Exmark QUEST QSP20BV443, Operator'S Manual

Page 1: ...QUEST SP MODELS For Serial Nos 850 000 Higher Part No 4500 582 Rev A ...

Page 2: ...da The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturer...

Page 3: ...lable online at http www exmark com manuals htm All Exmark equipment dealers and distributors are kept informed of the latest methods of servicing and are equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before l...

Page 4: ...lic Oil Level 32 Check Tire Pressures 33 Check Condition Of Belts 33 Lubricate Grease Fittings 33 Check Spark Plugs 33 Change Fuel Filter 33 Change Hydraulic System Filter and Fluid 33 Check Spark Arrester if equipped 34 Thread Locking Adhesives 35 Copper Based Anti seize 35 Dielectric Grease 35 Adjustments 35 Deck Leveling 35 Adjusting the Blade Slope 36 Pump Drive Belt Tension 37 Deck Belt Tensi...

Page 5: ...e users Never let children or untrained people operate or service the equipment Local regulations may restrict the age of the operator Only adults and mature teenagers should operate a mower and even mature teenagers should have adult supervision Be sure a teenager 1 has read and understands the Operator s Manual and recognizes the risks involved 2 is sufficiently mature to use caution and 3 is of...

Page 6: ...tem 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 Not fill gasoline containers inside a vehicle or on a t...

Page 7: ... wait for all moving parts to stop remove key and engage parking brake Before checking cleaning or working on the mower After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and operating the mower Before clearing blockages Whenever you leave the mower Stop engine wait for all moving parts to stop and engage parking brake Befor...

Page 8: ...lopes less than 15 degrees 2 Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near drop offs and water 3 Water Remove or mark obstacles such as rocks tree limbs etc from the mowing area Tall grass can hide obstacles Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Avoid sudden starts wh...

Page 9: ...rk s recommendation for weight limits for towed equipment and towing on slopes This information can be found in the hitch kit instruction sheet and on the decal Never allow children or others in or on towed equipment On slopes the weight of the towed equipment may cause loss of traction and loss of control Travel slowly and allow extra distance to stop Maintenance and Storage Disengage drives lowe...

Page 10: ...he 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 Be sure ignition switch is in the OFF position before charging the battery Keep all guards shields and all safety devices in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently ...

Page 11: ...essory has been installed make sure current safety signs are visible New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any air bubbles Familiarize yourself with the following safety signs and in...

Page 12: ...Safety 103 3270 107 2102 109 3148 109 6014 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 12 ...

Page 13: ...utral 5 Operator presence switch 6 Battery 116 1118 1 Height of cut 116 1119 116 1121 1 Rotate the drive release knob to loosen slide the knob and tighten 2 Push the machine 116 1496 116 2577 1 Fast 4 Choke on 2 Continuous variable setting 5 Choke off 3 Slow 117 2718 13 ...

Page 14: ...Read the instructions before servicing or performing maintenance 4 Refer to the Operator s manual for grease instructions 2 Time interval 5 Check hydraulic oil level and refer to the Operator s manual for further instructions 3 Check oil level 6 Check tire pressure 14 ...

Page 15: ...Safety 116 2834 15 ...

Page 16: ...l PTO must be disengaged brake engaged and motion control levers out neutral lock to start engine It is not necessary for the operator 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 ...

Page 17: ...22 25 inches 56 5 cm 2 ea 48 inch Deck 16 25 inches 41 3 cm 3 ea 52 inch Deck 18 00 inches 45 7 cm 3 ea 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 prov...

Page 18: ...m Blade Mounting Bolt lubricate with anti seize 50 60 ft lb 68 81 N m Engine Mounting Bolts In Tapped Bosses 27 33 ft lb 37 45 N m Engine Through Mounting Bolts 15 19 ft lb 20 25 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 60 ft lb 68 81 N m Deck Lift Flange Bearing Bolts 40 60 in lb 4 5 7 0 N m Rollo...

Page 19: ...he choke lever forward will put the choke in the ON position and moving the choke lever to the rear to the detent will put the choke in the OFF position Do Not run a warm engine with choke in the ON position Figure 6 1 Throttle lever 4 Blade control switch power take off 2 Choke lever 5 Ignition switch 3 Hour meter Throttle Control Located on right console red lever see Figure 6 The throttle is us...

Page 20: ...e Located behind and below the seat The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the jobsite and when parked inside a building Align valve handle with the fuel line to open Rotate 90 to close Drive Wheel Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck which...

Page 21: ...on right console see Figure 6 Switch must be pulled out up to engage the blades Switch is pushed in to disengage the blades The LCD indicator will appear when the PTO switch is disengaged see Figure 8 Deck Lift Pedal Located at the right front corner of the floor pan see Figure 10 Push the pedal forward with your foot to raise the cutting deck Allow the pedal to move rearward to lower the cutting ...

Page 22: ...he tabs interlocking as shown in Figure 11 to lock the roll bar in the raised operate position 2 Apply forward pressure to the upper hoop of the roll bar 3 Pull the knob and rotate 90 to hold in the unlatched position to lower the roll bar 4 To return to the operate position raise the roll bar and then rotate knobs 90 so that the tabs interlock partially Apply forward pressure to the roll bar uppe...

Page 23: ...ered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blade could occur Thrown objects or blade contact can cause serious injury or death Never operate the mower with the discharge deflector raised removed or altered unless there is a grass collection system or mulch kit in place and working properly The PTO push pull switch engages ...

Page 24: ...ward to the center to the neutral position 3 To move forward in a straight line move both levers forward with equal pressure To turn left or right pull the motion control lever back toward neutral in the desired turn direction The machine will move faster the farther the motion control levers are moved from the neutral position 4 To stop position both motion control levers in the neutral operate p...

Page 25: ...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 After adjusting the height of cut adjust the anti scalp rollers by removing the nyloc nut bushing spring disc washer and whizlock nut 6 Place the rollers in one of the positions shown Figure 16 Rollers will maintain 3 4 inch 19 mm clearance to the ground to minimize gouging and roll...

Page 26: ...r than the unit Do Not exceed a 15 angle between ramp and ground or between ramp and trailer or truck Avoid sudden acceleration while driving unit up a ramp to avoid tipping backward Avoid sudden deceleration while backing unit down a ramp to avoid tipping backward Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp that is wide enough to extend beyond t...

Page 27: ...mpt 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 27 ...

Page 28: ...aily Check the engine oil level Check the mower blades Check the safety interlock system Check the rollover protections systems roll bar knobs Check the seat belt Check for loose hardware Check the hydraulic oil level in the expansion tank Clean the engine and exhaust system area Clean the hydro fan cooling fins Clean the grass and debris build up from the machine and cutting deck Clean the grass ...

Page 29: ...rged before putting away for winter storage Check the voltage of the battery with a digital voltmeter or with the message display If the ignition key is turned to the on position for a few seconds the battery voltage will be displayed in the area where the hours are normally displayed Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to...

Page 30: ...touch and that both electrical systems are off and at the same voltage These instructions are for negative ground systems only 3 Connect the positive cable to the positive terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 18 Figure 18 1 Positive cable on discharged battery 2 Positive cable on booster battery 3 Negative cable on the booster battery 4 Neg...

Page 31: ... PTO disengaged and motion control levers in the neutral lock position starter must not crank Try to start with operator in seat parking brake engaged PTO engaged and motion control levers in the neutral lock position starter must not crank 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...

Page 32: ...ne Owner s Manual for maintenance instructions Change Engine Oil and Filter Service Interval After the first 5 hours Every 100 hours Yearly whichever comes first May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Drain oil while engine is warm from operation 3 The oil drain hose is located on right hand side of engine a...

Page 33: ...e Replace when necessary Replacement Filters Briggs Stratton Briggs Stratton P N 691035 Kawasaki Kawasaki P N 49019 7005 Note It is important to reinstall the fuel line hoses and secure with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage Change Hydraulic System Filter and Fluid Service Interval Aft...

Page 34: ...faces A With the bypass valve open and the engine running slowly move the directional control in both forward and reverse 5 or 6 times B With the bypass valve closed and the engine running slowly move the directional control in both forward and reverse directions 5 to 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 a...

Page 35: ... of contact Adjustments Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit CAUTION Raising the mower deck for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction all...

Page 36: ...e sure that the slack is removed from the deck hangers and the deck lift foot lever is pushed back against the stop then tighten the four leveling adjust locking nuts Figure 25 1 Leveling adjust locking nuts 3 Deck hanger 2 Deck lift arm 11 Recheck that blocks fit just snugly under the deck skirt Make sure all attachment bolts are tight 12 Continue leveling the deck by checking the front to rear b...

Page 37: ...n tighten the four leveling adjust locking nuts Figure 26 1 Leveling adjust locking nuts 3 Deck hanger 2 Deck lift arm 8 Carefully rotate the blades so they are facing front to rear Figure 27 and Figure 28 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 27 and Figure 28 If the front blade tip is not R see Block Height and Rake ...

Page 38: ... jam nut from the yoke on the side that needs adjustment Remove the hairpin and clevis pin see Figure 29 Figure 29 1 Hairpin 3 Yoke 2 Clevis pin 4 Jam nut Adjusting the Brake to Engage Shorten the linkage by turning the yoke clockwise Adjusting the Brake to Disengage Lengthen the linkage by turning the yoke counterclockwise 8 Reinstall the clevis pin and hair pin and tighten down the jam nut Repea...

Page 39: ...ng is obtained Figure 31 1 Control arm shaft 3 Tracking plate 2 Tracking plate nut Adjusting the Seat Ride Suspension The number of seat springs can be changed to maximize rider comfort More springs should be used with heavier operators and on rough terrain Fewer springs should be used with lighter operators and when mowing smooth well established lawns Always keep the number of springs on the lef...

Page 40: ...function has been confirmed C Using a pneumatic line blow out any debris from under the brake pole and around the brake spacers D Re torque each bolt M6 x 1 to 10 ft lb 13 N m 0 5 ft lb 0 7 N m E Using a 0 010 inch thick feeler gauge verify that a gap is present between the rotor and armature face on both sides of the brake pole as shown Due to the way the rotor and armature faces wear peaks and v...

Page 41: ... allow the hydro system to run cooler and improve the life of the hydro system 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lift the seat to access the LH and RH hydro drive area 3 Remove accumulated debris from the hydro fan cooling fins Clean Debris From Machine Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and ...

Page 42: ...s skin can cause severe burns Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the unit containing the battery is no long...

Page 43: ... dielectric grease and reconnect 6 Fuse is blown 6 Replace the blown fuse 7 Relay or switch is defective 7 Contact an Authorized Service Dealer Starter does not crank 8 Faulty module 8 Replace module 1 Fuel tank is empty 1 Fill the fuel tank 2 Fuel shutoff valve is closed 2 Open the fuel shutoff valve 3 Oil level in the crankcase is low 3 Add oil to the crankcase 4 The throttle and choke are not i...

Page 44: ...ing blade s is are bent 2 Install new cutting blade s 3 Mower deck is not level 3 Level mower deck from side to side and front to rear 4 Underside of mower is dirty 4 Clean the underside of the mower 5 Tire pressure in drive tires not correct 5 Adjust tire pressure in the drive tires 6 Blade spindle bent 6 Contact an Authorized Service Dealer Uneven cutting height 7 Tips of adjacent blades are at ...

Page 45: ... ORANGE FUSE BLOCK PTO CLUTCH TVS DIODE BROWN BLACK B CLUTCH FUSE 10 A ACCY FUSE 15 A REG FUSE 20 A B FUSE 25 A 2 1 1 A B 1 2 3 4 1 5 2 1 2 3 8 9 12 7 5 10 11 6 1 4 2 8 9 3 4 5 6 7 1 2 4 3 5 1 2 B A 2 6 3 1 5 4 3 7 5 1 2 4 6 8 A B 1 2 8 6 4 2 7 5 3 1 2 5 4 3 1 2 1 3 4 9 7 8 2 1 2 1 2 1 2 1 5 2 3 4 1 A B A B 1 7 12 6 3 1 4 6 5 2 A B G012611 POSITION CIRCUIT MAKE NONE B R I A B R I S 1 OFF 2 RUN 3 S...

Page 46: ...N M1 HOUR METER BK PTO CLUTCH ENGINE GND F3 10A BN VIO LT GN T BN OR R VIO VIO VIO REG AC AC IGNITION MODULES SPARK PLUG SPARK PLUG WIRE COLOR CODES START STARTER MAG B ENGINE GND FUEL SOLINOID BU W R PK GY PK SOLENOID GN U1 STARTER SOLENOID OFF 3 F2 25A 4 PK PK 8 4 7 BK PK R GY VIO 1 3 SW1 2 4 5 KEY SWITCH CONNECTION SW2 PTO SW IN OFF POSITION SW5 RH NEUT SWITCH IN NEUT LOCK SW6 SEAT SW W OPER IN...

Page 47: ...s except for engine and special emission system coverage 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 Service Dealer before obtaining any warranty service Contact any Exmark Service Dealer to arrange service at...

Page 48: ...Notes 48 ...

Page 49: ...Service Record Date Description of Work Done Service Done By 49 ...

Page 50: ...50 ...

Page 51: ...se 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 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 51 ...

Page 52: ...DISPOSAL SYSTEM OUT FRONT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM DUAL TAIL WHEEL FLOOR PAN EXTENDER HITCH KIT LIGHT KIT MICRO MULCH SYSTEM ROLL OVER PROTECTION SYSTEM ROPS SNOW BLADE SNOWBLOWER SUN SHADE TRASH CONTAINER ULTRA VAC COLLECTION SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM WEATHER CAB Place Model No and Serial No Label Here Included in the Literature Pack or Fill i...