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Exmark QUEST Operator's Manual

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

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Summary of Contents for Exmark QUEST

  • Page 1 QUEST™ For Serial Nos. 312,000,000 & Higher Part No. 4501-191 Rev. A...
  • Page 2 Removing standard original equipment parts and accessories may alter the warranty, traction, and safety of the machine. Failure to use original Exmark parts could cause serious injury or death. Making unauthorized changes to the engine or fuel system, may violate EPA and CARB regulations.

  • Page 3: Introduction

    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.

  • Page 4: Table Of Contents

    Contents Changing the Hydraulic System Filter and Oil..............40 Mower Maintenance ........42 Introduction ............3 Servicing the Cutting Blades ......42 Safety ..............5 Leveling the Mower Deck .......45 Safety Alert Symbol ......... 5 Mower Belt Maintenance ........48 Safe Operating Practices ........5 Replacing the Discharge Deflector ....50 Safety and Instructional Decals .......

  • Page 5: Safety

    Safety 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 This manual identifies potential hazards and has blade.

  • Page 6: Slope Operation

    • Avoid sudden starts when mowing uphill because Towing the mower may tip backwards. • Use for towing only if equipped with an Exmark • Be aware that operating on wet grass, across steep hitch kit. Do Not attach towed equipment except slopes or downhill may cause the mower to lose at the hitch point.
  • Page 7 • Use only genuine Exmark replacement parts to • Never fill containers inside a vehicle or on a ensure that original standards are maintained.
  • Page 8 Safety • 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.

  • Page 9: Safety And Instructional Decals

    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—don't operate the mower with the deflector up or removed;...
  • Page 10 Safety 110-6691 119-8814 1. Thrown object hazard—keep bystanders a safe distance 1. Parking position 4. Neutral from the machine. 2. Fast 5. Reverse 2. Thrown object hazard, mower—do not operate without 3. Slow the deflector, discharge cover, or grass collection system in place.
  • Page 11 Safety PTO Switch Symbols 1. PTO–disengage 2. PTO–engage 119-8871 42 Inch Model 1. Height-of-cut 121-2989 42 Inch Model 1. Bypass lever position for 2. Bypass lever position for pushing the machine operating the machine...
  • Page 12 Safety 116-4220 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...
  • Page 13 Safety 120-2239 1. Warning—read the Operator's Manual. 5. Warning—do not use split ramps, use a full ramps when transporting machine. 2. Warning—read the instructions before servicing or 6. Loss of traction/control hazard, slopes—loss of performing maintenance; move the motion control levers traction/control on a slope, disengage the blade control to the park (brake) position, remove the ignition key and switch (PTO), proceed off the slope slowly.

  • Page 14: Specifications

    Manual • PTO must be disengaged, motion control levers out (brake engaged) to start engine. (It is not • Engine Oil Type: Exmark 4-Cycle Premium necessary for the operator to be in the seat to Engine Oil start the engine.) •...

  • Page 15: Dimensions

    Blades are driven by one belt ZT2800 Integrated drive systems. (w/self-tensioning idler) direct from the engine. • Hydraulic Oil Type: Exmark Premium Hydro Oil. • Deck: Full floating deck is attached to out-front • Speeds: support frame. Maximum turf protection is –...

  • Page 16: Torque Requirements

    Product Overview Overall Height: Product Overview All Units 41.5 inches (105 cm) Tread Width: (Center to Center of Tires, Widthwise) 42 inch Deck 50 inch Deck Drive Wheels 31.5 inches 37.4 inches (80 cm) (95 cm) Caster Wheels 29.5 inches 36.9 inches (75 cm) (94 cm)

  • Page 17: Operation

    Operation Operation Blade Control Switch (Power Take-Off) Controls Located on the control panel. The blade control switch, represented by a power Note: Become familiar with all of the controls in take-off (PTO) symbol, engages and disengages Figure 3 and Figure 4 before you start the engine and power to the mower blades (see Figure 4).

  • Page 18: Operating Instructions

    Operation Pull the lever inward and rearward to raise the cutting DANGER deck. Allow the handle to move forward to lower the Mowing on wet grass or steep slopes can cause cutting deck. Move the deck height adjustment lever sliding and loss of control. Wheels dropping outward at the desired height-of-cut.

  • Page 19: Recommended Gasoline

    Operation Recommended Gasoline DANGER In certain conditions during fueling, static Fill fuel tank on level ground. See Fuel electricity can be released causing a spark which Recommendations in the Specifications section for can ignite gasoline vapors. A fire or explosion additional gasoline information.

  • Page 20: Checking The Engine Oil Level

    Operation 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. Filling the Fuel Tank Make sure the engine is shut off and the motion controls are in the park position.

  • Page 21: Operating The Blades

    Operation 2. Move the throttle midway to the Fast position. Note: Always engage the blades with the throttle in the midway position. 3. Pull out on the blade control switch, to the On position, to engage the blades (Figure 9). Figure 8 1.

  • Page 22: The Safety Interlock System

    • Do not tamper with the interlock switches. Note: If machine does not pass any of these tests, Do Not operate. Contact your authorized EXMARK • Check the operation of the interlock switches SERVICE DEALER. daily and replace any damaged switches before operating the machine.
  • Page 23 Operation Figure 10 Figure 11 1. Parking brake position 4. Forward (engaged) 2. Center unlock position 5. Backward (neutral) To turn, pull back on the motion control 3. Front of unit lever toward the direction you want to turn (Figure 10 and Figure 11). To go straight, apply equal pressure to both The farther you move the motion control levers motion control levers (Figure 10 and Figure 11).

  • Page 24: Stopping The Machine

    Operation adjustment lever inward and pulling up. The height can also be adjusted by moving the deck height adjustment lever inward and pushing the height-of-cut foot lever forward (Figure 13). The transport lever will automatically engage and will drop into place. Figure 12 Figure 13 To go straight, apply equal pressure to both...

  • Page 25: Positioning The Seat

    Operation the positions shown in Figure 15. Rollers will 1. Tip the seat forward. maintain 3/4 inches (19 mm) clearance to the 2. Loosen the adjustment bolts. ground to minimize gouging and roller wear or damage. Note: For Maximum Deck Flotation, place the rollers one hole position lower.

  • Page 26: Changing The Seat Ride Suspension

    Operation 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.

  • Page 27: Side Discharge

    Operation Side Discharge 2. Move the motion control levers outward to park position, stop the engine, and wait for all moving The mower has a hinged discharge deflector that parts to stop before leaving the operating position. disperses clippings to the side and down toward the 3.

  • Page 28: Operating Tips

    Operation Operating Tips WARNING Loading a unit on a trailer or truck increases Fast Throttle Setting the possibility of backward tip-over. Backward tip-over could cause serious injury or death. For best mowing and maximum air circulation, operate the engine at the Fast position. Air is required •...
  • Page 29 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.

  • Page 30: Maintenance

    Accidental starting of the engine could seriously and safety of the machine. Failure to use original injure you or other bystanders. Exmark parts could cause serious injury or death. Making unauthorized changes to the Remove the key from the ignition switch, engage...

  • Page 31: Premaintenance Procedures

    Maintenance Maintenance Service Maintenance Procedure Interval • Charge the battery and disconnect the battery cables. • Perform all maintenance procedures listed above before storage. Before storage • Paint any chipped surfaces. Monthly • Check the battery charge. • Inspect the emissions filter. Yearly Important: Refer to your Engine Operator's Manual for additional maintenance procedures.

  • Page 32: Engine Maintenance

    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 excess grease. Figure 23 Engine Maintenance 1.
  • Page 33 6. If the level is low, wipe off the area around the oil fill cap, remove cap and add oil to the “FULL” mark on the dipstick. Exmark 4-Cycle Premium Engine Oil is recommended; refer to the Engine Figure 25 Owner's manual for an acceptable alternative.

  • Page 34: Servicing The Spark Plug

    The spark plug is most accessible when the blower center. housing is removed for cleaning. 10. Apply a thin film of clean Exmark 4-Cycle 3. Remove the spark plug and metal washer. Premium Engine Oil to the rubber gasket on the new filter.

  • Page 35: Cleaning The Blower Housing

    Maintenance Cleaning the Blower Housing 3. The fuel filter is in the fuel line between the tank and engine. 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.

  • Page 36: Electrical System Maintenance

    Maintenance Electrical System DANGER Maintenance Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns. Swallowing electrolyte can be fatal or if it touches WARNING skin can cause severe burns. CALIFORNIA • Wear safety glasses to shield eyes, and rubber Proposition 65 Warning gloves to protect skin and clothing when Battery posts, terminals, and related...
  • Page 37 Maintenance 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.

  • Page 38: Installing The Battery

    Maintenance DANGER Jump starting a weak battery that is cracked, frozen, has low electrolyte level, or an open/shorted battery cell, can cause an explosion resulting in serious personal injury. Do Not jump start a weak battery if these conditions exist. 2.

  • Page 39: Drive System Maintenance

    Maintenance Servicing the Fuses Front Tires (caster wheels): • Ribbed: 13 psi (90 kPa) Service Interval: As required • Smooth: 20 psi (138 kPa) 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.

  • Page 40: Changing The Hydraulic System Filter And Oil

    Maintenance Check expansion reservoir and if necessary add 20W-50 engine oil to the FULL COLD line. Figure 35 1. Jacking points 3. Remove the nuts holding the transaxle support in place (Figure 36). Figure 34 1. Expansion reservoir 3. Engine 2.
  • Page 41 Maintenance Installing the Hydraulic System Filters Figure 37 Right side shown 1. Transaxle drive 4. Screws 2. Oil filter 5. Vent plug 3. Filter guard 5. Carefully clean area around filters. It is important that no dirt or contamination enter hydraulic system.

  • Page 42: Mower Maintenance

    If a blade is damaged or in irreparable damage to the transaxle drive worn, replace it immediately with a genuine Exmark system. replacement blade. For convenient sharpening and replacement, you may want to keep extra blades on Bleeding the Hydraulic System hand.
  • Page 43 Maintenance Figure 39 1. Cutting edge 3. Wear/slot forming Figure 41 2. Curved area 4. Damage 1. Blade, in position for measuring 2. Level surface Checking for Bent Blades 3. Measured distance between blade and surface (A) Note: The machine must be on a level surface for 4.
  • Page 44 To ensure optimum performance and continued safety WARNING conformance of the machine, use genuine Exmark replacement blades. Replacement blades made by A worn or damaged blade can break, and a other manufacturers may result in an unsafe machine.

  • Page 45: Leveling The Mower Deck

    42 Inch Decks injure or kill you or bystanders. 1. Blades side to side 3. Outside cutting edges Always install the original Exmark blades, 2. Sail area of blade 4. Measure from the tip washers and blade bolts as shown.
  • Page 46 Maintenance Figure 48 50 Inch Decks Figure 49 1. Hanger bracket 4. Side locking nut 1. Blades side to side 3. Outside cutting edges 2. Slotted adjustment 5. Side carriage bolt 2. Sail area of blade 4. Measure from the tip position of the blade to the flat surface here...
  • Page 47 Maintenance the new position (Figure 50). Tighten the rear locking nut on the hanger bracket. 10. Continue leveling the deck by checking the front-to-rear blade slope; refer to Adjusting the Front-to-Rear Blade Slope. Adjusting the Front-to-Rear Blade Slope Figure 52 Check the front-to-rear blade level any time you install 50 Inch Decks the mower.

  • Page 48: Mower Belt Maintenance

    Maintenance blade tip is 1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip (Figure 51 and Figure 52). 9. When the front-to-rear blade slope is correct check the side-to-side level of the mower again; refer to Leveling the Mower from Side-to-Side. Removing the Mower Service Interval: As required 1.
  • Page 49 Maintenance 3. Set the height-of-cut at the lowest cutting position [1-1/2 inch (38 mm)]. 4. Using a spring removal tool, (P/N. 92-5771), remove the idler spring from the deck hook to remove tension on the idler pulley and roll the belt off of the pulleys (Figure 56 and Figure 57).

  • Page 50: Replacing The Discharge Deflector

    Maintenance 6. Attach the front support rod to the mower deck 4. Replace the discharge deflector. with the clevis pin and hairpin cotter (Figure 54). 5. Slide rod, straight end, through the rear 7. Install the mower belt onto the engine pulley; discharge deflector bracket.
  • Page 51 Maintenance Figure 60 1. Rod and spring 3. Rod, short end, moved assembly installed behind mower bracket 2. Loop end of the spring 4. Short end, retained by installed into the notch in mower bracket. the deflector bracket 5. Secure the rod and spring assembly by twisting it so the short end of the rod can be placed behind the front bracket welded to the deck (Figure 60).

  • Page 52: Cleaning

    Maintenance Cleaning 6. Disengage the blade control switch, stop the engine, and remove the ignition key. Wait for all moving parts to stop. Washing the Underside of 7. Turn the water off and remove the coupling from the Mower the washout fitting. Note: If the mower is not clean after one Service Interval: Before each use or washing, soak it and let it stand for 30 minutes.

  • Page 53: Storage

    Storage Storage Stop the engine, allow it to cool, and drain the fuel tank; refer to Draining the Fuel Tank in the Fuel System Maintenance section. Cleaning and Storage Restart the engine and run it until it stops. 1. Disengage the blade control switch, move the Choke the engine.

  • Page 54: Troubleshooting

    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.
  • Page 55 Troubleshooting Problem Possible Cause Corrective Action Engine loses power 1. Engine load is excessive. 1. Reduce the ground speed. 2. Air cleaner is dirty. 2. Clean or replace the air cleaner element. 3. Oil level in the crankcase is low. 3.

  • Page 56: Schematics

    Schematics Schematics Electrical Diagram...
  • Page 57 Schematics Electrical Logic Schematic...
  • Page 58 To locate a dealer convenient to you, access our website at discretion) to be defective in factory materials or workmanship for a www.exmark.com. U.S. or Canada customers may also call period of three years for residential usage of Exmark Quest turf 402-223-6375. equipment.
  • Page 59 Notes:...
  • Page 60 Notes:...

  • Page 61: Service Record

    Service Record Date: Description of Work Done: Service Done By:...
  • Page 63 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.
  • Page 64 Pack) or Fill in Below Engine Model No. and Spec. No. Model No. Engine Serial No. (E/No) Serial No. ©2011 Exmark Mfg. Co., Inc. Part No. 4501-191 Rev. A Industrial Park Box 808 Printed in the USA Beatrice, NE 68310 All Rights Reserved www.exmark.com...

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