Exmark Quest Lawn Mower Operator's Manual
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Exmark Quest Lawn Mower Operator's Manual

Exmark mfg. co. inc. lawn mower operator manual
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QUEST
®
For Serial Nos.
720,000 & Higher
Part No. 4500-338 Rev. A

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Summary of Contents for Exmark Quest Lawn Mower

  • Page 1 QUEST ® For Serial Nos. 720,000 & Higher Part No. 4500-338 Rev. A...
  • Page 2 SAE J1940. As configured to meet safety, emission, and operating requirements, the actual engine horsepower on this class of lawn mower will be significantly lower. © 2007–2008—Exmark Mfg. Co., Inc. Industrial Park Box 808 Beatrice, NE 68310 Contact us at www.Exmark.com.

  • 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 Introduction ... 3 Safety ... 5 Safety Alert Symbol ... 5 Safe Operating Practices ... 5 Safety and Instructional Decals ... 8 Specifications ... 13 Model Numbers ... 13 Systems ... 13 Dimensions... 14 Torque Requirements ... 15 Product Overview ... 15 Operation ...

  • Page 5: Safety

    Safety Safety Alert Symbol This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Figure 2 1.

  • Page 6: Slope Operation

    Towing • Use for towing only if equipped with an Exmark hitch kit. Do Not attach towed equipment except at the hitch point. • Follow Exmark’s recommendation for weight limits for towed equipment and towing on slopes.
  • Page 7 Adjust and service as required. • Maintain or replace safety and instruction decals as necessary. • Use only genuine Exmark replacement parts to ensure that original standards are maintained. Exmark Riding Mower Safety The following list contains safety information specific...

  • Page 8: 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–Do Not operate 2. Cutting/dismemberment the mower with the hazard of hand or foot, discharge deflector up mower blade–stay away...
  • Page 9 109-6035 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.
  • Page 10 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 110-6691 1. Thrown objects 3. Cutting/dismemberment hazard–keep bystanders a safe distance from the machine.
  • Page 11 1. Read the instructions before servicing or performing maintenance. 2. Time interval 3. Check oil level. 1. Warning–read the Operator’s Manual. 2. Read the instructions before servicing or performing maintenance; apply parking brake, remove the ignition key and disconnect the spark plug wire. 3.
  • Page 12 Safety Some or all of these symbols are on your battery. 1. Explosion hazard 2. No fire, open flames, or smoking 3. Caustic liquid/chemical burn hazard 4. Wear eye protection Battery Symbols 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery.

  • Page 13: Specifications

    Specifications Model Numbers Serial Nos: 720,000 and Higher QST22BE482; QST23KC482; QST23KC522; QST24BE522 Systems Engine • Engine Specifications: See your Engine Owner’s Manual • RPM: Briggs & Stratton: Full Speed: 3650 ±100 (max) RPM (No Load) Idle: 1650 (min) RPM Kohler Command: Full Speed: 3600 ±75 (max) RPM (No Load) Idle: 1750 (min) RPM Fuel System •...

  • Page 14: Dimensions

    Specifications • Armrests: Standard–foam padded flip-up adjustable height armrests. • Seat Safety Switch: Incorporated into the Safety Interlock System. Hydrostatic Ground Drive System • Hydrostatic Pumps: Two Hydro Gear ZT2800 Integrated drive systems. • Hydraulic Oil Type: Use Mobil 1 15W-50 Synthetic motor oil.

  • Page 15: Torque Requirements

    Tread Width: (Center to Center of Tires, Widthwise) 48 inch Deck Drive Wheels 36.0 inches (91 cm) Caster Wheels 33.5 inches (85 cm) Wheel Base: (Center of Caster Tire to Center of Drive Tire) 48 inch Deck 52 inch Deck 48.9 inches (124 cm) 48.9 inches (124 cm) Curb Weight:...

  • Page 16: Operation

    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 machine. Ignition Switch Located on control panel. The ignition switch is used to start and stop the engine.

  • Page 17: Operating Instructions

    Parking Brake Lever Located on left side of the console (Figure 3). The brake lever engages a parking brake on the drive wheels. Pull the lever up and rearward to engage the brake. Push the lever forward and down to disengage the brake.

  • Page 18: Recommended Gasoline

    Operation See inside back cover to determine the approximate slope angle to be mowed. Recommended Gasoline Use UNLEADED Regular Gasoline suitable for automotive use (87 pump octane minimum). Important: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged.

  • Page 19: Checking The Engine Oil Level

    Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • Keeps gasoline fresh during storage of 30 days or less. For longer storage it is recommended that the fuel tank be drained. • Cleans the engine while it runs. •...

  • Page 20: Operating The Blades

    Operation Figure 7 1. Control panel 2. Blade control switch—Off position 3. Move the throttle lever to midway and the choke lever forward before starting a cold engine (Figure 8). Note: A warm or hot engine may not require choking. Figure 8 1.

  • Page 21: Stopping The Engine

    Figure 10 1. Control panel 2. Blade control switch—On position 4. Move throttle to full forward position before mowing. Disengaging the Blades Set throttle to midway position. Push the blade control switch to Off to disengage the blades (Figure 11). Figure 11 1.

  • Page 22: Driving Forward Or Backward

    - engine must initiate shutdown whether operator is on seat or not. Note: If machine does not pass any of these tests, do not operate. Contact your authorized EXMARK SERVICE DEALER. Important: It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing.

  • Page 23: Stopping The Machine

    Backward 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion control levers rearward (Figure 12). To go straight, apply equal pressure to both motion control levers (Figure 12). To turn, release the pressure on the motion control lever toward the direction you want to turn (Figure 12).

  • Page 24: Adjusting The Anti-Scalp Rollers

    Operation the predetermined cut height by slowly decreasing foot pressure allowing the foot lever to travel rearward. Adjusting the Anti-Scalp Rollers It is recommended to change the anti-scalp roller position when the height of cut has changed. 1. Stop the machine and move the drive levers to the neutral lock position.

  • Page 25: Adjusting The Motion Control Levers

    Figure 17 1. Bolt 3. Nut 2. Spring 4. Additional mounting holes Up to five springs can be secured to the seat box with a nut and bolt, see Figure 17. Refer to your Parts Manual for spring and hardware part numbers.

  • Page 26: Side Discharge

    Operation Figure 19 1. Front of the machine. 5. Lever position for pushing the machine 2. Rotate bypass release 6. Rotate bypass release knob counterclockwise knob clockwise 3. Lever position for 7. Release lever operating the machine. 4. Pull lever in this direction 4.

  • Page 27: Operating Tips

    WARNING Loading a unit on a trailer or truck increases the possibility of backward tip-over. Backward tip-over could cause serious injury 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.

  • Page 28: Cutting Speed

    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 29: Maintenance

    Maintenance Note: Determine the left and right sides of the machine from the normal operating position. While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders. Remove the key from the ignition switch, engage parking brake, and pull the wire(s) off the spark plug(s) before you do any maintenance.

  • Page 30: Premaintenance Procedures

    Maintenance Important: Refer to your Engine Operator’s Manual for additional maintenance procedures. Premaintenance Procedures Raising the Seat Make sure the motion control levers are locked in the neutral position. Lift the seat forward until the lanyard is tight. The following components can be accessed by raising the seat: •...

  • Page 31: Engine Maintenance

    Figure 22 Located on the back of the seat. 1. Read the instructions 4. Check oil level. before servicing or performing maintenance 2. Grease idler pivots. 5. Check hydraulic oil level and refer to Operator’s manual for further instructions. 3. Time interval. 6.

  • Page 32: Servicing The Engine Oil

    Maintenance Servicing Paper Element Service Interval: Every 25 hours (May need more often under extremely dusty or dirty conditions.) Every 100 hours/Yearly (whichever comes first)—Replace the air cleaner element. 1. Remove the air cleaner cover (Figure 23). 2. Remove the air cleaner element with the integral rubber seal.
  • Page 33 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Clean the area around the drain plug and on the machine frame. Place a pan underneath machine directly below the drain hole in the frame as shown in Figure 26 and Figure 27.

  • Page 34: Checking The Hydraulic Oil Level

    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 first 200 hours Note: Use only MOBIL 1 15W-50 Synthetic motor...

  • Page 35: Servicing The Spark Plug

    Servicing the Spark Plug Service Interval: Every 200 hours/Every 2 years (whichever comes first) Every 500 hours—Replace the spark plug. As stated in the maintenance intervals, remove the spark plug, check condition, and reset the gap or replace with a new plug as necessary. The spark plug is RFI compliant.

  • Page 36: Fuel System Maintenance

    Maintenance Important: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will cause engine damage due to overheating. Fuel System Maintenance Replacing the Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) DANGER In certain conditions, gasoline is extremely flammable and highly explosive.

  • Page 37: Charging The Battery

    Charging the Battery Removing the Battery WARNING Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, Do Not allow the battery terminals to touch any metal parts of the machine.

  • Page 38: Installing Battery

    Maintenance Voltage Percent Maximum Reading Charge Charger Settings 12.6 or 100% 16 volts/7 greater amps 12.4 – 12.6 75–100% 16 volts/7 amps 12.2 – 12.4 50–75% 16 volts/7 amps 12.0–12.2 25–50% 14.4 volts/4 amps 11.7–12.0 0–25% 14.4 volts/4 amps 11.7 or less 14.4 volts/2 amps 4.

  • Page 39: Drive System Maintenance

    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 40: Sharpening Blades

    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 conformance of the machine, use genuine Exmark replacement blades. Replacement blades made by other manufacturers may result in an unsafe machine.

  • Page 41: Mower Belt Maintenance

    Incorrect installation of the blade or components used to retain the blade cause the blade to come loose and could seriously injure or kill you or bystanders. Always install the original Exmark blades, washers and blade bolts as shown. Mower Belt Maintenance Inspecting the Belts...

  • Page 42: Leveling The Mower Deck

    Maintenance 6. Route the new belt around the engine pulley and mower 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 covers over the outside spindles. Leveling the Mower Deck The mower blades must be level from side to side.
  • Page 43 2. Park the machine on a level surface and disengage the blade control switch. 3. Move the motion control levers outward to the neutral position, engage the parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

  • Page 44: Removing The Mower Deck

    Maintenance Removing the Mower Deck 1. Park the machine on a level surface and disengage the blade control switch 2. Move the motion control levers outward to the neutral position, engage parking brake, stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

  • Page 45: Replacing The Discharge Deflector

    Replacing the Discharge Deflector DANGER An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur. Never operate the lawn mower unless you install a mulch plate, discharge deflector, or grass collection system.

  • Page 46: Cleaning

    Maintenance Cleaning Washing the Underside of the Mower Service Interval: Before each use or daily After each use, wash the underside of the mower to prevent grass buildup for improved mulch action and clipping dispersal. 1. Park the machine on a level surface and disengage the blade control switch.

  • Page 47: Storage

    Storage Cleaning and Storage 1. Disengage the blade control switch, move the motion controls outward to the neutral position, engage parking brake, stop the engine, and remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine.

  • Page 48: 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 49 Problem Engine loses power The machine does not drive. Abnormal vibration Uneven cutting height. Blades do not rotate. Possible Cause 1. Engine load is excessive. 2. Air cleaner is dirty. 3. Oil level in the crankcase is low. 4. Cooling fins and air passages for the engine are plugged.

  • Page 50: Schematics

    Schematics Schematics Electrical Diagram—Briggs & Stratton BROWN BROWN GREEN DARK GREEN DARK ORANGE VIOLET ORANGE VIOLET VIOLET ORANGE ORANGE BLUE DARK PINK PINK PINK PINK ORANGE VILOET PINK PINK BROWN BROWN GRAY ENGINE G007525 BROWN GREEN DARK BLUE DARK GREEN DARK GREEN DARK...
  • Page 51 Electrical Diagram—Kohler Command ENGINE BROWN BROWN GREEN DARK GREEN DARK ORANGE VIOLET ORANGE VIOLET VIOLET ORANGE ORANGE BLUE DARK PINK PINK PINK PINK ORANGE VILOET PINK PINK BROWN BROWN GRAY Schematics BROWN GREEN DARK BLUE BLUE DARK BLUE DARK GREEN DARK GREEN DARK...
  • Page 52 Exmark and found by us (in the exercise of our reasonable discretion) to be defective in factory materials or workmanship for a period of three years for residential usage** of Exmark Quest mowers.
  • Page 53 Notes:...

  • Page 54: Service Record

    Service Record Date: Description of Work Done: Service Done By:...
  • Page 56 © 2007—2008 Exmark Mfg. Co., Inc. Industrial Park Box 808 Beatrice, NE 68310 All Rights Reserved Part No. 4500-338 Rev. A (402) 223-6300 Fax (402) 223-5489 Printed In USA.

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