Exmark 850000 AND HIGHER manual

QUEST ® For Serial Nos. 850,000 & Higher Part No. 4500-523 Rev . B[...]

W ARNING CALIFORNIA Proposition 65 W ar ning The engine exhaust from this product contains chemicals kno wn 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) S[...]

Introduction R ead this infor mation carefully to learn how to operate and maintain your product properly and to av oid injur y and product damag e . Y ou are responsible for operating the product properly and safely . Exmark parts manuals are a v ailable online at http://www .exmark.com/man uals .htm. Y ou ma y contact Exmark directly at www .Exma[...]

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 b y the safety aler t symbol (Figure 2), whic h signals a hazard that may cause serious injur y or death if you do not follow the recommended precautions . Figure 2 1. Safety alert symbol This man ual uses tw o other words to highlight i[...]

Safety safely enough to protect themselv es and others from serious injur y . • Alwa ys follo w the recommendations for wheel weights or counterweights . Slope Operation Slopes are a major factor related to loss of control and tip-o ver accidents , which can result in sev ere injur y or death. Operation on all slopes requires extra caution. If yo[...]

Safety • Extinguish all cigarettes, cigars, pipes and other sources of ignition. • Use only an appro ved container . • Never remov e the gas 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 op[...]

Safety • Use only Exmark approved attac hments . W arranty may be voided if used with unapprov ed attachments . • If loading the machine onto a trailer or truck, use a single , full-width ramp only . T he ramp angle should not ex ceed 15 deg rees . Note: The left and right sides of the machine are deter mined while sitting in the seat in the no[...]

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.[...]

Safety 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 the discharge deector or collection system in place. 1 16-0531 1 16-0532 QST20BE422 Unit 1. Choke–on 2. Throttle–fast 3. Continuous variab[...]

Safety 1 17–2718 PTO Symbols 1. PTO—Of f 2. PTO—On 109-8965 1. W arning–read the Operator ’ s Manual. 5. T ipping 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 servic[...]

Safety 1 16-2321 1. Read the instructions before servicing or performing maintenance. 4. Check hydraulic oil level and refer to the Operator’s Manual for further instructions. 2. T ime interval 5. Check tire pressure. 3. Check oil level. 6. Refer to the Operator ’s manual for grease instructions. Battery Symbols Some or all of these symbols are[...]

Specications Specications Model Numbers Serial Nos: 850,000 and Higher QST20BE422; QST22BE482; QST24BE522; QST22BE482C; QST24BE522C Systems Engine • Engine Specications: See your Engine Owner’ s Manual • RPM: – 20HP Full Speed: 3300 ±100 (max) RPM (No Load) Idle: 1650 (min) RPM – 22HP & 24HP Full Speed: 3650 ±100 (max) RPM [...]

Specications • Ar mrests: Standard–foam padded ip-up adjustable height ar mrests (optional on the 42 inch unit). • Seat Safety Switc h: Incorporated into the Safety Interlock System. Hydrostatic Ground Drive System • Hydrostatic Pumps: T w o Hydro Gear ZT2800 Integ rated dri ve systems . • Hydraulic Oil T ype: Exmark Premium Hy dro [...]

Product Overview Overall Height: All Units 41.8 inc hes (106 cm) T read W idth: (Center to Center of Tires, W idthwise) 42 inch Deck 48 inch Deck 52 inch Deck Driv e Wheels 36.0 inches (91 cm) 36.0 inches (91 cm) 36.8 inches (93 cm) Caster Wheels 27.9 inches (71 cm) 33.5 inches (85 cm) 33.5 inches (85 cm) Wheel Base: (Center of Caster T ire to Cent[...]

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

Operation Parking Brake Lever Located on left side of the console (Figure 3). The brake lev er engag es a parking brak e on the driv e wheels . Pull the lev er up and rearward to engag e the brake . Push the lever forw ard and do wn to diseng age the brake . Height-of-Cut Foot Lever The height of cut lev er allo ws the operator to low er and raise [...]

Operation Important: Nev er use methanol, gasoline containing methanol, gasohol containing more than 10% ethanol, premium gasoline, or white gas because the fuel system could be damaged. Do Not mix oil with gasoline. DANGER In cer tain conditions gasoline is extremel y ammable and v apors are explosi v e. A re or explosion from gasoline can b[...]

Operation Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the mac hine to provide the follo wing 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 r uns . • Eliminates gum-like v ar nish buildup in the fuel [...]

Operation Figure 7 1. Throttle/Choke lever 5. Run 2. Blade control switch—Off position 6. Start 3. Ignition key 7. Choke 4. Off 8. Throttle–fast (detent position) 3. Mov e the lev er forw ard, bey ond the detent, to engag e the c hoke before starting a cold engine (Figure 7). Note: A w ar m or hot engine may not require choking . 4. T urn the i[...]

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

Operation Forward 1. Mov e the lev ers to the center , unloc ked position. 2. T o go forw ard, slo wly push the motion control levers forw ard ( Figure 9). Figure 9 1. Neutral position 3. Backward 2. Center unlock position 4. Forward T o go straight, apply equal pressure to both motion control lev ers (Figure 9). T o turn, pull bac k on the motion [...]

Operation Adjusting the Anti-Scalp Rollers It is recommended to change the anti-scalp roller position when the height of cut has c hanged. 1. Stop the mac hine and mo ve the driv e lev ers to the neutral loc k position. 2. Disengag e the PTO . 3. Engag e the park brak e. 4. Stop the engine , remov e the key and wait for all moving parts to stop . 5[...]

Operation Figure 13 1. Bolt 3. Nut 2. Spring 4. Additional mounting holes Up to v e springs can be secured to the seat box with a nut and bolt, see Figure 13. R efer to y our P arts Manual for spring and hardw are part n umbers . Adjusting the Motion Control Levers Adjusting the Height The motion control lev ers can be adjusted higher or low er [...]

Operation Figure 15 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 by turning countercloc kwise. Then pull the release lev er on t[...]

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 b[...]

Operation Long Grass If the grass is ever allo wed 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 mac hine’ s forward motion must be stopped while mowing[...]

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 starting of the engine could seriously injure y ou or other bystander s. Remo ve the key from the ignition s witch, engage parkin[...]

Maintenance Maintenance Ser vice Inter v al Maintenance Procedure Before storage • Charge the batter y and disconnect the battery cables . • P erform all maintenance procedures before storag e . • P aint any chipped surfaces . Monthly • Check the battery c harge. Important: R efer to y our Engine Operator’ s Man ual for additional mainten[...]

Maintenance Engine Maintenance Servicing the Air Cleaner Service Interval: Every 25 hours/Monthly (whichever comes rst) (May need more often under extremely dusty or dirty conditions.) Every 100 hours/Y early (whichever comes rst)—Replace the paper element. (More often under extremely dusty , dirty conditions.) This engine is equipped with [...]

Maintenance Figure 19 1. Oil dipstick 3. Oil level 2. Filler tube 5. R emov e the dipstick and c heck the oil lev el. The oil lev el should be up to , but not ov er , the “F” mark on the dipstic k. 6. If the lev el is low , add oil of the proper type , up to the “F” mark on the dipstic k. Alw ays c heck the level with the dipstic k before a[...]

Maintenance in-lb) torque . Wipe up any excess oil on the frame (Figure 20 ). Note: Dispose of the used oil at a recycling center . 9. Apply a thin lm of clean oil to the rubber gasket on the new lter . 10. Install the replacement oil lter to the mounting pad. T ur n the oil lter cloc kwise until the r ubber gasket contacts the pad, the[...]

Maintenance Figure 23 1. Oil lter 3. Left rear tire 2. V ent plug 6. Raise the rear of machine up and support with jack stands (or equiv alent suppor t) just high enough to allow driv e wheels to tur n freely . CAUTION Raising the mower f or ser vice or maintenance relying solely on mechanical or hy draulic jacks could be dangerous. The mechanic[...]

Maintenance Figure 24 1. Spark plug and wire location Checking the Spark Plug 1. Look at the center of the spark plug (Figure 25). If y ou see light bro wn or g ra y 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 t[...]

Maintenance Figure 26 1. Fuel tank 6. Hose clamps 2. Fuel shut off valve—off 7. Fuel line to engine 3. Fuel shut of f valve 8. Filter 4. Fuel shut off valve—on 9. Flow direction arrow 5. Fuel line from tank 4. T urn fuel shut off v alv e 90° to “off ” position. 5. Squeeze the ends of the hose clamps tog ether and slide them aw ay from the [...]

Maintenance CAUTION If the ignition is in the “ON” position there is potential for sparks and engagement of components. Sparks could cause an explosion or moving par ts could accidentally engage causing personal injur y Be sure ignition s witch is in the “OFF” position before charging the batter y . 1. P ark the machine on a level surface a[...]

Maintenance V oltage Reading Percent Charge Maximum Charger Settings Charging Inter v al 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 v olts/4 amps 2 Hours 11.7–12.0 0–25% 14.4 volts/4 amps 3 Hours 11.7 or less 0% 14.4 volts/2 amps 6 Hours or More Recommended Jump S[...]

Maintenance 4. Connect the other end of the positi ve cable to the positiv e ter minal of the booster batter y . 5. Connect the black neg ati v e (–) cable to the other ter minal (negativ e) of the booster batter y . 6. MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE ST ALLED VEHICLE (NOT TO THE NEGATIVE POST) A W A Y FR OM THE B A TTER Y . [...]

Maintenance Figure 30 1. V alve 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 . T earing and shredding turns grass brown at the edges, which slo ws growth and increases t[...]

Maintenance Figure 33 42 Inch Deck 1. Blades front to rear 2. Measure here 2. R otate the opposite ends of the blades forward. 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1. The difference betw een the dimensions obtained in steps 1 and 3 must not exceed 1/8 inch (3 mm). If this dimension ex cee[...]

Maintenance Figure 35 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer ( Figure 36). 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 36). R epeat this procedure until the blade [...]

Maintenance Figure 37 48 and 52 Inch Decks 1. Outside puley 4. Mower belt 2. Spring 5. Engine pulley 3. Idler pulley 6. Pull belt strands in this direction. Figure 38 42 Inch Deck 1. Outside puley 4. Mower belt 2. Spring 5. Engine pulley 3. Idler pulley 6. Pull belt strands in this direction. 6. R oute the new belt around the mow er pulleys . 7. Gr[...]

Maintenance 6. Set anti-scalp rollers to top holes or remo ve completely for this adjustment. 7. Set the height-of-cut lev er to the 3 inc h (76 mm) position. Place tw o “B” thick blocks (see Bloc k Height and Rake T able) under the rear edg e of the cutting dec k skir t; one on eac h side of the cutting deck. Place tw o “ A ” thick bloc ks[...]

Maintenance 9. Measure from the tip of the front blade to the at surface and the tip of the rear blade to the at surface (Figure 42 and Figure 43). If the front blade tip is not “R” (see Block Height and Rake T able in Lev eling the Mow er Deck ) low er than the rear blade tip , adjust the front deck hanger . Figure 42 48 and 52 Inch Deck[...]

Maintenance through the front discharge deector brack et, discharge deector , and rear deector brack et. 5. Make sure that the spring and rod are installed so that the rod is retained from sliding out by the front brack et and the spring holds the discharge deector in the do wn position. R efer to ( Figure 44) for proper orientation. Im[...]

Maintenance 6. If adjustment is necessar y , loosen the jam n ut from the yok e on the side that needs adjustment. R emov e the hairpin and clevis pin (see Figure 46). Figure 46 1. Hairpin 3. Y oke 2. Clevis pin 4. Jam nut • Adjusting the Brake to Eng age: Shor ten the linkage by tur ning the y oke clockwise . • Adjusting the Brake to Disengag [...]

Maintenance Note: If the mower is not clean after one washing, soak it and let it stand for 30 minutes . Then repeat the process . 8. R un the mo wer again for one to three minutes to remo v e ex cess water . W ARNING A brok en or missing w ashout tting could expose y ou and others to thrown objects or blade contact. Contact with blade or thrown[...]

Storage Storage Cleaning and Storage 1. Disengag e the blade control switch, mov e the motion controls outward 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 g rime from the external parts of the entire mac hine, especially the engine. Clean dirt and c haff from the o[...]

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 ov erlook the simple causes . F or example: star ting problems could be caused by 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. R educe the ground speed. 2. Air cleaner is dir ty . 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 obstructi[...]

Schematics Schematics Electrical Diagram FUEL SOLENOID BRAKE SWITCH RH MOTION CONTROL LH MOTION CONTROL STARTER LOCKOUT & KILL RELAY START SOLENOID GROUND START SOLENOID SIGNAL START SOLENOID B+ PTO CLUTCH GROUND ALTERNATOR OIL SWITCH HOUR METER ACCESSORIES FUSE BLOCK IGNITION SWITCH SEAT SWITCH PTO SWITCH ORANGE ORANGE Y S X A B ORANGE PINK PI[...]

Schematics Electrical Logic Schematic ST ART SOLENOID B+ ST ART SOLENOID GROUND SHOWN WITH CONTROL LEVERS IN NEUTRAL LOCK POSITION (HANDLES OUT) SHOWN WITH BRAKE DISENGAGED TERMINAL I TERMINAL A TERMINAL R TERMINAL B TERMINAL S GROUND GROUND - HOUR METER + 25 20 15 4 3 6 5 8 7 S R B A I ST ART RUN OFF B + R + I + A NONE CIRCUIT "MAKE" 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 on these products and found by us (in the exercise of our reasonable discretion) to be defe[...]

Notes: 55[...]

Notes: 56[...]

Service Record Date: Description of W ork Done: Service Done By: 57[...]

58[...]

59[...]

MID-MOUNT RIDING A CCESSORIES AND OPTIONS SEE EXMARK’S COMPLETE LINE OF 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 T OR CONTROLLED[...]