Exmark Quest QST24BE522, Quest QST22BE482 Operator's Manual

M
TM
For Serial Nos.
670,000 & Higher
®
FG. CO. INC.
on the purchase of your new Exmark equipment. This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble-free operation. If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor. If you need to order replacement parts from your dealer, always give the model number and serial number of your equipment as well as the part number, description and quantity of the part needed.
The Serial No. plate is located on the back left side of the seat box. For ease of ordering and reference, we suggest
record the information requested in the following identification table. that you
Place Model No. and Serial No. Label Here
(Included in Literature Pack)
or Fill in Below
Engine Model No. and Spec. No. (Code)
Engine Serial No. (E/No)
Model No.
Date Purchased
Serial No.
Part No. 109-6232 Rev B
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: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate the engine on any forest-covered, brush- covered, or grass-covered land. Other states or federal areas may have similar laws.
This spark ignition system complies with Canadian ICES-002, ISO 14982, EN 55012.
The enclosed 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 manufacturer in accordance with 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.
Engine Owners Manual
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. You may contact Exmark directly at www.Exmark.com for product and accessory information or help finding a dealer.
is
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 on the front cover.
Figure 1
Behind the seat
1. Model and serial number plate
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. Safety alert symbol.
This manual uses two other words to highlight information. special mechanical information and emphasizes general information worthy of special attention.
Important
calls attention to
Note
2
Specifications
Model Number:
QST22BE482; QST24BE522
Engine Specifications:
See Your Engine Owner’s Manual
RPM:
Full Speed: 3650 ± 100 (max) RPM
(No Load)
Idle: 1650 (min) RPM
Fuel System:
Capacity: 4.0 gal. (15.1L) Type of Fuel: Regular unleaded gasoline,
87 octane or higher.
Fuel Filter: replaceable in-line
STRATTON
Fuel Shut-Off Valve: in-line, 1/4 turn
P/N 695666
BRIGGS &
Electrical System:
Charging System: Flywheel Alternator Charging Capacity: 16 amps Battery Type: BCI Group U1 Battery Voltage: 12 Volt Polarity: Negative Ground Fuses: 1-25 amp, 1-20 amp, 1-15amp
blade type
Safety Interlock System:
PTO
must be
and
motion control levers out
lock)
to start engine
for the operator to be in the seat to start the engine.)
Operator must be in seat
engaged, brake is disengaged control levers are moved in
stop. Engine will stop if either the left, the right, or
both levers are
position while brake is engaged
disengaged, brake engaged
(neutral
. (It is not necessary
when PTO is
, or
or engine will
moved from neutral lock
.
motion
Operator Controls
Steering and Motion Control:
Separate levers, on each side of the console, control speed and direction of travel of the respective drive wheels.
Steering is controlled by varying the position of the levers relative to each other.
Moving motion control levers outward (in slots) locks the drive system in neutral.
Motion control levers are adjustable to two heights.
PTO Switch: Engages electric clutch (to
drive belt) which engages mower blades.
Parking Brake Lever: Engages parking
brake.
Deck Height Adjustment Pin: Sets cutting
height to desired position.
Deck Lift: Foot pedal that raises the deck.
Seat:
Type: Standard seat: high back, foam
padded with spring suspension.
Mounting: Hinged to tilt up for access to
battery and other components. Held in tilted position with lanyard. Adjustable fore and aft.
,
Armrests: Standard: foam padded flip-up
adjustable height armrests.
Seat Safety Switch: Incorporated into the
Safety Interlock System.
Hydrostatic Ground Drive System:
Hydrostatic Drive: Two Hydro Gear ZT2800
Integrated drive systems.
Hydraulic Oil: Use Mobil 1 15W-50 Synthetic
Motor Oil.
Speeds: All units:
0 – 7 mph (11.3 km/hr) forward. 0 – 5 mph (8.0 km/hr) reverse.
Drive wheel releases, located on left and right sides of engine deck, allow machine to be moved when the engine is not running and brake is off.
3
Tires and Wheels
Drive Tires:
(48”) 20 x 9-8 (52”) 20 x 10-8 All 4-ply
Front Caster Tires:
Pneumatic, 10 x 4 smooth tread tires.
Cutting Deck
48” Deck: 48” (122 cm) 52” Deck: 52” (132 cm) Discharge:
Side (Optional Mulch and/or Bag)
Blade Size:
48” Deck: 3 each - 16.25” blades 52” Deck: 3 each - 18” blades
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. Maximum turf protection is provided by
anti-scalp rollers: 3 rollers (48” & 52”) Deck design allows for bagging, mulching or
side discharge. Cutting Height Adjustment: a foot deck lift
lever is used to adjust the cutting height from 1.5” (3.8 cm) to 4.5” (11.4 cm.) in 1/2” (1.3 cm.) increments.
The cutting height adjustment handle has a transport position and all adjustments can be made while the operator remains seated.
Mulching Kit: Optional.
Kit numbers: 48” – P/N 109-5980
52” – P/N 109-5982
Dimensions
Overall Width:
Without deck:
48” Deck: 45.5” (116 cm) 52” Deck: 47.0” (119 cm)
Deflector up:
48” Deck: 48.3” (122 cm) 52” Deck: 53.0” (135 cm)
Deflector down:
48” Deck: 59.4” (151 cm) 52” Deck: 64.2 (163 cm)
Overall Length:
48” Deck: 73.4” (186 cm) 52” Deck: 73.4” (186 cm)
Overall Height:
48” Deck: 42.2” (107 cm) 52” Deck: 42.2” (107 cm)
Tread Width: (center to center of tires,
widthwise)
Drive Wheels:
48” Deck: 42.2” (107 cm) 52” Deck: 42.2” (107 cm)
Front Casters:
48” Deck: 42.2” (107 cm) 52” Deck: 42.2” (107 cm)
Wheel Base: (center of caster tire to center of
drive tire) 48” Deck: 42.2” (107 cm) 52” Deck: 42.2” (107 cm)
Curb Weight:
48” Deck: 645 lbs (292.6 kg) 52” Deck: 660 lbs (299.4 kg)
Torque Requirements
Spindle Pulley Nuts: 45-55 ft-lbs (61-75 N-m) Blade Mounting Bolt: 45-55 ft-lbs. (61-75N-m) Anti-Scalp Roller Nuts: 27-33 ft-lbs. (37-45 N-m) Engine Mounting Bolts: 27-33 ft-lbs. (37-45 N-m) Wheel Lug Nuts: 70-90 ft-lbs. (95-122 N-m) Clutch Mounting Bolt (secured with threadlocker):
50-55 ft-lbs. (68-75 N-m)
4
Contents
Introduction ................................................2
Specifications .............................................3
Safety ........................................................ 5
Safe Operating Practices ......................5
Exmark Riding Mower Safety................9
Slope Chart ......................................... 10
Safety and Instructional Decals............11
Product Overview .....................................15
Controls ..............................................16
Operation ..................................................17
Think Safety First................................. 17
Recommended Gasoline...................... 17
Checking the Engine Oil Level .............19
Starting the Engine...............................19
Operating the Blades ........................... 20
Stopping the Engine............................. 20
The Safety Interlock System ................20
Driving Forward or Backward...............21
Stopping the Machine ..........................22
Tracking Adjustment ............................22
Adjusting the Height of Cut................... 23
Positioning the Seat .............................23
Adjusting the Motion Control Levers.....23
Pushing the Machine by Hand .............24
Side Discharge.....................................25
Operating Tips ..................................... 25
Maintenance
Recommended Maintenance
Schedule(s).......................................... 27
Premaintenance Procedures .....................28
Raising the Seat...................................28
Accessing the Battery .......................... 28
Lubrication ................................................28
Greasing the Bearings..........................28
Engine Maintenance ..................................29
Servicing the Air Cleaner......................29
Servicing the Engine Oil .......................29
Checking the Hydraulic Oil Level..........31
Change the Hydraulic System Filter .....32
Servicing the Spark Plug ......................32
Cleaning the Blower Housing ...............33
Fuel System Maintenance .........................34
Replacing the Fuel Filter.......................34
Electrical System Maintenance .................35
Charging the Battery.............................35
Servicing the Fuses and Relays ...........36
Drive System Maintenance ........................37
Checking the Tire Pressure..................37
Mower Maintenance...................................37
Servicing the Cutting Blades.................37
Leveling the Mower Deck .....................39
Adjusting the Blade Slope ....................40
Removing the Mower Deck...................41
Mower Belt Maintenance ......................42
Installing the Mower Deck ....................42
Replacing the Discharge Deflector ......43
Cleaning.....................................................43
Washing the Underside of the Mower...43
Storage ......................................................44
Cleaning and Storage...........................44
Troubleshooting .........................................46
Schematics ................................................49
5
Safety
This machine meets or exceeds the safety specifications of the American National Standards Institute B71.1-2003 in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER-"personal safety instruction." Failure to comply with the instruction may result in personal injury or death.
Safe Operating Practices
The following instructions are from ANSI standard B71.1-2003. This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.
General Operation
Read, understand, and follow all
instructions in the operator’s manual and on the machine before starting.
Do not place hands or feet near rotating
parts or under the machine. Keep clear of the discharge opening at all times.
Allow only responsible adults who are
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 the mower discharge
direction and do not point it at anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Stop the blades when crossing gravel surfaces.
Do not operate the mower without either
the entire grass collection system or the discharge deflector in place.
Be alert, slow down and use caution when
making turns. Look behind and to the side before changing directions.
Never leave a running machine
unattended. Always turn off blades, engage parking brake, stop engine, and remove key before dismounting.
Turn off blades when not mowing. Stop
the engine, wait for all parts to come to a complete stop, engage parking brake, and remove key before cleaning the machine, removing the grass or unclogging the deflector.
Operate the machine only in daylight or
good artificial light.
Do not operate the machine while under
the influence of alcohol or drugs.
Watch for traffic when operatin g near or
crossing roadways.
Use extra care when loading or unloading
the machine into a trailer or truck.
Always wear eye protection when
operating the mower.
Data indicates that operators, age 60
years and above, are involved in a large percentage of riding mower-related injuries. These operators should evaluate their ability to operate the riding mower safely enough to protect themselves and others from serious injury.
Always follow the recommendations for
wheel weights or counterweights.
6
Slope Operation
Slopes are a major factor related to loss of control and tip-over accidents, which can result in severe injury or death. Operation on all slopes requires extra caution. If you cannot back up the slope or if you feel uneasy on it, do not mow it.
Do not mow slopes greater than
15 degrees.
Watch for ditches, holes, rocks, dips, and
rises that change the operating angle, as rough terrain could overturn the machine.
Choose a low ground speed so you will
not have to stop while operating on a slope.
Do not mow slopes when grass is wet.
Slippery conditions reduce traction and could cause sliding and loss of control.
Reduce speed and use extreme caution
on slopes.
Do not make sudden turns or rapid speed
changes.
Remove or mark obstacles such as rocks,
tree limbs, etc. from the mowing area. Tall grass can hide obstacles.
Avoid sudden starts when mowing uphill
because the mower may tip backwards.
Be aware that loss of traction may occur
going downhill. Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering.
Always avoid sudden starting or stopping
on a slope. If tires lose traction, disengage the blades and proceed slowly off the slope.
Use extreme care with grass collection
systems or other attachments. These can change the stability of the machine and cause loss of control.
Do not try to stabilize the machine by
putting your foot on the ground.
Do not mow near drop-offs, ditches, steep
banks or water. 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 last saw them.
Keep children out of the mowing area and
under the watchful care of another responsible adult, not the operator.
Be alert and turn the machine off if
children enter the area.
Before and while backing or changing
direction, look behind, down, and side-to- side for small children.
Never carry children, even with the blades
off. They may fall off and be seriously injured or interfere with safe machine operation.
Children who have been given rides in the
past may suddenly appear in the mowing area for another ride and be run over or backed over by the mower.
Never allow children to operate the
machine.
Use extra care when approaching blind
corners, shrubs, trees, the end of a fence or other objects that may obscure vision.
Towing
This machine does not make any
provisions for towing.
7
Service
Safe Handling of Gasoline: To avoid personal injury or property damage,
use extra care when handling gasoline and other fuels. They are flammable and the vapors are explosive.
Extinguish all cigarettes, cigars, pipes and
Use only an approved container.
Never remove the gas cap or add fuel
Never refuel the machine indoors.
Never store the machine or fuel container
Never fill containers inside a vehicle or on
Remove gas-powered equipment from the
Keep the nozzle in contact with the rim of
If fuel is spilled on clothing, change
Never overfill the fuel tank. Replace gas
other sources of ignition.
when the engine is running. Allow the engine to cool before refueling.
inside where there is an open flame, such as near a water heater or furnace.
a truck or trailer with a plastic liner. Always place containers on the ground away from your vehicle before filling.
truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container, rather than from a gasoline dispenser nozzle.
the fuel tank or container opening at all times until the fueling is complete. Do not use a nozzle lock-open device.
clothing immediately.
cap and tighten securely.
General Service:
Never run a machine inside a closed area.
Keep nuts and bolts tight, especially the
blade attachment bolts. Keep equipment in good condition.
Never tamper with safety devices. Check
their proper operation regularly.
Keep the machine free of grass, leaves, or
other debris build-up. Clean up oil or fuel spillage and fuel soaked debris. Allow the machine to cool before storing.
Stop and inspect the equipment if you
strike an object. Repair, if necessary, before restarting.
Never make any adjustments or repairs
with the engine running.
Grass collection system components are
subject to wear, damage and deterioration, which could 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 genuine Exmark replacement
parts to ensure that original standards are maintained.
8
Exmark Riding Mower Safety
The following list contains safety information specific to Exmark products or other safety information that you must know that is not included in the ANSI standards.
Engine exhaust contains carbon
monoxide, which is an odorless, deadly poison that can kill you. Do not run engine indoors or in an enclosed area.
Stop the engine, wait for all moving
parts to stop, engage parking brake, disconnect spark plug wire(s) and remove key before performing any service, repairs, maintenance or adjustments.
Keep hands, feet, hair, and loose
clothing away from attachment discharge area, underside of mower and any moving parts while engine is running.
Do not touch equipment or attachment
parts which may be hot from operation. Allow to cool before attempting to maintain, adjust or service.
Battery acid is poisonous and can cause
burns. Avoid contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery.
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. The ramp angle should not exceed 15 degrees.
Note:
are determined while sitting in the seat in the normal operating position.
The left and right sides of the machine
9
Slope Chart
10
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area of potential
PART NO. 106-5517 LOCATION: On LH & RH Rear Frame
PART NO. 109-6210 LOCATION: Under Seat Shield
PART NO. 110-6691 LOCATION: On Top Side of Deck, on Front
1
1
1
1 3
Corners of Deck
2
5
Some or all of these symbols are on the battery.
6
1. Warning – do
2
2
Battery Symbols
danger. Replace any decal that is damaged or lost.
not touch the hot surface.
PART NO. 109-6011 LOCATION: Inside Seat Box by Fuse Box
1. Read the Operator’s manual
2. Cutting/dismemberment hazard, fan and entanglement hazard, belt sta y away from moving parts.
1. Explosion hazard
2. No fire, open flame, or smoking.
3. Caustic liquid/chemical burn hazard.
4. Wear eye protection.
5. Read the Operator’s Manual.
6. Keep bystanders a safe distance from the battery.
7. Wear eye protection; explosive gases can cause blindness and other injuries.
8. Battery acid can cause blindness or severe burns.
9. Flush eyes immediately with wat er and
G1101
get medical help fast.
10. Contains lead; do not discard.
7
3
8
2
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.
4
9
10
1. Unused fuse
1
2
receptacle
2. Fuse
11
1
Control Lever
PART NO. 93-7009 LOCATION: Behind Discharge Deflector on
Deck Side Plate
1
PART NO. 109-6459 LOCATION: Under Belt Shields
2
1. Warning – do not operate the mower with the discharge deflector up or removed; keep the discharge deflector in place.
2. Cutting/dismemberment hazard of hand or foot, mower blade – stay away from moving parts.
1. Entanglement hazard, belt – do not open or remove safety shields while engine is running, keep shields in place.
1. Parking Brake
2. Machine Speed
3. Fast
1
2
3
4
5
6
PART NO. 109-6009 LOCATION: Near LH Motion
Control Lever
4. Slow
5. Neutral
6. Reverse
2
3
4
5
6
PART NO. 99-8936 LOCATION: Near RH Motion
1. Height of cut
1
PART NO. 109-6010 LOCATION: On Cut
Height Frame
12
PART NO. 109-6016 LOCATION: Near LH Motion Control Lever
A
B
B
D
E
F
C
A. Read the instructions
before servicing or performing
maintenance. B. Time interval. C. Check oil level. D. Refer to Operator’s
Manual for grease
instructions. E. Check hydraulic oil level
and refer to Operator’s
manual for further
instructions. F. Check tire pressure.
1
3
4
5
6
PART NO. 109-6013 LOCATION: Middle of Footrest
7
2
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. Thrown object hazard – keep bystanders a safe distance from the machine, pick up debris before operating, keep the discharge deflector in place.
4. Loss of traction/control hazard, slopes – loss of traction/control on slope, disengage the blade control switch (PTO), proceed off the slope slowly.
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 do not mow up and down slopes.
6. Cutting/dismemberment hazard of hand or foot, mower blade – stay away from moving parts.
7. Crushing/dismemberment hazard of bystanders, reversing;– do not carry passengers, look behind and down when reversing.
13
TRACTION DRIVE
BELT ROUTING
1
5
2
3
1. Engine stop
2. Engine run
3. Engine start
4. Power take-off (PTO), Blade control switch.
5. Read Operator’s Manual
6. Throttle - fast
7. Choke – on
8. Throttle – slow
9. Choke – off
PART NO. 109-6014 LOCATION: RH Side of
Seat Box
109-6029
4
6
7
8
9
PART NO. 109-6029 LOCATION: On Control Panel
DECK DRIVE
BELT ROUTING
PART NO. 109-6035 LOCATION: Left Rear Edge of Deck
1
PART NO. 109-6008 LOCATION: Next to Drive
1
PART NO. 109-6036 LOCATION: Top of Deck Near Washout Port
2
Release
2
3
1. Read the Operator’s
2. Rotate the drive release
3. Push the machine.
3
1. Read Operator’s Manual.
2. Remove the ignition key and read the instructions before servicing or performing maintenance.
3. Height of cut.
Manual.
knob to loosen, slide the knob, and tighten.
14
Product Overview
1. Operator seat
2. Front caster wheel
3. Anti-scalp roller
4. Washout fitting
Figure 3
5. Park brake
6. Rear drive wheel
7. Gas tank cap
1. Motion control levers
2. Engine
3. Control panel
4. Discharge deflector
Figure 4
5. Height of cut adjustment
6. Height of cut foot lever
7. Footrest
15
Controls
Become familiar with all of the controls in
Figure 3, Figure 4, and Figure 5 before you
start the engine and operate the machine.
Figure 5
Control Panel
1. Ignition switch 3. Throttle
2. Blade control switch 4. Choke (power take-off)
Ignition Switch
The ignition switch has three positions, Off, Run and Start. The key will turn to Start and move back to Run upon release. Turning the key to the Off position will stop the engine; however, always remove the key when leaving the machine to prevent someone from accidentally starting the engine (Figure 5).
Blade Control Switch (Power Take-Off)
The blade control switch, represented by a power take-off (PTO) symbol, engages and disengages power to the mower blades (Figure 5).
Throttle Control
The throttle is used to control engine speed. Moving throttle lever engine speed and moving throttle lever
rear
will decrease engine speed. Moving the throttle forward into the detent is full throttle (Figure 5).
forward
will increase
to the
Motion Control Levers and Parking Brake
The motion control levers are speed sensitive controls of independent wheel motors. Moving a lever forward or backward turns the wheel on the same side forward or in reverse; wheel speed is proportional to the amount the lever is moved. Moving the control levers outward from the center position locks them in the neutral position. Engaging the parking brake lever allows the operator to exit the machine (Figure 13). Always position the motion control levers into the neutral position and engage the park brake lever when you stop the machine or leave it unattended.
Height-of-Cut Foot Lever
The height of cut lever allows the operator to lower and raise the deck from the seated position. When the lever is moved forward, away from the operator the deck is raised from the ground and when moved back, towards the operator it is lowered toward the ground. Only adjust the height of cut while machine is not moving (Figure 14).
Choke Control
The choke is used to aid in starting a cold engine. choke in the choke lever forward will put the choke in the
“ON”
the rear will put the choke in the position (Figure 5).
DO NOT
position and moving the choke lever to
run a warm engine with the
“ON
position. Moving the
OFF”
16
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