Exmark QUEST 408 Operator's Manual
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Exmark QUEST 408 Operator's Manual

Exmark QUEST 408 Operator's Manual

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QUEST
®
For Serial Nos.
408,644,346 & Higher
Part No. 4505-333 Rev. A

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Summary of Contents for Exmark QUEST 408

  • Page 1 QUEST ® For Serial Nos. 408,644,346 & Higher Part No. 4505-333 Rev. A...
  • Page 2 To acquire a spark arrester for your unit, see your Engine Service Dealer. For all models that do not have Exmark engines, please refer to the engine manufacturer's information included with the machine. For models with Exmark engines, refer to this manual for information.

  • Page 3: Introduction

    All Exmark parts are thoroughly tested and inspected before leaving the factory, however, attention is required on your part if you are to obtain the fullest measure of satisfaction and performance.

  • Page 4: Table Of Contents

    Maintenance Safety..........34 Recommended Maintenance Schedule(s) ....35 Periodic Maintenance ........35 Lubrication.............36 Engine Safety ..........36 Engine Maintenance........36 Servicing an Exmark Engine......37 Servicing a Kohler Engine ......42 Cleaning the Blower Housing......47 Fuel System Maintenance .......47 Electrical System Maintenance......47 Charging the Battery........47 Drive System Maintenance ......50 Checking the Tire Pressure ......50...

  • Page 5: Safety

    Safety Safety General Safety This machine is capable of amputating hands and This machine has been designed in conformance feet and of throwing objects. Always follow all safety with the American National Standards Institute instructions to avoid serious personal injury or death. B71.1 for Consumer Turf Care Equipment–Safety •...

  • Page 6: 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. decal93-7009 93-7009 1. Warning—don't operate the mower with the deflector up or removed;...
  • Page 7 4. Check the tire pressure decal131-1097 131-1097 every 25 operating every 25 operating hours. hours. Exmark 708cc Engine Only 2. Engine oil 5. Read the Operator's Manual before 1. Oil drain performing maintenance. 3. Check the tire pressure every 25 operating hours.
  • Page 8 Safety decal139-2394 139-2394 1. Traction controls 4. Neutral 2. Fast 5. Reverse 3. Slow 6. Parking brake decal139-2395 decal139-5892 139-2395 139-5892 1. Parking brake 4. Neutral For Models with 54 Inch Deck 2. Fast 5. Reverse 1. Height of cut 3.
  • Page 9 Safety decal142-5861 decal142-5862 142-5861 142-5862 Models without Hour Meter Models with Hour Meter 1. Fast 4. Choke–Off 1. Fast 3. Choke–On 2. Slow 5. Optional hour meter 2. Slow 4. Choke–Off accessory 3. Choke–On decal142-5864 142-5864 decalptosymbols PTO Switch Symbols 1.
  • Page 10 Safety decal142-5846 142-5846 This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. It is important that each operator review the slope operation instructions in the operator’s manual and review the conditions in which the machine is being operated to determine if the machine may be operated in the conditions that day and on that site.

  • Page 11: Specifications

    – 54 inch S-Series model: Two Hydro Gear • PTO must be disengaged and motion control ZT2200 Integrated drive systems. levers moved to the outward position to engage the parking brake to start engine. (It is not • Hydraulic Oil Type: Exmark Premium Hydro Oil.
  • Page 12 Specifications • Speeds: – 50 inch Deck: 50 inches (127 cm) – 0-7.0 mph (11.3 km/hr) forward. – 54 inch Deck: 54 inches (138 cm) – 0-5.0 mph (8.0 km/hr) reverse. • Discharge: Side • Drive wheel releases, located on left and right •...

  • Page 13: Dimensions

    Specifications Dimensions 50 inch Deck 54 inch Deck Drive Wheels 34.8 inches 36.9 inches Overall Width: (88 cm) (94 cm) Caster Wheels 30.5 inches 35.8 inches E-Series (78 cm) (91 cm) 34 inch 42 inch 50 inch Deck Deck Deck Wheel Base: (Center of Caster Tire to Without 35.6 inches...

  • Page 14: Product Overview

    Operation Product Overview Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Become familiar with all the controls before starting the engine and operating the machine. Ignition Switch Located on control panel. The ignition switch is used to start and stop the engine.
  • Page 15 Operation the machine to prevent someone from accidentally starting the engine. Blade Control Switch (Power Take-Off) Located on control panel. The blade control switch, represented by a power take-off (PTO) symbol, engages and disengages power to the mower blades (see Figure 4). Pull up on the blade control switch to “ON”...

  • Page 16: Before Operation

    Only use accessories and attachments approved by Exmark. Fuel Window • Inspect the area where the machine is to be used Located on the left side of the machine (see Figure 7).
  • Page 17 If proper working condition. Replace worn or fuel is spilled, Do Not attempt to start the deteriorated parts with genuine Exmark parts engine. Move away from the area of the spill when necessary.

  • Page 18: Operating Instructions

    Operation the tank allows gasoline to expand. Overfilling Overfilling may result in fuel leakage or damage may result in fuel leakage or damage to the engine to the engine or emission system. or emission system. Shut the engine off, move the motion controls •...
  • Page 19 Operation that causes distractions; otherwise, injury or property is absolutely necessary. Always look down and damage may occur. behind you before moving the machine in reverse. • Park the machine on level ground. Stop engine, WARNING wait for all moving parts to stop, and remove key. Operating engine parts, especially the muffler, –...
  • Page 20 Operation injury or death. The operator is responsible for safe slope operation. Operating the machine on any slope requires extra caution. Before using the machine on a slope, the operator must: – Review and understand the slope instructions in the manual and on the machine. –...

  • Page 21: Checking The Engine Oil Level

    Operation Checking the Engine Oil warms. If the engine stalls or hesitates, slightly move the control forward for a few seconds. Level Before you start the engine and use the machine, Operating the Blades check the oil level in the engine crankcase; refer to Checking the Oil Level in Engine Maintenance The blade control switch, represented by a power section.
  • Page 22 Operation Move the motion control levers to the center T-slot position and then outward to engage the parking brake. Disengage the blade control switch. Place the throttle in the “FAST” position. Allow the engine to run for a minimum of 15 seconds, then turn the ignition switch to the “OFF”...

  • Page 23: The Safety Interlock System

    Operation The Safety Interlock System Understanding the Safety Interlock System CAUTION The safety interlock system is designed to prevent the If the safety interlock switches are disconnected engine from starting unless: or damaged the machine could operate • The blades are disengaged. unexpectedly causing personal injury.
  • Page 24 Operation Check Engine Starting Circuit Chart Note: In the Check Engine Starting Circuit Chart, the state of system item that is bold is being checked in each scenario. System Parking Brake Motion Control Levers Operator Outcome (Blades) Engaged (Both Disengaged Either right or left lever moved in Operator Starter must...
  • Page 25 Operation Check Shutdown Circuit Chart Note: The state of system item(s) that is bold is being checked in each scenario. System Engine Parking Brake PTO (Blades) Operator Outcome Disengaged Disengaged Raise off of seat Engine must begin Running idle (1/3 (Both motion (but don’t get off) shutdown within 1...

  • Page 26: Driving Forward Or Backward

    Operation Driving Forward or Backward The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the Fast position for best performance. Always operate in the Fast (full throttle) position. CAUTION Machine can spin very rapidly by positioning one lever too much ahead of the other.

  • Page 27: Stopping The Machine

    Operation CAUTION Children or bystanders may be injured if they move or attempt to operate the mower while it is unattended. Always disengage the blade control switch, move the motion control levers outward to engage the parking brake, and remove the key when leaving the machine unattended, even if just for a few minutes.

  • Page 28: Positioning The Seat

    Operation Move the seat to the desired position and tighten bolts. Tip the seat back to the closed position. • S-Series Units: Push the adjustment lever towards the center of the machine to release the seat adjuster track (Figure 18). g015168 Figure 16 For cutting heights above 3 1/2 inches (90 mm) use the...

  • Page 29: Adjusting The Motion Control Levers

    Operation Move the control lever to the next set of holes. Secure the lever with the hardware. Repeat the adjustment for the opposite control lever. Adjusting the Tilt The motion control levers can be tilted fore or aft for maximum operator comfort. Loosen the upper bolt holding the control lever to the control arm shaft.

  • Page 30: Pushing The Machine By Hand

    Operation Turn the ignition key “ON” but Do Not start the engine. Move one motion control lever inward to release the parking brake. The machine is now able to be pushed by hand. g294926 Figure 21 g333974 Figure 22 1. Bolt 1.

  • Page 31: After Operation

    Operation • Lock the brake and block the wheels. DANGER • Be sure the fuel shut-off valve is closed. Without the discharge deflector, mulch kit, or • Securely fasten the machine to the trailer or truck entire grass collection system mounted in place, with straps, chains, cable, or ropes.
  • Page 32 Operation Important: Do not use narrow individual ramps for each side of the machine. Ensure the ramp is long enough so that the angle with the ground does not exceed 15 degrees (Figure 24). On flat ground, this requires a ramp to be at least four times (4X) as long as the height of the trailer or truck bed to the ground.

  • Page 33: Operating Tips

    Exmark replacement grass grows at different rates at different times. blade. Only Exmark blades are to be used with this So to maintain the same cutting height, which is a unit. No other blades are approved.

  • Page 34: Maintenance

    • Carefully release pressure from components with to the original equipment or failure to use stored energy original Exmark parts could lead to serious injury or death. Unauthorized changes to the • Keep your hands and feet away from moving machine, engine, fuel or venting system, may parts or hot surfaces.

  • Page 35: Recommended Maintenance Schedule(S)

    • Clean the grass and debris build-up from the machine and cutting deck. • Clean the engine and exhaust system area. • Grease all lubrication points. • Clean the air cleaner foam element (more often in dusty, dirty conditions)(Exmark engine). Every 25 hours • Check the tire pressure.

  • Page 36: Lubrication

    Service Interval: Every 25 hours/Monthly (whichever comes first) Important: If you are using a machine with an Exmark engine above 5,000 ft (1500 m) for a Grease Type: NLGI grade #2 multi-purpose gun continuous period, ensure that the High Altitude grease.

  • Page 37: Servicing An Exmark Engine

    Maintenance Servicing an Exmark Engine and remove key. Wait for all moving parts to stop before leaving the operator’s position. Clean around the air cleaner cover to prevent dirt Servicing the Air Cleaner–Exmark from getting into the engine and causing damage.
  • Page 38 Replace the paper element if it is damaged or cannot be cleaned thoroughly. To learn more about the Exmark twin-cylinder engine go to https://exmark.com/engines or scan the QR code. g028322...
  • Page 39 Service Interval: After the first 5 hours Every 100 hours (change it more often under a heavy load or in high temperatures)(Exmark Engine). Park the machine so that the drain side is slightly lower than the opposite side to ensure the oil drains completely.
  • Page 40 Checking the Engine Oil Level section. g029570 Figure 35 Change the engine oil filter. Apply a thin film of clean Exmark 4-Cycle Premium Engine Oil to the rubber gasket on the new filter.
  • Page 41 The spark plug is most accessible when the blower housing is removed for cleaning. Installing the Spark Plug–Exmark g027484 Figure 37 Engine Install the spark plug. Make sure that the air gap Check the oil level;...

  • Page 42: Servicing A Kohler Engine

    Maintenance Checking the Spark Plug Park machine on level ground, move the motion control levers out to engage the parking brake, Inspect the spark plug disengage the blade control switch, stop engine, Note: If you see light brown or gray on the and remove key.
  • Page 43 Park machine on level ground, move the motion fill cap, remove cap/dipstick and add oil to the control levers out to engage the parking brake, “FULL” mark on the dipstick. Exmark 4-Cycle disengage the blade control switch, stop engine, Premium Engine Oil is recommended; refer to and remove key.
  • Page 44 Change the engine oil filter. Apply a thin film of drains completely. clean Exmark 4-Cycle Premium Engine Oil to the rubber gasket on the new filter. Start the engine and let it run until warm. This warms the oil so it drains better.
  • Page 45 Maintenance g194610 Figure 47 g027477 Figure 46 Check the oil level; refer to Checking the Engine Oil Level section. Note: Ensure the oil filter gasket touches the Start the engine and check for leaks. engine, then an extra 3/4 turn is completed. Servicing the Spark Plug Note: Dispose of the used oil at a recycling center.
  • Page 46 The spark plug is most accessible when the blower housing is removed for cleaning. Inspect the spark plug Note: If you see light brown or gray on the Installing the Spark Plug–Exmark insulator, the engine is operating properly. A Engine black coating on the insulator usually means the Install the spark plug.

  • Page 47: Cleaning The Blower Housing

    Maintenance Cleaning the Blower Housing Squeeze the ends of the hose clamps together and slide them away from the filter. 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 48 Maintenance DANGER Charging or jump starting the battery may produce explosive gases. Battery gases can explode causing serious injury. • Keep sparks, flames, or cigarettes away from battery. • Ventilate when charging or using battery in an enclosed space. • Make sure venting path of battery is always open once battery is filled with acid.
  • Page 49 Maintenance Note: To prevent damage due to freezing, DANGER battery should be fully charged before putting Jump starting a weak battery that is cracked, away for winter storage. frozen, has low electrolyte level, or an Check the voltage of the battery with a digital open/shorted battery cell, can cause an voltmeter.

  • Page 50: Drive System Maintenance

    Maintenance Servicing the Fuses Service Interval: As required 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. Fuse: • Main F1-25 amp, blade-type • Charge Circuit F2-15 amp, blade-type g012785 Figure 53 Flip up the seat to access the main wiring harness...

  • Page 51: Releasing The Electric Brake

    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. For convenient sharpening and replacement, you may want to keep extra blades on hand.
  • Page 52 3. Measured distance between blade and surface (A) to exceed 1/8 inch (3mm), the blade spindle could be bent. Contact an Authorized Exmark Rotate the same blade 180 degrees so that the Dealer for service.
  • Page 53 The blades must be replaced if a solid object is hit, if the blade is out of balance, or the blade is bent. To ensure optimum performance and continued safety g007201 conformance of the machine, use genuine Exmark Figure 64 replacement blades. Replacement blades made by 1. Blade 2.

  • Page 54: 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 55 Maintenance Check the side-to-side adjustments again. Repeat this procedure until the measurements are correct. Continue leveling the deck by checking the front-to-rear blade slope; refer to Adjusting the Front-to-Rear Blade Slope section. Adjusting the Front-to-Rear Blade Slope Check the front-to-rear blade level any time you install the mower.
  • Page 56 Maintenance To raise the front of the mower, tighten the adjustment nut. To lower the front of the mower, loosen the adjustment nut. After adjustment, check the front-to-rear slope again. Continue adjusting the nut until the front blade tip is 1/16-5/16 inch (1.6-7.9 mm) lower than the rear blade tip (Figure 69 and Figure 70).
  • Page 57 Maintenance g295768 Figure 73 1. Lift arm 3. Washer 2. Hairpin cotter g014635 Figure 72 1. Front support rod 3. Deck bracket Remove the lift arm from the deck pin. 2. Locking nut Repeat steps B and C for the other side of the machine.

  • Page 58: Mower Belt Maintenance

    Maintenance At all four corners of the deck, remove the Slide the mower deck under the machine. hairpin cotter and washer from the deck Lower the height of cut lever to the lowest position. Install the mower belt onto the engine pulley; refer to Replacing the Mower Belt.

  • Page 59: Replacing The Discharge Deflector

    Maintenance Set the height of cut at the lowest cutting position Route the new belt around the engine pulley and [1 1/2 inch (38 mm)]. mower pulleys. Remove the hairpin cotter and push in the tab on Using a spring removal tool, (P/N 92-5771), the cover to remove the pulley covers.
  • Page 60 Maintenance for all moving parts to stop before leaving the operating position. Remove the nut (3/8 inch) from the rod under the mower (Figure 79). g296957 Figure 79 g332166 1. Mower deck 5. Rod Figure 78 2. Short standoff 6. Spring 1.

  • Page 61: Cleaning

    Maintenance Cleaning wash the machine. Avoid excessive use of water, especially near the control panel, under the seat, around the engine, hydraulic pumps, Cleaning and Storing Safety and motors. • Park machine on level ground, move the motion Clean Engine and Exhaust control levers out to engage the parking brake, disengage drives, stop engine, and remove key.
  • Page 62 Maintenance Battery Disposal DANGER Battery electrolyte contains sulfuric acid, which is poisonous and can cause severe burns. Swallowing electrolyte can be fatal or if it touches skin can cause severe burns. • Wear safety glasses to shield eyes, and rubber gloves to protect skin and clothing when handling electrolyte.

  • Page 63: 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 64 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 65: Schematics

    Schematics Schematics Electrical Logic Schematic g330623...

  • Page 66: Information

    While the exposure from Exmark products may be negligible or well within the “no significant risk” range, out of an abundance of caution, Exmark has elected to provide the Prop 65 warnings. Moreover, if Exmark does not provide these warnings, it could be sued by the State of California or by...
  • Page 67 Notes:...
  • Page 68 Notes:...
  • Page 69 Service Record Date: Description of Work Done: Service Done By:...
  • Page 71 g011841 Figure 80 This page may be copied for personal use. 1. The maximum slope you can 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 72 Pack) or Fill in Below Engine Model No. and Spec. No. Model No. Engine Serial No. (E/No) Serial No. ©2020 Exmark Mfg. Co., Inc. Part No. 4505-333 Rev. A 415 Industrial Row (402) 223-6375 Beatrice, NE 68310 Fax (402) 223-5489...

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