QUEST ® For Serial Nos. 850,000 & Higher Part No. 4500-523 Rev.
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: The engine in this product is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code (CPRC) Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC 4126.
Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. Exmark parts manuals are available online at http://www.exmark.com/manuals.htm. You may contact Exmark directly at www.Exmark.com for product and accessory information or help finding a dealer.
Contents Checking the Tire Pressure ............................ 39 Mower Maintenance ...................................... 40 Servicing the Cutting Blades .......................... 40 Mower Belt Maintenance ............................... 42 Leveling the Mower Deck .............................. 43 Adjusting the Blade Slope .............................. 44 Replacing the Discharge Deflector ................. 45 Adjustments ..................................................... 46 Tracking Adjustment ....
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 blade. 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.
Safety Children safely enough to protect themselves and others from serious injury. • Always follow the recommendations for wheel weights or counterweights. Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. • Keep children out of the mowing area and under the watchful care of another responsible adult, not the operator.
Safety • Extinguish all cigarettes, cigars, pipes and other sources of ignition. • Use only an approved container. • Never remove the gas cap or add fuel when the engine is running. Allow the engine to cool before refueling. • Never refuel the machine indoors. • Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace. • Never fill containers inside a vehicle or on a truck or trailer with a plastic liner.
Safety • 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. The ramp angle should not exceed 15 degrees.
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 or removed; keep the from moving parts. discharge deflector in place. 109-6008 1. Read the Operator’s Manual. 2.
Safety 109-9120 1. Fuse 109-6035 Deck Drive Belt Routing 2. Diode 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. 109-9173 1. Parking brake 2. Fast 3. Slow 4. Neutral 5. Reverse 6. Machine Speed 109-6210 1. Read the Operator’s Manual. 2. Cutting/dismemberment hazard, fan and entanglement hazard, belt–stay away from moving parts. 109-9182 1. Machine speed 2. Fast 3. Slow 109-6459 1.
Safety 110-6691 1. Thrown objects hazard–keep bystanders a safe distance from the machine. 2. Thrown objects hazard, mower–keep the discharge deflector or collection system in place. 3. Cutting/dismemberment of hand or foot–stay away from moving parts. 116-0532 QST20BE422 Unit 1. 2. 3. 4.
Safety 117–2718 PTO Symbols 1. PTO—Off 2. PTO—On 109-8965 5. Tipping 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 servicing or performing 6. Cutting/dismemberment hazard of hand or foot, mower maintenance; apply parking brake, remove the ignition key blade–stay away from moving parts. and disconnect the spark plug wire. 3.
Safety 116-2321 1. Read the instructions before servicing or performing maintenance. 2. Time interval 3. Check oil level. 4. Check hydraulic oil level and refer to the Operator’s Manual for further instructions. 5. Check tire pressure. 6. Refer to the Operator’s manual for grease instructions. Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 5. Read the Operator’s Manual. 2. No fire, open flames, or smoking 6. Keep bystanders a safe distance from the battery. 7.
Specifications Specifications Model Numbers Serial Nos: 850,000 and Higher QST20BE422; QST22BE482; QST24BE522; QST22BE482C; QST24BE522C Systems engine. (It is not necessary for the operator to be in the seat to start the engine.) Engine • Operator must be in seat when PTO is engaged, brake is disengaged, or motion control levers are moved in or engine will stop.
Specifications • Armrests: Standard–foam padded flip-up adjustable height armrests (optional on the 42 inch unit). • Blade Size: (3 ea.) – 42 inch Deck: 21.25 inches (53.9 cm) – 48 inch Deck: 16.25 inches (41.3 cm) • Seat Safety Switch: Incorporated into the Safety Interlock System. – 52 inch Deck: 18.00 inches (45.7 cm) • Blade Spindles: Solid steel spindles with no maintenance bearings. Hydrostatic Ground Drive System • Hydrostatic Pumps: Two Hydro Gear ZT2800 Integrated drive systems.
Product Overview Overall Height: Product Overview All Units 41.8 inches (106 cm) Tread Width: (Center to Center of Tires, Widthwise) 42 inch Deck 48 inch Deck 52 inch Deck Drive 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 Tire to Center of Drive Tire) Figure 3 All Units 1. 2. 3. 4. 5. 6. 7. 48.
Operation Operation Blade Control Switch (Power Take-Off) Controls Located on the control panel. Note: Become familiar with all of the controls in Figure 3 and Figure 4 before you start the engine and operate the machine. The blade control switch, represented by a power take-off (PTO) symbol, engages and disengages power to the mower blades (see Figure 4). Ignition Switch Pull out on the blade control switch to “On” to engage the blades. Located on control panel.
Operation Parking Brake Lever DANGER Located on left side of the console (Figure 3). Mowing on wet grass or steep slopes can cause sliding and loss of control. Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning. A loss of traction is a loss of steering control. The brake lever engages a parking brake on the drive wheels. Pull the lever up and rearward to engage the brake.
Operation Important: Never 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 certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage.
Operation 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. • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Add the correct amount of gas stabilizer/conditioner to the gas.
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 8). Figure 7 1. Throttle/Choke lever 2. Blade control switch—Off position 3. Ignition key 4. Off 5. Run 6. Start 7. Choke 8. Throttle–fast (detent position) Figure 8 1. Throttle–Midway position 3.
Operation The Safety Interlock System Try to start with operator in seat, parking brake engaged, PTO disengaged, and the left motion control lever in, starter must not crank, repeat again with the right lever in, then with both levers in - starter must not crank. CAUTION If the safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. • Do not tamper with the interlock switches.
Operation Forward Stopping the Machine 1. Move the levers to the center, unlocked position. 2. To go forward, slowly push the motion control levers forward (Figure 9). To stop the machine, move the motion control levers to neutral and outward to the neutral position, disengage the blade control switch, move the throttle lever to between Fast and half throttle, and turn the ignition key to off. Remember to remove the key from the ignition switch.
Operation Adjusting the Anti-Scalp Rollers • 48 and 52 Inch Units: 1. Push the adjustment lever towards the center of the machine to release the seat adjuster track (Figure 12). 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. 2. Disengage the PTO. 3. Engage the park brake. 4. Stop the engine, remove the key and wait for all moving parts to stop. 5.
Operation 2. Move the control lever to the next set of holes. Secure the lever with the hardware. 3. 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. 1. Loosen the upper bolt holding the control lever to the control arm shaft. Figure 13 1. Bolt 2. Spring 2. Loosen the lower bolt just enough to pivot the control lever fore or aft (Figure 14).
Operation DANGER Without the discharge deflector, mulch kit, or entire grass collection system mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Never remove the discharge deflector from the mower because the discharge deflector routes material down toward the turf. If the discharge deflector is ever damaged, replace it immediately. • Never put your hands or feet under the mower.
Operation 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. • If individual ramps must be used, use enough ramps to create an unbroken ramp surface wider than the unit.
Operation Long Grass If the grass is ever allowed 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 machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.
Maintenance Maintenance Note: Determine the left and right sides of the machine from the normal operating position. WARNING WARNING While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders. Removing standard original equipment parts, or using non-Exmark replacement parts and accessories may alter the warranty, traction, and safety of the machine.
Maintenance Maintenance Service Interval Before storage Monthly Maintenance Procedure • Charge the battery and disconnect the battery cables. • Perform all maintenance procedures before storage. • Paint any chipped surfaces. • Check the battery charge. Important: Refer to your Engine Operator’s Manual for additional maintenance procedures.
Maintenance Engine Maintenance Servicing Paper Element Service Interval: Every 25 hours/Monthly (whichever comes first) (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 18). 2. Remove the air cleaner element with the integral rubber seal. 3. Remove the foam sleeve from the element. 4. Gently tap the pleated side of the paper element to dislodge dirt.
Maintenance 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 20. Figure 19 1. Oil dipstick 2. Filler tube 3. Oil level 5. Remove the dipstick and check the oil level. The oil level should be up to, but not over, the “F” mark on the dipstick. 6.
Maintenance Change the Hydraulic System Filter in-lb) torque. Wipe up any excess oil on the frame (Figure 20 ). Note: Dispose of the used oil at a recycling center. Service Interval: After the first 100 hours Every 500 hours thereafter (Every 250 hours if using Mobil 1 15W50) 9. Apply a thin film of clean oil to the rubber gasket on the new filter. 10. Install the replacement oil filter to the mounting pad.
Maintenance 6 times). Check the oil level, and add oil as required after stopping the engine. C. It may be necessary to repeat steps A and B until all the air is completely purged from the system. When the transaxle operates at normal noise levels and moves smoothly forward and reverse at normal speeds, then the transaxle is considered purged. Do Not change hydraulic system oil (except for what can be drained when changing filter), unless it is felt the oil has been contaminated or been extremely hot.
Maintenance Cleaning the Blower Housing 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. 1. Remove the blower housing and any other cooling shrouds. 2. Clean the cooling fins and external surfaces as necessary. 3. Make sure the cooling shrouds are reinstalled Figure 24 1.
Maintenance 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. • Do Not allow metal tools to short between the battery terminals and metal parts of the machine. Figure 26 1. 2. 3. 4. 5.
Maintenance CAUTION WARNING If the ignition is in the “ON” position there is potential for sparks and engagement of components. Sparks could cause an explosion or moving parts could accidentally engage causing personal injury Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Maintenance Voltage Reading Percent Charge Maximum Charger Settings Charging Interval 12.4 – 12.6 75–100% 16 volts/7 amps 30 Minutes 12.2 – 12.4 50–75% 16 volts/7 amps 1 Hour 12.0–12.2 25–50% 14.4 volts/4 2 Hours amps 11.7–12.0 0–25% 14.4 volts/4 3 Hours amps 11.7 or less 0% 14.4 volts/2 6 Hours or More amps CAUTION Connecting the jumper cables incorrectly (wrong polarity) can immediately damage the electrical system.
Maintenance 4. Connect the other end of the positive cable to the positive terminal of the booster battery. 5. Connect the black negative (–) cable to the other terminal (negative) of the booster battery. 6. MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE (NOT TO THE NEGATIVE POST) AWAY FROM THE BATTERY. STAND BACK. 7. Start the vehicle and remove the cables in the reverse order of connection (the engine block (black) connection is the first to disconnect). Installing the Battery 1.
Maintenance Inspecting the Blades 1. Inspect the cutting edges (Figure 31). If the edges are not sharp or have nicks, remove and sharpen the blades; refer to Sharpening the Blades. 2. Inspect the blades, especially the curved area. If you notice any damage, wear, or a slot forming in this area (item 3 in Figure 31), immediately install a new blade. Figure 30 1.
Maintenance (Figure 34). Refer to Removing the Blades and Installing the Blades. 3. Once the blade has been removed, inspect the spring disc washer. If the washer appears to be damaged (the washer surface has been marred) or flattened, the bolt and washer assembly must be replaced. Removing the Blades The blades must be replaced if a solid object is hit, if the blade is out of balance, or the blade is bent.
Maintenance Mower Belt Maintenance Inspecting the Belts Service Interval: Every 25 hours/Monthly (whichever comes first) Figure 35 1. Sharpen at original angle Check the belts for cracks, frayed edges, burn marks, or any other damage. Replace damaged belts. 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.
Maintenance 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. 3. Check the air pressure of all four tires. If needed, adjust to the recommended inflation; refer to Checking the Tire Pressure in Drive System Maintenance section.
Maintenance 4. Check the air pressure of all four tires. If needed, adjust to the recommended inflation; refer to Checking the Tire Pressure in Drive System Maintenance section. 5. Check and adjust the side-to-side blade level if you have not checked the setting; refer to Leveling the Mower. 6. Set the height-of-cut lever to the 3 inch (76 mm) position.
Maintenance Replacing the Discharge Deflector 9. Measure from the tip of the front blade to the flat surface and the tip of the rear blade to the flat surface (Figure 42 and Figure 43). If the front blade tip is not “R” (see Block Height and Rake Table in Leveling the Mower Deck) lower than the rear blade tip, adjust the front deck hanger. 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.
Maintenance Adjustments through the front discharge deflector bracket, discharge deflector, and rear deflector bracket. 5. Make sure that the spring and rod are installed so that the rod is retained from sliding out by the front bracket and the spring holds the discharge deflector in the down position. Refer to (Figure 44) for proper orientation.
Maintenance Cleaning 6. If adjustment is necessary, loosen the jam nut from the yoke on the side that needs adjustment. Remove the hairpin and clevis pin (see Figure 46). 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. 2.
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. Run the mower again for one to three minutes to remove excess water. WARNING A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with blade or thrown debris can cause injury or death. • Replace broken or missing washout fitting immediately, before using mower again. • Plug any hole(s) in mower with bolts and locknuts.
Storage Storage D. Restart the engine and run it until it stops. E. Choke the engine. Start and run the engine until it will not start. Cleaning and Storage 10. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug in Engine Maintenance section. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s).
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. Do Not attempt to service or replace major items or any items that call for special timing of adjustments procedures (such as valves, governor, etc.).
Troubleshooting Problem Engine loses power The machine does not drive. Abnormal vibration Uneven cutting height. Possible Cause 1. Engine load is excessive. 1. Reduce the ground speed. 2. Air cleaner is dirty. 3. Oil level in the crankcase is low. 4. Cooling fins and air passages for the engine are plugged. 5. The spark plug(s) is pitted, fouled, or the gap is incorrect. 6. Vent hole in the fuel cap is closed. 7. Dirt in fuel filter. 8. Dirt, water, or stale fuel is in the fuel system. 9.
CONNECTIONS ACCESSORY BATTERY IGNITION START RECTIFIER TERMINAL A TERMINAL B TERMINAL I TERMINAL S TERMINAL R TERMINAL R TERMINAL A B+R+I+S B+R+I+A NONE TERMINAL IGNITION SWITCH TERMINAL B TERMINAL S TERMINAL I 3. START 2. RUN 1.
SHOWN WITH CONTROL LEVERS IN NEUTRAL LOCK POSITION (HANDLES OUT) LH MOTION CONTROL RH MOTION CONTROL BRAKE SWITCH SHOWN WITH BRAKE DISENGAGED YELLOW YELLOW GREEN GREEN VIOLET VIOLET YELLOW VIOLET VIOLET VIOLET GRAY PINK PINK PINK BLACK BROWN BROWN BLACK STARTER LOCKOUT & KILL RELAY DK. GREEN DK. GREEN START SOLENOID GROUND ORANGE VIOLET BROWN WHITE YELLOW GRAY YELLOW SEAT SWITCH (OPERATOR IN SEAT) START SOLENOID SIGNAL DK. BLUE START RUN DK.
Exmark Quest Turf Equipment 3-Year Limited Consumer Warranty (30-Day Limited Commercial Warranty) Consumer Warranty Conditions and Products Covered Exmark Mfg. Co. Inc.
Notes: 55
Notes: 56
Service Record Date: Description of Work Done: 57 Service Done By:
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 TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO-MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM OUT-FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL-TAIL WHEEL SN
