Exmark Quest Lawn Mower manual

QUEST ® For Serial Nos. 720,000 & Higher Part No. 4500-338 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: This engine is not equipped with a spark arr ester mufer . It is a violation of Califor nia Public Resource Code Section 4442 to use or op[...]

Introduction R ead this infor mation carefully to lear n how to operate and maintain y our product properly and to av oid injury and product damage. Y ou are responsible for operating the product properly and safely . Y ou may contact Exmark directly at www .Exmark.com for product and accessor y infor mation or help nding a dealer . Whenever y o[...]

Contents Introduction .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 3 Safety .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . 5 Safety Alert Symbol . . . . . . . .. . . . . . . . . . . . . . . . .[...]

Safety Safety Safety Alert Symbol This man ual identies potential hazards and has safety messages identied by the safety alert symbol (Figure 2), which signals a hazard that ma y cause serious injury or death if you do not follo w the recommended precautions . Figure 2 1. Safety alert symbol This manual uses tw o other w ords to highlight inf[...]

Safety safely enough to protect themselves 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 , which can result in sev ere injur y or death. Operation on all slopes requires extra caution. If you [...]

Safety • Extinguish all cigarettes , cigars, pipes and other sources of ignition. • Use only an approv ed container . • Never remo ve the gas cap or add fuel when the engine is r unning . Allo w 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 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–Do Not operate the mower with the discharge deector up or removed; keep the discharge deector in place. 2. Cutting/dismem[...]

Safety 109-6035 Deck Drive Belt Routing 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. 109-6210 1. Read the Operator’s Manual. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt–stay away from moving parts. 109-6459 1. E[...]

Safety 109-9173 1. Parking brake 4. Neutral 2. Fast 5. Reverse 3. Slow 6. Machine Speed 109-9182 1. Machine speed 4. Neutral 2. Fast 5. Reverse 3. Slow 1 10-6691 1. Thrown objects hazard–keep bystanders a safe distance from the machine. 3. Cutting/dismemberment of hand or foot–stay away from moving parts. 2. Thrown objects hazard, mower–keep [...]

Safety 109-6016 1. Read the instructions before servicing or performing maintenance. 4. Refer to the Operator’s manual for grease instructions. 2. T ime interval 5. Check hydraulic oil level and refer to the Operator’s Manual for further instructions. 3. Check oil level. 6. Check tire pressure. 109-8965 1. W arning–read the Operator’s Manua[...]

Safety Battery Symbols Some or all of these symbols are on your battery . 1. Explosion hazard 5. Read the Operator’s Manual. 9. Flush eyes immediately with water and get medical help fast. 2. No re, open ames, or smoking 6. Keep bystanders a safe distance from the battery . 10. Contains lead; do not discard. 3. Caustic liquid/chemical burn [...]

Specications Specications Model Numbers Serial Nos: 720,000 and Higher QST22BE482; QST23K C482; QST23K C522; QST24BE522 Systems Engine • Engine Specications: See y our Engine Owner’ s Manual • RPM: Brig gs & Stratton: Full Speed: 3650 ±100 (max) RPM (No Load) Idle: 1650 (min) RPM Kohler Command: Full Speed: 3600 ±75 (max) RPM ([...]

Specications • Ar mrests: Standard–foam padded ip-up adjustable height ar mrests . • Seat Safety Switch: Incorporated into the Safety Interlock System. Hydrostatic Ground Drive System • Hydrostatic Pumps: T w o Hy dro Gear ZT2800 Integ rated dri ve systems . • Hydraulic Oil T ype: Use Mobil 1 15W -50 Synthetic motor oil. • Speeds:[...]

Product Overview T read Width: (Center to Center of Tires, W idthwise) 48 inch Deck 52 inch Deck Driv e Wheels 36.0 inches (91 cm) 36.8 inc hes (93 cm) Caster Wheels 33.5 inches (85 cm) 33.5 inc hes (85 cm) Wheel Base: (Center of Caster T ire to Center of Drive Tire) 48 inch Deck 52 inch Deck 48.9 inches (124 cm) 48.9 inches (124 cm) Curb Weight: 4[...]

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

Operation Parking Brake Lever Located on left side of the console (Figure 3). The brak e lev er engages a parking brake on the dri ve wheels . Pull the lev er up and rearward to engag e the brak e . Push the lev er forw ard and down to disengag e the brake . Height-of-Cut Foot Lever The height of cut lev er allo ws the operator to lo wer and raise [...]

Operation See inside bac k co ver to deter mine the appro ximate slope angle to be mow ed. Recommended Gasoline Use UNLEADED R egular Gasoline suitable for automotiv e use (87 pump octane minimum). Important: Nev er use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do N[...]

Operation Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the mac hine to provide the following benets: • Keeps gasoline fresh during storage of 30 da ys or less . F or longer storage it is recommended that the fuel tank be drained. • Cleans the engine while it runs. • Eliminates gum-lik e v arnish buildup in the fuel sys[...]

Operation Figure 7 1. Control panel 2. Blade control switch—Off position 3. Mov e the throttle lev er to midw ay and the chok e lever forward before starting a cold engine (Figure 8). Note: A warm or hot engine may not require choking . Figure 8 1. Control panel 4. Throttle—slow 2. Choke—on 5. Throttle—fast 3. Choke–off 4. T urn the ignit[...]

Operation Figure 10 1. Control panel 2. Blade control switch—On position 4. Mov e throttle to full forward position before mowing . Disengaging the Blades Set throttle to midwa y position. Push the blade control switch to Off to disengage the blades (Figure 11). Figure 1 1 1. Control panel 2. Blade control switch—Off position Stopping the Engin[...]

Operation T ry to start with operator in seat, parking brak e engaged , PTO engaged and motion control levers in the neutral lock position - starter must not crank . T ry to start with operator in seat, parking brak e engaged , PTO disengaged , and the left motion control lev er in , starter must not crank, repeat again with the right lev er in, th[...]

Operation Backward 1. Mov e the lev ers to the center , unlock ed position. 2. T o go bac kward, slowly pull the motion control levers rearw ard (Figure 12). T o go straight, apply equal pressure to both motion control lev ers (Figure 12). T o turn, release the pressure on the motion control lev er tow ard the direction you want to turn (Figure 12)[...]

Operation the predeter mined cut height by slowly decreasing foot pressure allowing the foot lev er to trav el rearward. Adjusting the Anti-Scalp Rollers It is recommended to change the anti-scalp roller position when the height of cut has c hang ed. 1. Stop the machine and mo ve the driv e lev ers to the neutral lock position. 2. Disengag e the PT[...]

Operation Figure 17 1. Bolt 3. Nut 2. Spring 4. Additional mounting holes Up to v e springs can be secured to the seat bo x with a n ut and bolt, see Figure 17. R efer to your P arts Manual for spring and hardw are part numbers . Adjusting the Motion Control Levers Adjusting the Height The motion control lev ers can be adjusted higher or low er [...]

Operation Figure 19 1. Front of the machine. 5. Lever position for pushing the machine 2. Rotate bypass release knob counterclockwise 6. Rotate bypass release knob clockwise 3. Lever position for operating the machine. 7. Release lever 4. Pull lever in this direction 4. Loosen the knob b y turning counterclockwise . Then pull the release lev er on [...]

Operation W ARNING Loading a unit on a trailer or truck increases the possibility of backw ard tip-ov er . Backw ard tip-o ver 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 indi vidual ramps for each side of the unit. • If individual ramps must be[...]

Operation Cutting Speed T o impro ve cut quality , use a slo wer g round speed. A void Cutting T oo Low If the cutting width of the mo wer is wider than the mow er y ou previously used, raise the cutting height to ensure that unev en turf is not cut too short. Long Grass If the g rass is ev er allow ed to g ro w slightly longer than nor mal, or if [...]

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 bystanders. Remo ve the k ey from the ignition s witch, engage parki[...]

Maintenance Important: Refer to y our Engine Operator’ s Manual for additional maintenance procedures. Premaintenance Procedures Raising the Seat Make sure the motion control lev ers are lock ed in the neutral position. Lift the seat forward until the lanyard is tight. The follo wing components can be accessed b y raising the seat: • Auxiliary [...]

Maintenance Figure 22 Located on the back of the seat. 1. Read the instructions before servicing or performing maintenance 4. Check oil level. 2. Grease idler pivots. 5. Check hydraulic oil level and refer to Operator ’ s manual for further instructions. 3. T ime interval. 6. Check tire pressure. 4. Connect a grease gun to eac h tting (Figure [...]

Maintenance Servicing Paper Element Service Interval: Every 25 hours (May need more often under extremely dusty or dirty conditions.) Every 100 hours/Y early (whichever comes rst)—Replace the air cleaner element. 1. R emov e the air cleaner co ver (Figure 23). 2. R emov e the air cleaner element with the integral r ubber seal. 3. Gently tap th[...]

Maintenance 3. Stop the engine , remo ve the key , and wait for all moving parts to stop before lea ving the operating position. 4. Clean the area around the drain plug and on the machine frame. Place a pan underneath mac hine directly belo w the drain hole in the frame as shown in Figure 26 and Figure 27. Figure 26 Briggs & Stratton engine 1. [...]

Maintenance Checking the Hydraulic Oil Level 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 29 1. Engine 2. Expansion tank Change the Hydraulic System Filter Service Interval: After the rst 200 hours Note: Use only MOBIL 1 15W -50 Synthetic mot[...]

Maintenance Servicing the Spark Plug Service Interval: Every 200 hours/Every 2 years (whichever comes rst) Every 500 hours—Replace the spark plug. As stated in the maintenance inter v als , remov e the spark plug, check condition, and reset the gap or replace with a new plug as necessar y . The spark plug is RFI compliant. Equiv alent alternat[...]

Maintenance Important: Operating the engine with a block ed grass screen, dir ty or plugged cooling ns, and/or cooling shrouds remov ed, will cause engine damage due to o verheating . Fuel System Maintenance Replacing the Fuel Filter Service Interval: Every 100 hours/Y early (whichever comes rst) DANGER In cer tain conditions, gasoline is ext[...]

Maintenance Charging the Battery Removing the Battery W ARNING Batter y ter minals or metal tools could short against metal machine components causing sparks. Sparks can cause the batter y gasses to explode, resulting in personal injur y . • When removing or installing the batter y , Do Not allow the batter y ter minals to touch an y metal par ts[...]

Maintenance V oltage Reading Percent Charge Maximum Charger Settings Charging Inter val 12.6 or g reater 100% 16 v olts/7 amps No Charging R equired 12.4 – 12.6 75–100% 16 volts/7 amps 30 Min utes 12.2 – 12.4 50–75% 16 v olts/7 amps 1 Hour 12.0–12.2 25–50% 14.4 volts/4 amps 2 Hours 11.7–12.0 0–25% 14.4 volts/4 amps 3 Hours 11.7 or l[...]

Maintenance 2. R emov e cov er as sho wn in Figure 36. 3. T o replace a fuse, pull out on the fuse to remo ve it Drive System Maintenance Checking the T ire Pressure Service Interval: Every 25 hours/Monthly (whichever comes rst) Maintain the air pressure in the front and rear tires as specied. Uneven tire pressure can cause unev en cut. Check[...]

Maintenance Figure 39 1. Blades front to rear 3. Measure here 2. Outside cutting edges 2. R otate the opposite ends of the blades forward. 3. Measure from a lev el 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 m ust not ex ceed 1/8 inc h (3 mm). If this d[...]

Maintenance Figure 41 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 42). If the blade sta ys 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 42). R epeat this procedure until the blade [...]

Maintenance 6. R oute the new belt around the engine pulley and mow er 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 cov ers ov er the outside spindles . Leveling the Mower Deck The mow er blades must be lev el from side to side . Check the side-to-side lev el a[...]

Maintenance 2. P ark the machine on a lev el surface and disengag e the blade control switc h. 3. Mov e the motion control levers outward to the neutral position, engag e the parking brake , stop the engine, remo ve the k ey , and wait for all moving parts to stop before lea ving the operating position. 4. Check the air pressure of all four tires .[...]

Maintenance Removing the Mower Deck 1. P ark the machine on a lev el surface and disengag e the blade control switc h 2. Mov e the motion control lev ers outw ard to the neutral position, engage parking brake , stop the engine, remov e the k ey , and w ait for all mo ving parts to stop before leaving the operating position. 3. Place blocks under de[...]

Maintenance Replacing the Discharge Deector DANGER An unco vered discharge opening could allo w the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injur y . Also, contact with the blade could occur . Never operate the la wn mow er unless y ou install a mulch plate, discharge deector , or grass[...]

Maintenance Cleaning W ashing the Underside of the Mower Service Interval: Before each use or daily After each use, w ash the underside of the mo wer to prevent grass buildup for improv ed m ulch action and clipping dispersal. 1. P ark the machine on a lev el surface and disengag e the blade control switc h. 2. Mov e the motion control lev ers outw[...]

Storage Storage Cleaning and Storage 1. Disengag e the blade control switc h, mov e the motion controls outw ard to the neutral position, engag e parking brak e, stop the engine, and remov e the key . 2. R emov e grass clippings , dirt, and grime from the external parts of the entire machine , especially the engine. Clean dirt and chaff from the ou[...]

T roubleshooting T roubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mow er use. When a problem occurs , Do Not o verlook the simple causes . F or example: starting problems could be caused by an empty fuel tank. The follo wing table lists some of the common causes [...]

T roubleshooting Problem Possible Cause Cor rectiv e Action 1. Engine load is ex cessiv e. 1. R educe the ground speed. 2. Air cleaner is dirty . 2. Clean or replace the air cleaner element. 3. Oil lev el in the crankcase is lo w . 3. Add oil to the crankcase . 4. Cooling ns and air passages for the engine are plug ged. 4. R emove the obstructio[...]

Schematics Schematics Electrical Diagram—Briggs & Stratton TERMINAL I TERMINAL S TERMINAL X TERMINAL Y TERMINAL B TERMINAL A 3. ST ART POSITION 1. OFF 2. RUN B + I + S CIRCUIT "MAKE" X + Y NONE B + I + A IGNITION SWITCH TERMINAL CONNECTIONS TERMINAL A  VOL T AGE REGULA T OR TERMINAL B BA TTER Y TERMINAL I  HOUR METER, PT O [...]

Schematics Electrical Diagram—Kohler Command TERMINAL I TERMINAL S TERMINAL X TERMINAL Y TERMINAL B TERMINAL A 3. ST ART POSITION 1. OFF 2. RUN B + I + S CIRCUIT "MAKE" X + Y NONE B + I + A IGNITION SWITCH TERMINAL CONNECTIONS TERMINAL A  VOL T A GE REGULAT OR TERMINAL B BA TTER Y TERMINAL I  HOUR METER, PTO SWITCH TERMINAL S ?[...]

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 manufactured by Exmark and found by us (in the ex ercise of our reasonable discretion) to b[...]

Notes: 53[...]

Service Record Date: Description of Work Done: Service Done By: 54[...]

55[...]

© 2007—200 8 Exmark M fg. Co., Inc. Part No. 45 00-338 Rev. A Industrial Park Box 808 (402) 223- 6300 Beatrice, N E 68310 Fax (402) 223-5489 All Rights R eserved Printed In USA.[...]