both forward and reverse (5 or 6 times).

Note: Use only MOBIL 1 15W-50 Synthetic motor
oil.
1. Stop engine, wait for all moving parts to stop, and
allow engine to cool. Remove key and engage
parking brake.

B. 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.

2. Locate the two filters under the transmissions.
Remove filter guards.

C. It may be necessary to repeat steps A and
B until all the air is completely purged from
the system. When the transaxle operates at
normal noise levels and moves smoothly
forward and reverse at normal speeds, then
the transaxle is considered purged.

3. Carefully clean area around filters. It is important
that no dirt or contamination enter hydraulic
system.
4. Unscrew filters to remove and allow oil to drain
from drive system.
Important: Before reinstalling new filters,
apply a thin coat of oil on the surface of the
filters rubber seal.

Do Not change hydraulic system oil (except for what
can be drained when changing filter), unless it is felt
the oil has been contaminated or been extremely hot.

Turn the filters clockwise until rubber seal
contacts the filter adapter then tighten the filter
an additional 3/4 to 1 full turn.

Changing oil unnecessarily could damage hydraulic
system by introducing contaminates into the system.

Maintenance

Servicing the Spark Plug

Checking the Spark Plug

Service Interval: Every 200 hours/Every 2
years (whichever comes
first)
Every 500 hours—Replace
the spark plug.

1. Look at the center of the spark plug (Figure 32).
If you see light brown or gray on the insulator, the
engine is operating properly. A black coating on
the insulator usually means the air cleaner is dirty.
Important: Never clean the spark plug.
Always replace the spark plug when it has a
black coating, worn electrodes, an oily film,
or cracks.

As stated in the maintenance intervals, remove the
spark plug, check condition, and reset the gap or
replace with a new plug as necessary.

2. Check the gap between the center and side
electrodes (Figure 32). Bend the side electrode if
the gap is not correct.

The spark plug is RFI compliant. Equivalent alternate
brand plugs can also be used.
Type: Champion XC92YC (for Briggs & Stratton)
Champion RC12YC or QC12C may be used if your
area does not require compliance with Canadian
ICES-002, ISO 14982, or EN 55012.
Type: Champion RC12YC (for Kohler Command)
Air Gap: 0.030 inch (0.76 mm)

Removing the Spark Plug

Figure 32

1. Disengage the blade control switch, move the
motion controls outward to the park position,
stop the engine, and remove the key.
2. Pull the wire off of the spark plug (Figure 31).
Clean around the spark plug to prevent dirt from
falling into the engine and potentially causing
damage.

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.

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.

2. Tighten the spark plug to 15 ft-lb (20 N-m).
3. Push the wire onto the spark plug (Figure 31).

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.

Figure 31
1. Spark plug and wire location

3. Make sure the cooling shrouds are reinstalled
35

Maintenance
Important: Operating the engine with a blocked
grass screen, dirty or plugged cooling fins,
and/or cooling shrouds removed, will cause
engine damage due to overheating.

Fuel System Maintenance
Replacing the Fuel Filter
Service Interval: Every 100 hours/Yearly
(whichever comes first)

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.

Figure 33
1.
2.
3.
4.
5.

• Perform any fuel related maintenance
when the engine is cold. Do this outdoors
in an open area. Wipe up any gasoline
that spills.

Fuel tank
Fuel shut off valve—off
Fuel shut off valve
Fuel shut off valve—on
Fuel line from tank

6.
7.
8.
9.

Hose clamps
Fuel line to engine
Filter
Flow direction arrow

4. Turn fuel shut off valve 90° to “off ” position.

• Never smoke when draining gasoline, and
stay away from an open flame or where a
spark may ignite the gasoline fumes.

5. Squeeze the ends of the hose clamps together and
slide them away from the filter (Figure 33).
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. Move the hose clamps close to the filter
(Figure 33) to secure it in place.

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.

8. Turn fuel shut off valve back to “on” position.

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.

Electrical System
Maintenance

3. The fuel filter is in the fuel line between the tank
and engine.

WARNING
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the State of
California to cause cancer and reproductive
harm. Wash hands after handling.

Maintenance

Charging the Battery

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.

Removing the Battery

WARNING

• Always disconnect the negative (black)
battery cable before disconnecting the
positive (red) cable.

Battery terminals or metal tools could short
against metal machine components causing
sparks. Sparks can cause the battery gasses
to explode, resulting in personal injury.

• Always connect the positive (red) battery
cable before connecting the negative
(black) cable.

• When removing or installing the battery,
Do Not allow the battery terminals to
touch any metal parts of the machine.

5. Slide the rubber cover up the positive (red) cable.
Disconnect the positive (red) cable from the
battery post. Retain all fasteners.

• Do Not allow metal tools to short between
the battery terminals and metal parts of
the machine.

6. Remove the battery hold-down (Figure 34) and
lift the battery from the battery tray.

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.

Charging the Battery

3. Raise the seat.

2. Allowing batteries to stand for an extended period
without recharging them will result in reduced
performance and service life. To preserve
optimum battery performance and life, recharge
batteries in storage when the open circuit voltage
drops to 12.4 volts.

1. Remove the battery from the chassis; refer to
Removing the Battery.

4. Disconnect the negative (black) ground cable
from the battery post (Figure 34). Retain all
fasteners.

Note: To prevent damage due to freezing,
battery should be fully charged before putting
away for winter storage.
3. Check the voltage of the battery with a digital
voltmeter. Locate the voltage reading of the
battery in the table below and charge the battery
for the recommended time interval to bring the
charge up to a full charge of 12.6 volts or greater.
Important: Make sure the negative battery
cables are disconnected and the battery
charger used for charging the battery has an
output of 16 volts and 7 amps or less to avoid
damaging the battery (see chart below for
recommended charger settings).

Figure 34
1.
2.
3.
4.

Battery hold-down
Wingnut
Negative battery post
Bolt, washer, and nut

5. Terminal boot
6. Positive battery post
7. Battery

Maintenance
Voltage
Reading

Percent
Charge

Maximum
Charger
Settings

Charging
Interval

12.6 or
greater

100%

16 volts/7
amps

No
Charging
Required

12.4 – 12.6

75–100%

16 volts/7
amps

30 Minutes

12.2 – 12.4

50–75%

16 volts/7
amps

1 Hour

12.0–12.2

25–50%

14.4 volts/4 2 Hours
amps

11.7–12.0

0–25%

14.4 volts/4 3 Hours
amps

11.7 or less

14.4 volts/2 6 Hours or
More
amps

3. Install the negative battery cable to the negative
(-) battery terminal using the fasteners removed
previously.
4. Slide the red terminal boot onto the positive (red)
battery post.
5. Secure the battery with the hold-down (Figure 34).

Servicing the Fuses and
Relay
The electrical system is protected by fuses. It requires
no maintenance; however, if a fuse blows, check
the component/circuit for a malfunction or short.
There is also a replaceable relay/s next to the fuse.
Refer to your Parts manual for correct replacement
components.
Fuse Block:
• Main fuse: 25 amp fuse, blade-type
• Charge Circuit: 20 amp fuse, blade-type
• Auxiliary circuit: 15 amp fuse, blade-type
• Diode: TVS
1. Raise the seat to gain access to the fuse holder
(Figure 36).

4. When the battery is fully charged, unplug
the charger from the electrical outlet, then
disconnect the charger leads from the battery
posts (Figure 35).

Figure 35
1. Negative battery post
2. Black (-) charger lead

3. Red (+) charger lead
4. Positive battery post

Note: Do Not run the machine with the battery
disconnected, electrical damage may occur.

Installing the Battery
Figure 36

1. Position the battery in the tray with the terminal
posts toward the operating position (Figure 34).

1.
2.
3.
4.

2. Install the positive (red) battery cable to the
positive (+) battery terminal using the fasteners
removed previously
38

Cover
Relay
Auxilliary–15 amp
Charge–20 amp

5.
6.
7.
8.

Main–25 amp
Diode
Briggs & Stratton unit
Kohler Command unit

Maintenance
2. Remove cover as shown in Figure 36.

WARNING

3. To replace a fuse, pull out on the fuse to remove it

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.

Drive System Maintenance
Checking the Tire Pressure

• Inspect the blade periodically for wear or
damage.

Service Interval: Every 25 hours/Monthly
(whichever comes first)

• Replace a worn or damaged blade.

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 37).

Before Inspecting or Servicing the
Blades

Check the tires when they are cold to get the most
accurate pressure reading.

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).

Rear Tires: 13 psi (90 kPa)
Front Tires (caster wheels): 13 psi (90 kPa)

Inspecting the Blades
1. Inspect the cutting edges (Figure 38). If the edges
are not sharp or have nicks, remove and sharpen
the blades; refer to Sharpening the Blades.
Figure 37

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 38), immediately install
a new blade.

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, which slows growth
and increases the chance of disease.

Figure 38
1. Cutting edge
2. Curved area

Check the cutter blades daily for sharpness, and for
any wear or damage. File down any nicks and sharpen
the blades as necessary. If a blade is damaged or
worn, replace it immediately with a genuine Exmark
replacement blade. For convenient sharpening and
replacement, you may want to keep extra blades on
hand.

3. Wear/slot forming

Checking for Bent Blades
1. Rotate the blades until the ends face forward
and backward (Figure 39). Measure from a level
surface to the cutting edge, of the blades. Note
this dimension.

Maintenance
(Figure 40). Refer to Removing the Blades and
Installing the Blades.
3. Once the blade has been removed, inspect the
spring disc washer. If the washer appears to be
damaged (the washer surface has been marred)
or flattened, the bolt and washer assembly must
be replaced.

Removing the Blades
The blades must be replaced if a solid object is hit, if
the blade is out of balance, or the blade is bent. To
ensure optimum performance and continued safety
conformance of the machine, use genuine Exmark
replacement blades. Replacement blades made by
other manufacturers may result in an unsafe machine.

Figure 39
1. Blades front to rear
2. Outside cutting edges

3. Measure here

2. Rotate the opposite ends of the blades forward.

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 40).

3. Measure from a level surface to the cutting edge
of the blades at the same position as in step 1.
The difference between the dimensions obtained
in steps 1 and 3 must not exceed 1/8 inch (3
mm). If this dimension exceeds 1/8 inch (3 mm),
the blade is bent and must be replaced. Refer
to Removing the Blades and Installing the
Blades.

WARNING
A blade that is bent or damaged could break
apart and could seriously injure or kill you
or bystanders.
• Always replace bent or damaged blade
with a new blade.

Figure 40
1. Blade
2. Washer
3. Bolt and washer assembly. Apply lubricant to
threads—torque to 32-42 ft-lb (43-57 N-m).

• Never file or create sharp notches in the
edges or surfaces of blade.

Checking for Loose Blades or
Damaged Spring Disc Washers

Sharpening the Blades

1. Place a wrench on the blade bolt and torque to
32-42 ft lb (43-57 N-m).

1. Use a file to sharpen the cutting edge at both ends
of the blade (Figure 41). Maintain the original
angle. The blade retains its balance if the same
amount of material is removed from both cutting
edges.

2. With the wrench still on the blade bolt, hold the
blade spindle stationary and using a rag or thickly
padded glove, try to rotate the blade. If the blade
rotates relative to the spindle guard without
further tightening the blade bolt, the spring
disc washer has been flattened or damaged and
the bolt and washer assembly must be replaced

Maintenance

Mower Belt Maintenance
Inspecting the Belts
Service Interval: Every 25 hours
Figure 41

Check the belts for cracks, frayed edges, burn marks,
or any other damage. Replace damaged belts.

1. Sharpen at original angle

Replacing the Mower Belt

2. Check the balance of the blade by putting it on a
blade balancer (Figure 42). 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 42).
Repeat this procedure until the blade is balanced.

Squealing when the belt is rotating, blades slipping
when cutting grass, frayed belt edges, burn marks,
and cracks are signs of a worn mower belt. Replace
the mower belt if any of these conditions are evident.
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.

Figure 42
1. Blade

2. Balancer

3. Set the height-of-cut at 1-1/2 inch (38 mm).
4. Remove the belt covers over the outside spindles.
5. Pull the idler pulley in the direction shown in
Figure 48 and roll the belt off of the pulleys.

Installing the Blades
1. Install the blade onto the spindle shaft (Figure 40).

WARNING

Important: The curved part of the blade
must be pointing upward toward the inside of
the mower to ensure proper cutting.

The spring is under tension when installed
and can cause personal injury.

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.

Be careful when removing the belt.

3. Torque the blade bolt to 32-42 ft-lb (43-57 N-m).

WARNING
Incorrect installation of the blade or
components used to retain the blade cause
the blade to come loose and could seriously
injure or kill you or bystanders.

Figure 43
1. Outside puley
2. Spring
3. Idler pulley

Always install the original Exmark blades,
washers and blade bolts as shown.

4. Mower belt
5. Engine pulley
6. Pull idler in this direction.

Maintenance
6. Route the new belt around the engine pulley and
mower pulleys.
7. Pull the idler pulley in the direction shown in
Figure 43 and route the belt onto the idler pulley.
8. Install the belt covers over the outside spindles.

7. Set anti-scalp rollers to top holes or remove
completely for this adjustment.
8. Set the height-of-cut lever to the 3 inch (76 mm)
position. Place two 2 1/2 inch (6.35 cm) thick
blocks under the rear edge of the cutting deck
skirt; one on each side of the cutting deck. Place
two 2 5/16 inch (5.89 cm) blocks under each side
of the front edge of the deck, but not under the
anti-scalp roller brackets.
9. Carefully rotate the blades side to side (Figure 44).
10. 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
11. Recheck that blocks fit just snugly under the deck
skirt. Make sure all attachment bolts are tight
12. Continue leveling the deck by checking the
front-to-rear blade slope; refer to Adjusting the
Front-to-Rear Blade Slope.
13. Recheck blades for levelness and repeat deck
leveling procedure if necessary.

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.
1. Park the machine on a level surface and disengage
the blade control switch.
2. Move the motion control levers outward to the
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.
3. Check the air pressure of all four tires. If needed,
adjust to the recommended inflation; refer to
Checking the Tire Pressure in Drive System
Maintenance section. If either one is out of range
then follow adjustment procedure.
4. Carefully rotate the blades side to side.
5. Measure between the outside cutting edges and
the flat surface (Figure 44). If both measurements
are not within 3/16 inch (5 mm), an adjustment is
required; continue with this procedure.

Figure 45
1. Deck lift arm
2. Float retaining nut

Figure 44
1. Blades side to side
2. Outside cutting edges

3. Measure here

3. Deck hanger
4. Leveling adjust locking
nut

Adjusting the Blade Slope

6. Check the front-to-rear blade level any time you
install the mower. If the front blade tip is not
1/16-5/16 inch (1.6-7.9 mm) lower than the rear
blade tip, adjust the blade level. If measurements
from steps 5 or 6 are out of range, then follow
Adjusting the Blade Slope.

1. Check the front-to-rear blade level any time you
install the mower. If the front blade tip is not
1/16-5/16 inch (1.6-7.9 mm) lower than the rear
blade tip, adjust the blade level using the following
instructions:
42

Maintenance
2. Park the machine on a level surface and disengage
the blade control switch.
3. Move the motion control levers outward to
the neutral position, engage the parking brake,
stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
4. Check the air pressure of all four tires. If needed,
adjust to the recommended inflation; refer to
Checking the Tire Pressure in Drive System
Maintenance section.
5. Check and adjust the side-to-side blade level if you
have not checked the setting; refer to Leveling
the Mower.
6. Set the height-of-cut lever to the 3 inch (76 mm)
position. Place two 2 1/2 inch (6.35 cm) thick
blocks under the rear edge of the cutting deck
skirt; one on each side of the cutting deck. Place
two 2 5/16 inch (5.89 cm) blocks under each side
of the front edge of the deck, but not under the
anti-scalp roller brackets.

Figure 46
3. Deck hanger
4. Leveling adjust locking
nut

1. Deck lift arm
2. Float retaining nut

7. Loosen the leveling adjust locking nuts (item 4)
on all four corners so that the deck is sitting
securely on all four blocks. Make sure that the
deck hangers are all the way down (at the top of
the slot) and the deck lift foot lever is pushed back
against the stop, then tighten the four leveling
adjust locking nuts (Figure 46).

8. Carefully rotate the blades so they are facing front
to rear (Figure 47).
9. Measure from the tip of the front blade to the flat
surface and the tip of the rear blade to the flat
surface (Figure 47). If the front blade tip is not
1/16-5/16 inch (1.6-7.9 mm) lower than the rear
blade tip, adjust the front deck hanger.

Figure 47
1. Blades front to rear
2. Outside cutting edges

3. 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

Removing the Mower Deck
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. Place blocks under deck for support. Lower the
height-of-cut lever to the lowest position.
4. Remove the hardware from the deck hanger and
deck lift arm on both sides of the deck (Figure 48).
Figure 49
1. Deck lift arm

2. Deck strut

6. Slide the mower rearward to remove the mower
belt from the engine pulley.
7. Slide the mower out from underneath the
machine.
Note: Retain all parts for future installation.

Installing the Mower Deck
1. Park the machine on a level surface and disengage
the blade control switch.

Figure 48
1. Deck lift arm

2. Deck hanger

2. Move the motion control levers outward to the
neutral position, engage parking brake, stop the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating position.

5. Remove the nut, bolt, and pivot bushing from the
deck strut (Figure 48). Carefully lower the front
of the mower deck to the ground (Figure 49).

3. Slide the mower under the machine.
4. Lower the height-of-cut lever to the lowest
position.
5. Use the existing hardware to attach the rear deck
strut of the mower to the deck lift arm (Figure 49).
6. Attach the hardware from the deck hanger and
deck lift arm on both sides of the deck (Figure 48).
7. Install the mower belt onto the engine pulley;
refer to Replacing the Mower Belt.

Maintenance

Replacing the Discharge
Deflector

through the front discharge deflector bracket,
discharge deflector, and rear deflector bracket.
5. Make sure that the spring and rod are installed
so that the rod is retained from sliding out
by the front bracket and the spring holds the
discharge deflector in the down position. Refer to
(Figure 50) for proper orientation.

DANGER
An uncovered discharge opening could allow
the lawn mower to throw objects in the
operator’s or bystander’s direction and result
in serious injury. Also, contact with the blade
could occur.

Important: The discharge deflector must be
spring loaded in the down position. Lift the
deflector up to test that it snaps to the full
down position.

Never operate the lawn mower unless you
install a mulch plate, discharge deflector, or
grass collection system.
1. Locate items shown in Figure 50.

Figure 50
1. Rod
2. Spring
3. Discharge deflector

4. Mower deck
5. Discharge deflector
bracket
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 50.
Place spring on rod and slide rod, straight end,
45

Maintenance

Cleaning

Note: If the mower is not clean after one
washing, soak it and let it stand for 30 minutes.
Then repeat the process.

Washing the Underside of
the Mower

8. Run the mower again for one to three minutes
to remove excess water.

Service Interval: Before each use or daily

WARNING

After each use, wash the underside of the mower to
prevent grass buildup for improved mulch action and
clipping dispersal.

A broken or missing washout fitting could
expose you and others to thrown objects or
blade contact. Contact with blade or thrown
debris can cause injury or death.

1. Park the machine on a level surface and disengage
the blade control switch.

• Replace broken or missing washout
fitting immediately, before using mower
again.

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.

• Plug any hole(s) in mower with bolts and
locknuts.

3. Attach the hose coupling to the end of the mower
washout fitting, and turn the water on high
(Figure 51).

• Never put your hands or feet under the
mower or through openings in the mower.

Note: Spread petroleum jelly on the washout
fitting O-ring to make the coupling slide on easier
and protect the O-ring.

Figure 51

4. Lower the mower to the lowest height-of-cut.
5. Sit on the seat and start the engine. Engage the
blade control switch and let the mower run for
one to three minutes.
6. Disengage the blade control switch, stop the
engine, and remove the ignition key. Wait for all
moving parts to stop.
7. Turn the water off and remove the coupling from
the washout fitting.

Storage

C. Stop the engine, allow it to cool, and drain the
fuel tank; refer to Draining the Fuel Tank in
Fuel System Maintenance section.

Cleaning and Storage

D. Restart the engine and run it until it stops.

1. Disengage the blade control switch, move the
motion controls outward to the neutral position,
engage parking brake, stop the engine, and
remove the key.

E. Choke the engine. Start and run the engine
until it will not start.
F. Dispose of fuel properly. Recycle as per local
codes.

2. Remove grass clippings, dirt, and grime from the
external parts of the entire machine, especially the
engine. Clean dirt and chaff from the outside of
the engine cylinder head fins and blower housing.

Important: Do Not store
stabilizer/conditioned gasoline over
30 days.

Important: You can wash the machine with
mild detergent and water. Do Not pressure
wash the machine. Avoid excessive use of
water, especially near the control panel,
engine, hydraulic pumps, and motors.

10. Remove the spark plug(s) and check its condition;
refer to Servicing the Spark Plug in Engine
Maintenance section. With the spark plug(s)
removed from the engine, pour two tablespoons
of engine oil into the spark plug hole. Use the
starter to crank the engine and distribute the oil
inside the cylinder. Install the spark plug(s). Do
Not install the wire on the spark plug(s).

3. Service the air cleaner; refer to Servicing the Air
Cleaner in Engine Maintenance section.
4. Grease and oil the machine; refer to Lubrication
section.

11. Clean any dirt and chaff from the top of the
mower.

5. Change the crankcase oil and filter; refer
to Servicing the Engine Oil in Engine
Maintenance section.

12. Scrape any heavy buildup of grass and dirt from
the underside of the mower, then wash the mower
with a garden hose.

6. Check the tire pressure; refer to Checking the
Tire Pressure in Drive System Maintenance
section.

13. Check the condition of the drive and mower belts.
14. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is worn or
damaged.

7. Charge the battery; refer to Servicing the
Battery in Electrical System Maintenance section.

15. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.

8. Check the condition of the blades; refer to
Servicing the Cutting Blades in Mower
Maintenance section.

16. Store the machine in a clean, dry garage or storage
area. Remove the key from the ignition switch
and keep it in a memorable place. Cover the
machine to protect it and keep it clean.

9. Prepare the machine for storage when non-use
occurs over 30 days. Prepare the machine for
storage as follows.
A. Add a petroleum based stabilizer/conditioner
to the fuel in the tank. Follow the mixing
instructions from the stabilizer manufacturer.
Do Not use an alcohol based stabilizer
(ethanol or methanol).
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh gasoline and
used at all times.
B. Run the engine to distribute the conditioned
fuel through the fuel system (5 minutes).

Troubleshooting

Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be
caused by an empty fuel tank.
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major
items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors DO NOT pull on the wires to separate the connectors.
Problem
The engine overheats.

The starter does not crank

Engine will not start, starts hard, or fails to
keep running

Possible Cause

Corrective Action

1. The engine load is excessive.

1. Reduce ground speed.

2. The oil level in the crankcase is low.
3. The cooling fins and air passages under
the engine blower housing are plugged.
4. The air cleaner is dirty.
5. Dirt, water, or stale fuel is in fuel system.

2. Add oil to the crankcase.
3. Remove the obstruction from the cooling
fins and air passages.
4. Clean or replace the air cleaner element.
5. Contact an Authorized Service Dealer.

1. The blade control switch is engaged.

1. Move the blade control switch to
Disengaged.

2. The motion control levers are not in the
park position.
3. The operator is not seated.
4. The battery is dead.
5. The electrical connections are corroded
or loose.
6. A fuse is blown.
7. A relay or switch is damaged.

2. Move the motion control levers outward
to the park position.
3. Sit on the seat.
4. Charge the battery.
5. Check the electrical connections for good
contact.
6. Replace the fuse.
7. Contact an Authorized Service Dealer.

1. Fuel tank is empty.

1. Fill the fuel tank.

2. The choke is not on.
3. The air cleaner is dirty.
4. The spark plug wire(s) is loose or
disconnected.
5. The spark plug(s) is pitted, fouled, or the
gap is incorrect.
6. There is dirt in fuel filter.
7. Dirt, water, or stale fuel is in the fuel
system.
8. There is incorrect fuel in the fuel tank.

2. Move the choke lever to On.
3. Clean or replace the air cleaner element.
4. Install the wire(s) on the spark plug.

9. The oil level in the crankcase is low.

5. Install a new, correctly gapped spark
plug(s).
6. Replace the fuel filter.
7. Contact an Authorized Service Dealer.
8. Drain the tank and replace the fuel with
the proper type.
9. Add oil to the crankcase.

Troubleshooting
Problem
Engine loses power

The machine does not drive.

Abnormal vibration

Uneven cutting height.

Possible Cause
1. Engine load is excessive.

1. Reduce the ground speed.

2. Air cleaner is dirty.
3. Oil level in the crankcase is low.
4. Cooling fins and air passages for the
engine are plugged.
5. The spark plug(s) is pitted, fouled, or the
gap is incorrect.
6. Vent hole in the fuel cap is closed.
7. Dirt in fuel filter.
8. Dirt, water, or stale fuel is in the fuel
system.
9. There is incorrect fuel in the fuel tank.

2. Clean or replace the air cleaner element.
3. Add oil to the crankcase.
4. Remove the obstructions from the cooling
fins and air passages.
5. Install a new, correctly gapped spark
plug(s).
6. Open the vent in the fuel cap.
7. Replace the fuel filter.
8. Contact an Authorized Service Dealer.
9. Drain the tank and replace the fuel with
the proper type.

1. The drive belts are worn, loose, or broken.

1. Contact an Authorized Service Dealer.

2. The drive belts are off of the pulleys.
3. The drive is in bypass mode.

2. Contact an Authorized Service Dealer.
3. Take machine out of bypass mode. Refer
to Pushing the Machine by Hand
section.

1. Engine mounting bolts are loose.

1. Tighten the engine mounting bolts.

2. Loose engine pulley, idler pulley, or blade
pulley.
3. Engine pulley is damaged.
4. Cutting blade(s) is/are bent or unbalanced.
5. Blade is loose.

2. Tighten the appropriate pulley.

6. Blade spindle is bent.

3. Contact an Authorized Service Dealer.
4. Install new cutting blade(s).
5. Tighten the blade mounting bolt and
inspect the blade spring disc washer for
damage (See Servicing the Cutting
Blades section).
6. Contact an Authorized Service Dealer.

1. Blade(s) not sharp.

1. Sharpen the blade(s).

2. Cutting blade(s) is/are bent.
3. A blade is loose.

2. Install new cutting blade(s).
3. Tighten the blade mounting bolt and
inspect the blade spring disc washer for
damage (See Servicing the Cutting
Blades section).
4. Level mower deck from side-to-side and
front-to-rear.
5. Adjust the anti-scalp wheel height.
6. Clean the underside of the mower.
7. Adjust tire pressure.
8. Contact an Authorized Service Dealer.

4. Mower deck is not level.
5.
6.
7.
8.
Blades do not rotate.

Corrective Action

An anti-scalp wheel is not set correctly
Underside of mower is dirty.
Tire pressure in drive tires not correct.
Blade spindle bent.

1. Drive belt is worn, loose or broken.

1. Install new drive belt.

2. Drive belt is off pulley.

2. Install drive belt and check adjusting
shafts and belt guides for correct position.
3. Install new deck belt.
4. Install deck pulley and check the idler
pulley, idler arm and spring for correct
position and function.
5. Install a new mower belt.

3. Deck belt is worn, loose or broken.
4. Deck belt is off pulley.

5. The mower belt is worn, loose, or broken.

HOUR METER, PTO SWITCH

SOLENOID

SEAT SWITCH, ACCESSORIES

HOUR METER, PTO SWITCH

TERMINAL B

TERMINAL I

TERMINAL S

TERMINAL X

TERMINAL Y

LH
MOTION
CONTROL

RH
MOTION
CONTROL

BRAKE
SWITCH

G007525

VIOLET

GRAY

1
1

5
4

2
3

8 1

3
4

1
2

FUSE BLOCK

YELLOW
WHITE

LIGHT BLUE
VIOLET

LIGHT BLUE

PINK

ORANGE
BLACK

STARTER LOCKOUT
& KILL RELAY

START
SOLENOID
GROUND

START
SOLENOID
SIGNAL

START
SOLENOID
B+

PTO
CLUTCH

BLACK

DARK GREEN

BLACK

DARK GREEN

YELLOW

PINK

YELLOW

DARK BLUE

GREEN

PINK

Y S X A B

DARK GREEN

VIOLET
GREEN

VIOLET

BROWN

YELLOW

GRAY
VIOLET

CONNECTORS VIEWED FROM WIRE END

NOTE:

VOLTAGE REGULATOR

BATTERY

TERMINAL A

CONNECTIONS

TERMINAL A

TERMINAL

IGNITION SWITCH

TERMINAL Y

TERMINAL X

X +Y

TERMINAL B

B+I+S

B+I+A

TERMINAL S
TERMINAL I

3. START

2. RUN

VILOET
ORANGE

BROWN

YELLOW
YELLOW

NONE

PINK
DARK GREEN

1. OFF

PINK

RED

IGNITION SWITCH

RED

VIOLET
ORANGE

SEAT SWITCH

PINK
PINK
DARK BLUE
ORANGE
ORANGE
VIOLET
RED

CIRCUIT "MAKE"

RED
VIOLET

POSITION

2
3
5
4

BROWN

WHITE
BLACK
BLACK

ORANGE
DARK GREEN
DARK GREEN
BROWN
BROWN

PTO SWITCH

GROUND

FUEL SOLENOID
MAGNETO

OIL SWITCH
ALTERNATOR

HOUR METER

ACCESSORIES

Schematics

Schematics
Electrical Diagram—Briggs & Stratton
ENGINE

HOUR METER, PTO SWITCH

SOLENOID

SEAT SWITCH, ACCESSORIES

HOUR METER, PTO SWITCH

TERMINAL B

TERMINAL I

TERMINAL S

TERMINAL X

TERMINAL Y

LH
MOTION
CONTROL

RH
MOTION
CONTROL

BRAKE
SWITCH

G007526

VIOLET

5
4

2
3

8 1

3
4

1
2

FUSE BLOCK

BLUE
YELLOW
WHITE

LIGHT BLUE
VIOLET

LIGHT BLUE

PINK

ORANGE
BLACK

KILL RELAY

STARTER LOCKOUT
SOLENOID

START
SOLENOID
B+

PTO
CLUTCH

BLACK

DARK BLUE

BLACK

DARK GREEN

YELLOW

DARK GREEN

YELLOW

PINK

GREEN

DARK GREEN

VIOLET
GREEN

VIOLET

GRAY

Y S X A B

BROWN

YELLOW

GRAY
VIOLET

CONNECTORS VIEWED FROM WIRE END

NOTE:

VOLTAGE REGULATOR

BATTERY

TERMINAL A

CONNECTIONS

TERMINAL A

TERMINAL

IGNITION SWITCH

TERMINAL Y

TERMINAL X

X +Y

TERMINAL B

B+I+S

B+I+A

TERMINAL S
TERMINAL I

3. START

2. RUN

PINK

BROWN

YELLOW
YELLOW

NONE

PINK
DARK GREEN

1. OFF

PINK

RED

IGNITION SWITCH

RED

VIOLET
ORANGE

SEAT SWITCH

PINK
PINK
DARK BLUE
ORANGE
ORANGE
VIOLET
RED

CIRCUIT "MAKE"

RED
VIOLET

POSITION

2
3
5
4

BROWN

WHITE
BLACK
BLACK

VILOET
ORANGE
DARK BLUE
BLUE

ORANGE
DARK GREEN
DARK GREEN
BROWN
BROWN

PTO SWITCH

GROUND

FUEL SOLENOID
MAGNETO

OIL SWITCH
ALTERNATOR

HOUR METER

ACCESSORIES

Schematics

Electrical Diagram—Kohler Command
ENGINE

3-Year Limited Consumer Warranty
(30-Day Limited Commercial Warranty)
Exmark Quest Riding Mowers
(For units purchased on or after January 1, 2007)
All warranty work must be performed by an authorized Exmark
Service Dealer using Exmark approved replacement parts.

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
manufactured by Exmark 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 mowers.

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. Customers may also call 402-223-6375.

This warranty applies to Exmark Quest mowers purchased on or after
January 1, 2007 sold in the US 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.
•
•
•
•

Products
Attachments
Belts and Tires
Battery
Engine*

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

Warranty Period
1 year
90 days
1 Year Prorated
3-Year, 3rd Year Covered by Exmark

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.

* Please refer to the manufacturer’s warranty statement that is
included in the literature packet. 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.
** 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.

General Conditions
The sole liability of Exmark and Exmark Warranty Company with
respect to this warranty shall be repair and replacement as set forth
herein. Neither Exmark nor Exmark Warranty Company shall
have any liability for any other cost, loss or damage, including
but not limited to, any incidental or consequential loss or
damage.

Exmark will cover up to $45 for associated pick-up and delivery
charges to and from any authorized Exmark Service Dealer. This will
apply to the first warrantable service repair only. Additional
transportation charges may apply, contact your Dealer for details.
Limited Warranty for Commercial Use
Exmark Quest mowers and attachments used for commercial,
institutional, or rental use are warranted against defects in materials
or workmanship for the following time periods from the date of
purchase:
Products
• Air Cooled Gas Engines
• All other items

In particular, we shall have no liability or responsibility for:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other extraordinary
repair charges or charge 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.

Warranty Period
90 day limited warranty
30 day limited warranty

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 or other than as recommended in the operator's manual
or other operational instructions provided by Exmark.

No Claim of breach of warranty shall be cause for cancellation or
rescission of the contract of sale of any Exmark mower.
Some states do not allow exclusions of incidental or consequential
damages, 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.

There are no other express warranties except for engine and special
emission system coverage stated elsewhere herein or included with
the product.

G007486

Notes:

Service Record
Date:

Description of Work Done:

Service Done By:

Part No. 4500-338 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed In USA.

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