Exmark QUEST Operator's Manual
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Exmark QUEST Operator's Manual

Exmark QUEST Operator's Manual

For serial nos. 920,000 & higher
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QUEST
™
For Serial Nos.
920,000 & Higher
Part No. 4500-895 Rev. A

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Summary of Contents for Exmark QUEST

  • Page 1 QUEST ™ For Serial Nos. 920,000 & Higher Part No. 4500-895 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 Leveling the Mower Deck ......43 Mower Belt Maintenance ....... 46 Replacing the Discharge Deflector ....47 Introduction ............3 Cleaning ............48 Safety ..............5 Washing the Underside of the Mower ..... 48 Safety Alert Symbol ......... 5 Clean Engine and Exhaust System Safe Operating Practices ........

  • 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 120-5465 1. Bypass lever position for 2. Bypass lever position for pushing the machine operating the machine PTO Switch Symbols 1. PTO–disengage 2. PTO–engage 119-8871 42 Inch Model 1. Height-of-cut 116-4769 50 Inch Model 1. Fast 3. Slow 2. Continuous variable setting 4.
  • Page 12 Safety 120-5462 42 Inch Model 1. Fast 3. Slow 2. Continuous variable setting 4. Choke 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.
  • Page 13 Safety Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 9. Flush eyes immediately with water 5. Read the Operator’s Manual. and get medical help fast. 2. No fire, open flames, or smoking 6. Keep bystanders a safe distance 10.

  • Page 14: Specifications

    Integrated drive systems. or motion control levers are moved in or engine – 50 inch unit: Two Hydro Gear ZT2200 will stop. Integrated drive systems. Operator Controls • Hydraulic Oil Type: Exmark Premium Hydro Oil. • Steering and Motion Control: • Speeds:...

  • Page 15: Dimensions

    Specifications – 0-7.0 mph (11.3 km/hr) forward. – 50 inch Deck: 4.0 inches (10.2 cm) – 0-5.0 mph (8.0 km/hr) reverse. • Cutting Height Adjustment: A hand deck lift lever with foot assist is used to adjust the cutting • Drive wheel releases, located on left and right height from 1 1/2 inch (3.8 cm) to 4 1/2 inches sides of engine deck, allow machine to be moved (11.4 cm) in 1/2 inch (1.3 cm) increments.

  • Page 16: Torque Requirements

    Product Overview Curb Weight: Product Overview 42 inch Deck 50 inch Deck 531 lb (241 kg) 614 lb (279 kg) Torque Requirements Bolt Location Torque Spindle Pulley Nut 35-65 ft-lb (47-88 N-m) Blade Mounting Bolt 35-65 ft-lb (47-88 N-m) Engine Mounting Bolts 330-400 in-lb (37-45 N-m) Wheel Lug Nuts 70-90 ft-lb (95-122 N-m)

  • 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 Operation Important: Never use methanol, gasoline DANGER containing methanol, gasohol containing more In certain conditions during fueling, static than 10% ethanol, premium gasoline, or white electricity can be released causing a spark which gas because the fuel system could be damaged. can ignite gasoline vapors.

  • 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. Gasoline/Alcohol blends Gasohol (up to 10 percent ethyl alcohol, 90 percent unleaded gasoline by volume) is approved for fuel use by the engine manufacturer.

  • Page 21: Operating The Blades

    Operation 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. Ignition key 5. Throttle lever 2. Off 6.

  • 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 lever 3. Front of unit toward the direction you want to turn (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 3. Raise the seat to locate the bypass levers behind DANGER the battery, on the frame. Without the discharge deflector, mulch kit, or 4. To disengage the wheel motors, move the bypass entire grass collection system mounted in place, levers forward and then out to lock them in place you and others are exposed to blade contact and as shown in Figure 20.

  • 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 • Check the battery charge. Monthly Yearly • Inspect the emissions filter. Important: Refer to your Engine Operator’s Manual for additional maintenance procedures. Premaintenance Periodic Maintenance Procedures Lubrication Raising the Seat Greasing the Bearings Make sure the motion control levers are locked in the Service Interval: Every 25 hours/Monthly park position.

  • 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 Figure 25 Engine Oil is recommended; refer to the Engine 1.

  • Page 34: Servicing The Spark Plug

    Maintenance 10. Apply a thin film of clean Exmark 4-Cycle is usually the most effective method for cleaning. Premium Engine Oil to the rubber gasket on the The spark plug is most accessible when the new filter. blower housing is removed for cleaning.

  • 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 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 Figure 34 replacement blade. For convenient sharpening and 1.
  • Page 41 1/8 inch (3mm), the blade spindle 5. Measure from the tip of the blade to the flat could be bent. Contact an Authorized Exmark surface here. The variance should be no more Dealer for service.
  • Page 42 To Repeat this procedure until the blade is balanced. 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.

  • Page 43: Leveling The Mower Deck

    Maintenance Leveling the Mower Deck Check to ensure the mower deck is level any time you install the mower or when you see an uneven cut on your lawn. The mower deck must be checked for bent blades prior to leveling; any bent blades must be removed and replaced.
  • Page 44 Maintenance Figure 45 42 Inch Decks 1. Blades front to rear 2. Measure from the tip of the blade to the flat surface here Figure 44 1. Hanger bracket 3. Side locking nut 2. Rear locking nut 4. Adjustment notches 9.
  • Page 45 Maintenance Figure 47 1. Adjusting rod 3. Lock nut 2. Adjusting block Figure 48 7. To raise the front of the mower, tighten the adjustment nut. To lower the front of the mower, 1. Front support rod 3. Deck bracket loosen the adjustment nut.

  • Page 46: Mower Belt Maintenance

    Maintenance Note: Retain all parts for future installation. Mower Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours/Monthly (whichever comes first) Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. Replacing the Mower Belt 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.

  • Page 47: Replacing The Discharge Deflector

    Maintenance 5. Route the new belt around the engine pulley and mower pulleys (Figure 51). 6. Using a spring removal tool, (P/N 92-5771), install the idler spring over the deck hook and placing tension on the idler pulley and mower belt (Figure 50 and Figure 51).

  • Page 48: 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 49: 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 50: 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 51 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 52: Schematics

    Schematics Schematics Electrical Diagram...
  • Page 53 Schematics Electrical Logic Schematic...
  • Page 54 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 55 Notes:...
  • Page 56 Notes:...

  • Page 57: Service Record

    Service Record Date: Description of Work Done: Service Done By:...
  • Page 59 Figure 54 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 60 SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS MID-MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM (ROPS) DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT...

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