Exmark 4501-191 Rev.A manual

QUEST™ For Serial Nos. 312,000,000 & Higher Part No. 4501-191 Rev . A[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals known to the State of Califor nia to cause cancer , bir th defects, or other reproductiv e har m. Important: The engine in this product is not equipped with a spark arr ester mufer . It is a violation of Califor nia Public Resource Code (CPRC) Se[...]

Introduction R ead this infor mation carefully to learn ho w to operate and maintain your product properly and to av oid injury and product damag e . Y ou are responsible for operating the product properly and safely . Exmark parts manuals are av ailable online at http://www .exmark.com. Y ou may contact Exmark directly at www .Exmark.com for produ[...]

Contents Introduction . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . 3 Safety .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. 5 Safety Aler t Symbol . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. [...]

Safety Safety Safety Alert Symbol This manual identies potential hazards and has safety messages identied by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injur y or death if y ou do not follow the recommended precautions . Figure 2 Safety Alert Symbol This man ual uses tw o other w ords to highlight infor [...]

Safety safely enough to protect themselv es and others from serious injury . • Alwa ys follow the recommendations for wheel weights or counterw eights . Slope Operation Slopes are a major factor related to loss of control and tip-ov er accidents , whic h can result in severe injur y or death. Operation on all slopes requires extra caution. If y o[...]

Safety • Extinguish all cigarettes , cigars, pipes and other sources of ignition. • Use only an approv ed container . • Never remov e the g as cap or add fuel when the engine is r unning . Allow the engine to cool before refueling . • Never refuel the machine indoors . • Never store the mac hine or fuel container inside where there is an [...]

Safety • Batter y gases can explode . K eep cig arettes , sparks and ames a wa y from battery . • Use only Exmark approv ed attachments . W arranty ma y be v oided if used with unappro v ed attachments . • If loading the mac hine onto a trailer or tr uc k, use a single, full-width ramp only . The ramp angle should not ex ceed 15 deg rees .[...]

Safety Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger . R eplace any decal that is damaged or lost. 93-7009 1. W arning—don't operate the mower with the deector up or removed; keep the deector in place. 2. Cutting/dismemberment hazard o[...]

Safety 1 10-6691 1. Thrown object hazard—keep bystanders a safe distance from the machine. 2. Thrown object hazard, mower—do not operate without the deector , discharge cover , or grass collection system in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts. 1 12-9840 1. Read the Operator's Manual . 3. Remove [...]

Safety 1 19-8871 42 Inch Model 1. Height-of-cut 121-2989 42 Inch Model 1. Bypass lever position for pushing the machine 2. Bypass lever position for operating the machine PTO Switch Symbols 1. PTO–disengage 2. PTO–engage 1 1[...]

Safety 1 16-4220 50 Inch Model 1. Fast 3. Slow 2. Continuous variable setting 4. Choke 120-5462 42 Inch Model 1. Fast 3. Slow 2. Continuous variable setting 4. Choke 12[...]

Safety 120-2239 1. W arning—read the Operator's Manual. 5. W arning—do not use split ramps, use a full ramps when transporting machine. 2. W arning—read the instructions before servicing or performing maintenance; move the motion control levers to the park (brake) position, remove the ignition key and disconnect the spark plug wire. 6. L[...]

Specications Specications Model Numbers Serial Nos: 312,000,000 and Higher QTE651KA421; QTE691KA501; QTS691KA502 Systems Engine • Engine Specications: See your Engine Owner’ s Manual • Engine Oil T ype: Exmark 4-Cycle Premium Engine Oil • RPM: Full Speed: 3300 ±100 (max) RPM (No Load) Idle: 1650 (min) RPM Fuel System • Capacity:[...]

Specications • Mounting: Hinged to tilt up for access to batter y and other components . Adjustable fore and aft. • Ar mrests: Standard–padded ip-up ar mrests . • Seat Safety Switch: Incorporated into the Safety Interlock System. Hydrostatic Ground Drive System • Hydrostatic Pumps: – 42 inc h unit: T w o Hy dro Gear ZT2100 Integ r[...]

Product Overview Overall Height: All Units 41.5 inc hes (105 cm) T read W idth: (Center to Center of Tires, W idthwise) 42 inch Deck 50 inch Deck Driv e Wheels 31.5 inc hes (80 cm) 37.4 inc hes (95 cm) Caster Wheels 29.5 inches (75 cm) 36.9 inc hes (94 cm) Wheel Base: (Center of Caster T ire to Center of Drive Tire) All Units 45.6 inc hes (116 cm) [...]

Operation Operation Controls Note: Become familiar with all of the controls in Figure 3 and Figure 4 before y ou start the engine and operate the mac hine . Ignition Switch Located on control panel. The ignition switc h is used to star t and stop the engine. The switc h has three positions “OFF”, “RUN” and “ST AR T” ( Figure 4). Insert [...]

Operation Pull the lever inw ard and rearw ard to raise the cutting deck. Allow the handle to mo ve forw ard to low er the cutting dec k. Mo ve the deck height adjustment lev er outward at the desired height-of-cut. Only adjust the height of cut while the machine is not mo ving . Height-of-Cut Foot Lever The height-of-cut foot lev er allows the ope[...]

Operation Recommended Gasoline Fill fuel tank on level ground. See Fuel Recommendations in the Specications section for additional gasoline infor mation. Do Not add oil to gasoline. Do Not ov erll fuel tank. Fill the fuel tank to the bottom of the ller nec k. The empty space in the tank allows gasoline to expand. Ov erlling may result i[...]

Operation cor rect amount of gas stabilizer/conditioner to the gas . Note: A fuel stabilizer/conditioner is most effectiv e when mixed with fresh gasoline. T o minimize the chance of v ar nish deposits in the fuel system, use fuel stabilizer at all times . Filling the Fuel T ank Make sure the engine is shut off and the motion controls are in the pa[...]

Operation Figure 8 1. Ignition key 5. Throttle lever 2. Off 6. Choke control 3. Run 7. Blade control switch—Off position 4. Start 3. Pull up on the c hoke control to engag e the chok e before starting a cold engine (Figure 8). Note: A w ar m or hot engine may not require choking . 4. T urn the ignition k ey to Start to energize the starter. When [...]

Operation The Safety Interlock System CAUTION If the safety inter lock s witches are disconnected or dama ged the machine could operate unexpectedly causing per sonal injur y . • Do not tamper with the interlock s witches. • Check the operation of the interlock s witches daily and replace an y damaged switches before operating the machine. Unde[...]

Operation Figure 10 1. Parking brake position (engaged) 4. Forward 2. Center unlock position (neutral) 5. Backward 3. Front of unit T o go straight, apply equal pressure to both motion control levers ( Figure 10 and Figure 11). G008952 Figure 1 1 T o turn, pull back on the motion control lever to ward the direction y ou want to turn (Figure 10 and [...]

Operation G008953 Figure 12 T o go straight, apply equal pressure to both motion control levers (Figure 10 and Figure 12). T o turn, release the pressure on the motion control lever to ward the direction you want to turn (Figure 10 and Figure 12). T o stop , push the motion control levers to neutral. Stopping the Machine T o stop the machine , mov [...]

Operation the positions sho wn in Figure 15. Rollers will maintain 3/4 inc hes (19 mm) clearance to the g round to minimize g ouging and roller wear or damage. Note: F or Maximum Deck Flotation, place the rollers one hole position low er . R ollers should maintain 1/4 inc h (6.35 mm) clearance to the g round. Do Not adjust rollers to support the de[...]

Operation Changing the Seat Ride Suspension The n umber of seat springs can be c hanged to maximize rider comfort. More springs should be used with hea vier operators and on rough ter rain. F ew er springs should be used with lighter operators and when mowing smooth, w ell established la wns . Alwa ys keep the n umber of springs on the left and rig[...]

Operation 2. Mov e the motion control lev ers outward to park position, stop the engine, and wait for all moving parts to stop before leaving the operating position. 3. Locate the bypass lev ers on the frame on both sides of the engine . 4. Mov e the bypass lev ers forw ard through the k ey hole and do wn to loc k them in place as shown in Figure 2[...]

Operation W ARNING Loading a unit on a trailer or tr uck increases the possibility of backw ard tip-ov er . Backw ard tip-ov er could cause serious injur y or death. • Use extreme caution when operating a unit on a ramp. • Use only a single, full width ramp; Do Not use individual ramps for each side of the unit. • If indi vidual ramps must be[...]

Operation Long Grass If the g rass is ev er allow ed to g ro w slightly longer than nor mal, or if it contains a high deg ree of moisture, raise the cutting height higher than usual and cut the g rass at this setting . Then cut the g rass again using the lo wer , nor mal setting . When Stopping If the machine’ s forw ard motion must be stopped wh[...]

Maintenance Maintenance Note: Deter mine the left and right sides of the mac hine from the nor mal operating position. W ARNING While maintenance or adjustments are being made, someone could star t the engine. Accidental star ting of the engine could seriously injure y ou or other bystander s. Remo ve the k ey from the ignition switch, engage parki[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedure Before storage • Charge the battery and disconnect the battery cables . • P erform all maintenance procedures listed abov e before storag e . • P aint any c hipped surfaces . Monthly • Chec k the battery charge. Y early • Inspect the emissions lter . Important: R efer to[...]

Maintenance Figure 22 Located on the seat pan 1. Read the instructions before servicing or performing maintenance. 2. Check tire pressure every 25 operating hours. 3. Grease every 25 operating hours. 4. Engine 4. Wipe up any ex cess grease. Engine Maintenance Servicing the Air Cleaner Service Interval: Every 25 hours/Monthly (whichever comes rst[...]

Maintenance 2. Make sure the engine is stopped, lev el, and is cool so the oil has had time to drain into the sump . 3. T o k eep dirt, grass clippings , etc ., out of the engine, clean the area around the oil ll cap/dipstick before removing it. 4. R emov e the oil ll cap/dipstick; wipe oil off . R einsert the dipstick push into place, but Do[...]

Maintenance and retain the hose . Wipe up any ex cess oil on the frame (Figure 25). Note: Dispose of the used oil at a recycling center . 10. Apply a thin lm of clean Exmark 4-Cycle Premium Engine Oil to the rubber gasket on the new lter . 11. Install the replacement oil lter to the mounting pad. T ur n the oil lter cloc kwise until the[...]

Maintenance Cleaning the Blower Housing Service Interval: Every 100 hours/Y early (whichever comes rst) More often under dirty conditions. T o ensure proper cooling, mak e sure the g rass screen, cooling ns , and other external surfaces of the engine are kept clean at all times . 1. R emov e the blo wer housing and any other cooling shrouds .[...]

Maintenance Electrical System Maintenance W ARNING CALIFORNIA Proposition 65 W ar ning Batter y posts, ter minals, and related accessories contain lead and lead compounds, chemicals kno wn to the State of Califor nia to cause cancer and reproductiv e har m. W ash hands after handling . Charging the Battery Removing the Battery W ARNING Batter y ter[...]

Maintenance Figure 29 1. Negative battery post 4. Positive battery post 2. Bolt, washer , and nut 5. Battery strap 3. T erminal boot 6. Battery W ARNING Incor rect batter y ca ble routing could damage the machine and cables causing sparks. Sparks can cause the batter y gasses to explode, resulting in personal injur y . • Always disconnect the neg[...]

Maintenance DANGER J ump star ting a w eak batter y that is crack ed, frozen, has low electrolyte level, or an open/shor ted batter y cell, can cause an explosion resulting in serious personal injur y . Do Not jump star t a weak batter y if these conditions exist. 2. Make sure the booster is a good and fully c harged lead acid batter y at 12.6 v ol[...]

Maintenance Servicing the Fuses Service Interval: As required The electrical system is protected b y fuses . It requires no maintenance; howev er , if a fuse blo ws , check the component/circuit for a malfunction or shor t. Fuse: • Main F1-30 amp , blade-type • Charge Circuit F2-25 amp , blade-type 1. R emov e the four screws securing the contr[...]

Maintenance Check expansion reser voir and if necessary add 20W -50 engine oil to the FULL COLD line . g017656 3 2 1 Figure 34 1. Expansion reservoir 3. Engine 2. Full Cold line Changing the Hydraulic System Filter and Oil Service Interval: After the rst 50 hours Every 400 hours thereafter . The lter and oil are c hanged at the same time . Do[...]

Maintenance G010254 1 2 3 4 5 Figure 37 Right side shown 1. T ransaxle drive 4. Screws 2. Oil lter 5. V ent plug 3. Filter guard 5. Carefully clean area around lters . It is impor tant that no dir t or contamination enter h y draulic system. 6. Place a container below the lter to catch the oil that drains when the lter and vent plugs ar[...]

Maintenance and install that v ent plug . T orque the plug to 180 in-lb (20.3 N-m). 7. Continue to add oil through the expansion reser voir until it reac hes the FULL COLD line on the expansion reser voir . 8. Install the transaxle guard. Refer to Figure 36 for the cor rect tor que values for the n uts and bolts . 9. Proceed to the Bleeding the Hyd[...]

Maintenance Figure 39 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Damage Checking for Bent Blades Note: The machine must be on a lev el surface for the following procedure . 1. Raise the mo wer dec k to the highest height-of-cut position; also considered the 'transpor t' position. 2. While wearing thickly padded glov es or othe[...]

Maintenance G014973 1 2 3 Figure 43 1. Opposing blade edge, in position for measuring 2. Level surface 3. Second measured distance between blade and surface (B) W ARNING A w or n 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 injur y or death. •[...]

Maintenance Figure 45 1. Sharpen at original angle 2. Check the balance of the blade b y putting it on a blade balancer (Figure 46). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, le some metal off the end of the sail area only (Figure 46). R epeat this procedure until the blade [...]

Maintenance G005278 1 2 2 3 3 4 4 Figure 48 50 Inch Decks 1. Blades side to side 3. Outside cutting edges 2. Sail area of blade 4. Measure from the tip of the blade to the at surface here 5. Measure between the outside cutting edges and the at surface (Figure 47 and Figure 48). If both measurements are not within 3/16 inc h (5 mm), an adjustm[...]

Maintenance the new position (Figure 50). Tighten the rear locking nut on the hanger brac ket. 10. Contin ue lev eling the dec k by c hecking the front-to-rear blade slope; refer to Adjusting the Front-to-R ear Blade Slope . Adjusting the Front-to-Rear Blade Slope Check the front-to-rear blade level any time you install the mow er . If the front of[...]

Maintenance blade tip is 1/16-5/16 inc h (1.6-7.9 mm) low er than the rear blade tip (Figure 51 and Figure 52). 9. When the front-to-rear blade slope is cor rect chec k the side-to-side level of the mow er again; refer to Lev eling the Mow er from Side-to-Side . Removing the Mower Service Interval: As required 1. P ark the mac hine on a lev el surf[...]

Maintenance 3. Set the height-of-cut at the lo west cutting position [1-1/2 inch (38 mm)]. 4. Using a spring remo v al tool, (P/N . 92-5771), remov e the idler spring from the deck hook to remov e tension on the idler pulley and roll the belt off of the pulleys ( Figure 56 and Figure 57). W ARNING The spring is under tension when installed and can [...]

Maintenance 6. Attach the front support rod to the mo wer deck with the clevis pin and hairpin cotter (Figure 54). 7. Install the mo wer belt onto the engine pulley; refer to Replacing the Mo wer Belt . Replacing the Discharge Deector DANGER An uncov ered discharge opening could allo w the lawn mower to throw objects in the operator’ s or byst[...]

Maintenance g017617 1 3 2 4 5 Figure 59 1. Rod 4. Deck brackets 2. Spring 5. Spring installed over the rod 3. Deector assembly 2. P osition the new discharge deector assembly with the brack et ends betw een the welded brack ets on the deck as shown in Figure 59. 3. Install the spring onto the straight end of the rod. P osition the spring on t[...]

Maintenance Cleaning W ashing the Underside of the Mower Service Interval: Before each use or daily—Clean the mower housing. W ash the underside of the mo wer after each use to prevent grass buildup for impro v ed mulc h action and clipping dispersal. 1. P ark the mac hine on a lev el surface and disengage the blade control switch. 2. Mov e the m[...]

Storage Storage Cleaning and Storage 1. Disengag e the blade control switch, mov e the motion controls outw ard to the park position, stop the engine, and remo ve the k ey . 2. R emov e g rass 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 cylind[...]

T roubleshooting T roubleshooting 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 ov erlook the simple causes . F or example: star ting problems could be caused b y an empty fuel tank. The following table lists some of the common causes [...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e. 1. Reduce the ground speed. 2. Air cleaner is dir ty . 2. Clean or replace the air cleaner element. 3. Oil level in the crankcase is low . 3. Add oil to the crankcase. 4. Cooling ns and air passages for the engine are plug ged. 4. Remo ve the obstructions [...]

Schematics Schematics Electrical Diagram 56[...]

Schematics Electrical Logic Schematic G014644 57[...]

Consumer Warranty Conditions and Pr oducts Covered Exmark Mfg. Co. Inc. and its aff iliate, Exmark W arranty Company , pursuant to an agreement between them, jointly warrant on the terms and conditions herein, that we will repair , replace or adjust any part on these products and found by us (in the exercise of our reasonable discretion) to be defe[...]

Notes: 59[...]

Notes: 60[...]

Service Record Date: Description of W ork Done: Service Done By: 61[...]

62[...]

G01 1841 Figure 62 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees . Use the slope indicator to determine the degree of slope of hills before operating. Do Not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2.[...]

MID-MOUNT RIDING A CCESSORIES AND OPTIONS EXMARK A CCESSORIES AND OPTIONS* W ALK-BEHIND A CCESSORIES AND OPTIONS GRASS CA TCHER MICRO-MULCH SYSTEM TURF STRIPER ST ANDON CUST OM RIDE SEA T SUSPENSION SYSTEM FULL SUSPENSION SEA T DECK LIFT ASSIST KIT HITCH KIT LIGHT KIT 12 V PO WER PORT MICRO-MULCH SYSTEM OPERA TOR CONTR OLLED DISCHARGE SUN SHADE TRA[...]