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Exmark QUEST Operator'S Manual Download Page 29

Maintenance

Maintenance

Note:

Determine the left and right sides of the machine from the normal operating position.

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.

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. Also push the wire(s) aside so it does not accidentally
contact the spark plug(s).

WARNING

The engine can become very hot. Touching a hot engine can cause severe burns.

Allow the engine to cool completely before service or making repairs around the engine area.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

Maintenance Procedure

After the first 5 hours

• Change the engine oil.

After the first 200 hours

• Change the hydraulic system filter.

Before each use or daily

• Check the safety interlock system.
• Check the air cleaner for dirty, loose, or damage.
• Check the air intake and cooling areas, clean as necessary.
• Check the oil level before starting or after every 8 hours.
• Check the hydraulic oil level in the expansion tank.
• Check the mower blades.
• Clean the mower housing.

Every 25 hours

• Grease all lubrication points.
• Service the air cleaner. (May need more often under extremely dusty or dirty conditions.)
• Check the tire pressure.
• Check the belts.

Every 100 hours

• Replace the paper element. (More often under extremely dusty, dirty conditions.)
• Replace the air cleaner element.
• Change the engine oil and filter.
• Clean the blower housing. More often under dirty conditions.
• Replace the fuel filter.

Every 200 hours

• Service the spark plug.

Every 500 hours

• Replace the spark plug.

Before storage

• Charge the battery and disconnect the battery cables.
• Perform all maintenance procedures before storage.
• Paint any chipped surfaces.

Monthly

• Check the battery charge.

29

Summary of Contents for QUEST

Page 1: ...QUEST For Serial Nos 720 000 Higher Part No 4500 338 Rev A ...

Page 2: ...14982 EN 55012 The enclosed Engine Owner s Manual is supplied for information regarding the US Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Replacements may be ordered through the engine manufacturer For models with stated engine horsepower the gross horsepower of the engine was laboratory rated by the engine manufa...

Page 3: ...for product and accessory information or help finding a dealer 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 Write the numbers in the space provided Figure 1 Behind the ...

Page 4: ...harge 26 Transporting 26 Operating Tips 27 Maintenance 29 Recommended Maintenance Schedule s 29 Premaintenance Procedures 30 Raising the Seat 30 Accessing the Battery 30 Periodic Maintenance 30 Lubrication 30 Engine Maintenance 31 Servicing the Engine Oil 32 Checking the Hydraulic Oil Level 34 Change the Hydraulic System Filter 34 Servicing the Spark Plug 35 Cleaning the Blower Housing 35 Fuel Sys...

Page 5: ... familiar with the instructions to operate the machine Clear the area of objects such as rocks toys wire etc which could be picked up and thrown by the blade Be sure the area is clear of other people before mowing Stop the machine if anyone enters the area Never carry passengers Do Not mow in reverse unless absolutely necessary Always look down and behind before and while backing up Be aware of th...

Page 6: ... Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning Use a walk behind mower and or a hand trimmer near drop offs ditches steep banks or water Children 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...

Page 7: ... expose moving parts or allow objects to be thrown Frequently check components and replace with manufacturers recommended parts when necessary Mower blades are sharp and can cut Wrap the blades or wear gloves and use extra caution when servicing them Check for proper brake operation frequently Adjust and service as required Maintain or replace safety and instruction decals as necessary Use only ge...

Page 8: ...rge deflector in place 2 Cutting dismemberment hazard of hand or foot mower blade stay away from moving parts 106 5517 1 Warning Do Not touch the hot surface 109 6008 1 Read the Operator s Manual 3 Push the machine 2 Rotate the drive release knob to loosen slide the knob and tighten 109 6014 Traction Drive Belt Routing 109 6029 1 Engine stop 6 Throttle fast 2 Engine run 7 Choke on 3 Engine start 8...

Page 9: ...ing 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 109 6459 1 Entanglement hazard belt Do Not open or remove safety shields while engine is running keep shields in place 109 8759 1 Height of cut 109 9120 1 Fuse 2 Diode 9 ...

Page 10: ... 4 Neutral 2 Fast 5 Reverse 3 Slow 110 6691 1 Thrown objects hazard keep bystanders a safe distance from the machine 3 Cutting dismemberment of hand or foot stay away from moving parts 2 Thrown objects hazard mower keep the discharge deflector or collection system in place PTO Symbols 1 PTO Off 2 PTO On 10 ...

Page 11: ...ow up and down slopes less than 15 degrees 2 Read the instructions before servicing or performing maintenance apply parking brake remove the ignition key and disconnect the spark plug wire 6 Cutting dismemberment hazard of hand or foot mower blade stay away from moving parts 3 Thrown object hazard keep bystanders a safe distance from the machine pick up debris before operating keep the discharge d...

Page 12: ...y with water and get medical help fast 2 No fire open flames or smoking 6 Keep bystanders a safe distance from the battery 10 Contains lead do not discard 3 Caustic liquid chemical burn hazard 7 Wear eye protection explosive gases can cause blindness and other injuries 4 Wear eye protection 8 Battery acid can cause blindness or severe burns 12 ...

Page 13: ... to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or motion control levers are moved in or engine will stop Engine will stop if either the left the right or both levers are moved from neutral lock position while brake is engaged Operator Controls Steering and Motion Control Note Motion control levers are adjustable to two heights Separate lever...

Page 14: ... 16 25 inches 41 3 cm 52 inch Deck 18 00 inches 45 7 cm Blade Spindles Solid steel spindles with no maintenance bearings Deck Drive Electric clutch mounted on vertical engine shaft Blades are driven by one belt w self tensioning idler direct from the engine Deck Full floating deck is attached to out front support frame Maximum turf protection is provided with three anti scalp rollers both deck siz...

Page 15: ... Spindle Pulley Nut 95 105 ft lb 129 142 N m Blade Mounting Bolt lubricate with anti seize 32 42 ft lb 43 57 N m Engine Mounting Bolts 27 33 ft lb 37 45 N m Anti Scalp Roller Nyloc Nut 27 33 ft lb 37 45 N m Wheel Lug Nuts 70 90 ft lb 95 122 N m Clutch Mounting Bolt secured with threadlocker 50 55 ft lb 68 75 N m Spark Plug 15 ft lb 20 N m Product Overview Figure 3 1 Front caster wheel 8 Engine 2 A...

Page 16: ... the blade control switch to On to engage the blades Push the blade control switch to Off to disengage the blades Choke Control Located on control panel The choke is used to aid in starting a cold engine Do Not run a warm engine with the choke in the ON position Moving the choke lever forward will put the choke in the ON position and moving the choke lever to the rear will put the choke in the OFF...

Page 17: ...ting Instructions Think Safety First Note Determine the left and right sides of the machine from the normal operating position Please carefully read all of the safety instructions and decals in the safety section Knowing this information could help you your family pets or bystanders avoid injury DANGER Mowing on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over e...

Page 18: ...y of gasoline Do Not operate without entire exhaust system in place and in proper working condition 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 Always place gasoline containers on the ground away from your vehicle before filling Do ...

Page 19: ...ne alcohol blends are not approved Filling the Fuel Tank 1 Shut the engine off and set the motion controls to the neutral position and engage parking brake 2 Clean around the fuel tank cap and remove the cap 3 Add unleaded regular gasoline until the body of the tank is full but fuel does not fill the neck of the tank Figure 6 This space in the neck of the tank allows gasoline to expand Do not fill...

Page 20: ...nstructions can burn out the starter motor Figure 9 1 Ignition key start position 4 Start 2 Control panel 5 Run 3 Choke 6 Off 5 If the engine stalls or hesitates move the choke lever partially forward for a few seconds Figure 9 Operating the Blades The blade control switch represented by a power take off PTO symbol engages and disengages power to the mower blades This switch controls power to any ...

Page 21: ...daily and replace any damaged switches before operating the machine Understanding the Safety Interlock System The safety interlock system is designed to prevent the engine from starting unless The blades are disengaged The motion control levers are in the neutral position The parking brake is engaged The safety interlock system is designed to initiate engine shutdown when The parking brake is dise...

Page 22: ...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 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...

Page 23: ...ld the motion control limiter stop Move the stop back until the unit drives straight Tighten the screws to lock the stop in place Readjust handles if necessary Figure 13 1 Control arm shaft 3 Adjust stop 2 Limiter stop screws CAUTION Children or bystanders may be injured if they move or attempt to operate the mower while it is unattended Always remove the ignition key and move the motion control l...

Page 24: ...mm clearance to the ground Do Not adjust rollers to support the deck Figure 15 For cutting heights above 3 1 2 inches 38 mm use the bottom hole The rollers will still be effective against scalping 1 Anti scalp roller mounting bracket 2 Cutting height 7 Torque hardware to 27 33 ft lb 37 45 N m or loss of roller may result Positioning the Seat The seat can move forward and backward Position the seat...

Page 25: ...ver 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 2 Loosen the lower bolt just enough to pivot the control lever fore or aft Figure 18 Tighten both bolts to secure the control in the new position 3 Repeat the adjustment for the opposite control lever Pushing the Machine ...

Page 26: ...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 Never try to clear discharge area or mower blades unless you move the move the blade control switch to Off and rotate the i...

Page 27: ...ends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving up a ramp and sudden deceleration when backing down a ramp Both maneuvers can cause the unit to tip backward Operating Tips Fast Throttle Setting For bes...

Page 28: ...id this move onto a previously cut area with the blades engaged Keep the Underside of the Mower Clean Clean clippings and dirt from the underside of the mower after each use If grass and dirt build up inside the mower cutting quality will eventually become unsatisfactory Blade Maintenance Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shr...

Page 29: ... Change the hydraulic system filter Before each use or daily Check the safety interlock system Check the air cleaner for dirty loose or damage Check the air intake and cooling areas clean as necessary Check the oil level before starting or after every 8 hours Check the hydraulic oil level in the expansion tank Check the mower blades Clean the mower housing Every 25 hours Grease all lubrication poi...

Page 30: ...e the seat Figure 20 Figure 20 1 Auxiliary 12V Plug 3 Seat 2 Battery Periodic Maintenance Lubrication Greasing the Bearings Grease Type NGLI grade 2 multi purpose gun grease Grease the front caster pivots and wheels Figure 21 1 G007184 Figure 21 1 Front caster tire 1 Park the machine on a level surface and disengage the blade control switch 2 Move the motion control levers outward to the neutral p...

Page 31: ... paper element More often under extremely dusty dirty conditions This engine is equipped with a replaceable high density paper air cleaner element Check the air cleaner daily or before starting the engine Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace all bent or damaged air cleaner components Note Operat...

Page 32: ... stopped level and is cool so the oil has had time to drain into the sump 3 To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap dipstick before removing it 4 Pull and remove the oil fill cap dipstick wipe oil off Reinsert the dipstick and push firmly into place Figure 25 Figure 25 1 Oil dipstick 3 Oil level 2 Filler tube 5 Remove the dipstick and check the oil...

Page 33: ...drained completely install the oil drain plug Tighten the plug to 14 N m 125 in lb torque Wipe up any excess oil on the frame Figure 26 and Figure 27 Note Dispose of the used oil at a recycling center 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 Turn the oil filter clockwise until the rubber gasket contacts the pa...

Page 34: ...all plug Torque plugs to 180 in lb 244 N m Continue to add oil until it reaches the FULL COLD line on the expansion reservoir Figure 30 1 Oil filter 3 Left rear tire 2 Vent plug 6 Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely 7 Start engine and move throttle control ahead to 1 2 throttle position Disengage park...

Page 35: ...ower housing is removed for cleaning 3 Remove the spark plug and metal washer Figure 31 1 Spark plug and wire location Checking the Spark Plug 1 Look at the center of the spark plug Figure 32 If you see light brown or gray on the insulator the engine is operating properly A black coating on the insulator usually means the air cleaner is dirty Important Never clean the spark plug Always replace the...

Page 36: ...ward 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 The fuel filter is in the fuel line between the tank and engine Figure 33 1 Fuel tank 6 Hose clamps 2 Fuel shut off valve off 7 Fuel line to engine 3 Fuel shut off valve 8 Filter 4 Fuel shut off valve on 9 Flow direction arrow 5 Fuel line fr...

Page 37: ...s disconnect the negative black battery cable before disconnecting the positive red cable Always connect the positive red battery cable before connecting the negative black cable 5 Slide the rubber cover up the positive red cable Disconnect the positive red cable from the battery post Retain all fasteners 6 Remove the battery hold down Figure 34 and lift the battery from the battery tray Charging ...

Page 38: ...operating position Figure 34 2 Install the positive red battery cable to the positive battery terminal using the fasteners removed previously 3 Install the negative battery cable to the negative battery terminal using the fasteners removed previously 4 Slide the red terminal boot onto the positive red battery post 5 Secure the battery with the hold down Figure 34 Servicing the Fuses and Relay The ...

Page 39: ...iately with a genuine Exmark replacement blade For convenient sharpening and replacement you may want to keep extra blades on hand WARNING A worn or damaged blade can break and a piece of the blade could be thrown into the operator s or bystander s area resulting in serious personal injury or death Inspect the blade periodically for wear or damage Replace a worn or damaged blade Before Inspecting ...

Page 40: ...ghtening the blade bolt the spring disc washer has been flattened or damaged and the bolt and washer assembly must be replaced Figure 40 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 ...

Page 41: ...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 Service Interval Every 25 hours 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 gr...

Page 42: ...than the rear blade tip adjust the blade level If measurements from steps 5 or 6 are out of range then follow Adjusting the Blade Slope 7 Set anti scalp rollers to top holes or remove completely for this adjustment 8 Set the height of cut lever to the 3 inch 76 mm position Place two 2 1 2 inch 6 35 cm thick blocks under the rear edge of the cutting deck skirt one on each side of the cutting deck P...

Page 43: ...f the front edge of the deck but not under the anti scalp roller brackets 7 Loosen the leveling adjust locking nuts item 4 on all four corners so that the deck is sitting securely on all four blocks Make sure that the deck hangers are all the way down at the top of the slot and the deck lift foot lever is pushed back against the stop then tighten the four leveling adjust locking nuts Figure 46 Fig...

Page 44: ...ure 49 1 Deck lift arm 2 Deck strut 6 Slide the mower rearward to remove the mower belt from the engine pulley 7 Slide the mower out from underneath the machine Note Retain all parts for future installation Installing 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...

Page 45: ...ge deflector Remove the damaged or worn discharge deflector 3 Install new discharge deflector 4 Orient the spring so that the short leg points towards the discharge deflector and the longer leg points towards the deck as shown in Figure 50 Place spring on rod and slide rod straight end through the front discharge deflector bracket discharge deflector and rear deflector bracket 5 Make sure that the...

Page 46: ...ure 51 4 Lower the mower to the lowest height of cut 5 Sit on the seat and start the engine Engage the blade control switch and let the mower run for one to three minutes 6 Disengage the blade control switch stop the engine and remove the ignition key Wait for all moving parts to stop 7 Turn the water off and remove the coupling from the washout fitting Note If the mower is not clean after one was...

Page 47: ...e an alcohol based stabilizer ethanol or methanol Note A fuel stabilizer conditioner is most effective when mixed with fresh gasoline and used at all times B Run the engine to distribute the conditioned fuel through the fuel system 5 minutes C Stop the engine allow it to cool and drain the fuel tank refer to Draining the Fuel Tank in Fuel System Maintenance section D Restart the engine and run it ...

Page 48: ... an Authorized Service Dealer 1 The blade control switch is engaged 1 Move the blade control switch to Disengaged 2 The motion control levers are not in the park position 2 Move the motion control levers outward to the park position 3 The operator is not seated 3 Sit on the seat 4 The battery is dead 4 Charge the battery 5 The electrical connections are corroded or loose 5 Check the electrical con...

Page 49: ...ey 3 Engine pulley is damaged 3 Contact an Authorized Service Dealer 4 Cutting blade s is are bent or unbalanced 4 Install new cutting blade s 5 Blade is loose 5 Tighten the blade mounting bolt and inspect the blade spring disc washer for damage See Servicing the Cutting Blades section Abnormal vibration 6 Blade spindle is bent 6 Contact an Authorized Service Dealer 1 Blade s not sharp 1 Sharpen t...

Page 50: ...SOLENOID B PTO CLUTCH GROUND ALTERNATOR OIL SWITCH HOUR METER ACCESSORIES FUSE BLOCK IGNITION SWITCH SEAT SWITCH PTO SWITCH ORANGE ORANGE ORANGE ORANGE ORANGE DARK GREEN DARK GREEN BROWN BROWN VIOLET VIOLET VIOLET RED RED RED Y S X A B I ORANGE BLACK PINK LIGHT BLUE LIGHT BLUE PINK PINK PINK PINK PINK PINK DARK BLUE RED VIOLET YELLOW WHITE BLACK BLACK DARK GREEN DARK GREEN DARK GREEN BROWN GRAY BR...

Page 51: ...SORIES FUSE BLOCK IGNITION SWITCH SEAT SWITCH PTO SWITCH ORANGE ORANGE ORANGE ORANGE ORANGE DARK GREEN DARK GREEN BROWN BROWN VIOLET VIOLET VIOLET RED RED RED Y S X A B I ORANGE BLACK PINK LIGHT BLUE LIGHT BLUE PINK PINK PINK PINK PINK PINK DARK BLUE DARK BLUE BLUE RED VIOLET YELLOW BLUE WHITE BLACK BLACK DARK GREEN DARK GREEN DARK GREEN BROWN GRAY BROWN YELLOW YELLOW YELLOW GREEN GREEN VIOLET VIO...

Page 52: ...provided by Exmark There are no other express warranties except for engine and special emission system coverage stated elsewhere herein or included with the product All warranty work must be performed by an authorized Exmark Service Dealer using Exmark approved replacement parts Instructions for Obtaining Warranty Service The product must be registered with original proof of purchase by an Exmark ...

Page 53: ...Notes 53 ...

Page 54: ...Service Record Date Description of Work Done Service Done By 54 ...

Page 55: ...55 ...

Page 56: ... 2007 2008 Exmark Mfg Co Inc Part No 4500 338 Rev A Industrial Park Box 808 402 223 6300 Beatrice NE 68310 Fax 402 223 5489 All Rights Reserved Printed In USA ...

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