Page 2 - WARNING; CALIFORNIA
WARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this productcontains chemicals known to the State ofCalifornia to cause cancer, birth defects, orother reproductive harm. Important: This engine is not equipped with a spark arrester muffler. It is a violation ofCalifornia Public Reso...
Page 3 - Introduction
Introduction Read this information carefully to learn how tooperate and maintain your product properly and toavoid injury and product damage. You are responsiblefor operating the product properly and safely. You may contact Exmark directly atwww.Exmark.com for product and accessoryinformation or hel...
Page 4 - Contents
Contents Introduction ........................................................... 3Safety ..................................................................... 5 Safety Alert Symbol ......................................... 5Safe Operating Practices .................................. 5Safety and Ins...
Page 5 - Safety; Safety Alert Symbol; Important; Safe Operating Practices; General Operation
Safety Safety Safety Alert Symbol This manual identifies potential hazards and hassafety messages identified by the safety alert symbol(Figure 2), which signals a hazard that may causeserious injury or death if you do not follow therecommended precautions. Figure 2 1. Safety alert symbol This manual...
Page 6 - Slope Operation; Do Not mow slopes greater than 15 degrees.; Children; Never allow children to operate the machine.; Towing; Travel slowly and allow extra distance to stop.; Service; Safe Handling of Gasoline
Safety safely enough to protect themselves and othersfrom serious injury. • Always follow the recommendations for wheelweights or counterweights. Slope Operation Slopes are a major factor related to loss of controland tip-over accidents, which can result in severeinjury or death. Operation on all sl...
Page 7 - Use only an approved container.; Exmark Riding Mower Safety; The left and right sides of the machine are
Safety • Extinguish all cigarettes, cigars, pipes and othersources of ignition. • Use only an approved container. • Never remove the gas cap or add fuel when theengine is running. Allow the engine to cool beforerefueling. • Never refuel the machine indoors. • Never store the machine or fuel containe...
Page 8 - Safety and Instructional Decals
Safety Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any areaof potential danger. Replace any decal that is damaged or lost. 93-7009 1. Warning–Do Not operatethe mower with thedischarge deflector upor removed; keep thedischarge...
Page 13 - Specifications; Model Numbers
Specifications Specifications Model Numbers Serial Nos: 720,000 and Higher QST22BE482; QST23KC482; QST23KC522; QST24BE522 Systems Engine • Engine Specifications: See your Engine Owner’sManual • RPM: Briggs & Stratton: Full Speed: 3650 ±100 (max)RPM (No Load) Idle: 1650 (min) RPM Kohler Command: ...
Page 14 - Hydrostatic Ground Drive System; Cutting Deck; Dimensions
Specifications • Armrests: Standard–foam padded flip-upadjustable height armrests. • Seat Safety Switch: Incorporated into the SafetyInterlock System. Hydrostatic Ground Drive System • Hydrostatic Pumps: Two Hydro Gear ZT2800Integrated drive systems. • Hydraulic Oil Type: Use Mobil 1 15W-50Synthetic...
Page 15 - Torque Requirements; Product Overview
Product Overview Tread Width: (Center to Center ofTires, Widthwise) 48 inch Deck 52 inch Deck Drive Wheels 36.0 inches(91 cm) 36.8 inches(93 cm) Caster Wheels 33.5 inches(85 cm) 33.5 inches(85 cm) Wheel Base: (Center of Caster Tire toCenter of Drive Tire) 48 inch Deck 52 inch Deck 48.9 inches (124 c...
Page 16 - Operation; Controls; Ignition Switch; Choke Control
Operation Operation Controls Note: Become familiar with all of the controls in Figure 3 and Figure 4 before you start the engine andoperate the machine. Ignition Switch Located on control panel. The ignition switch is used to start and stop theengine. The switch has three positions “OFF”,“RUN” and “...
Page 17 - Parking Brake Lever; Operating Instructions; Think Safety First; DANGER
Operation Parking Brake Lever Located on left side of the console (Figure 3). The brake lever engages a parking brake on the drivewheels. Pull the lever up and rearward to engage the brake. Push the lever forward and down to disengage thebrake. Height-of-Cut Foot Lever The height of cut lever allows...
Page 18 - Recommended Gasoline; Never use methanol, gasoline; Avoid prolonged breathing of vapors.
Operation See inside back cover to determine the approximateslope angle to be mowed. Recommended Gasoline Use UNLEADED Regular Gasoline suitable forautomotive use (87 pump octane minimum). Important: Never use methanol, gasoline containing methanol, or gasohol containingmore than 10% ethanol because...
Page 19 - Using Stabilizer/Conditioner; Checking the Oil Level; Starting the Engine
Operation Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the machine toprovide the following benefits: • Keeps gasoline fresh during storage of 30 days orless. For longer storage it is recommended thatthe fuel tank be drained. • Cleans the engine while it runs. • Eliminates gum-li...
Page 20 - Do not engage the starter for; Operating the Blades; Engaging the Blades
Operation Figure 7 1. Control panel 2. Blade controlswitch—Off position 3. Move the throttle lever to midway and the choke lever forward before starting a cold engine(Figure 8). Note: A warm or hot engine may not require choking. Figure 8 1. Control panel 4. Throttle—slow 2. Choke—on 5. Throttle—fas...
Page 21 - Disengaging the Blades; Stopping the Engine; Testing the Safety Interlock System
Operation Figure 10 1. Control panel 2. Blade controlswitch—On position 4. Move throttle to full forward position before mowing. Disengaging the Blades Set throttle to midway position. Push the bladecontrol switch to Off to disengage the blades(Figure 11). Figure 11 1. Control panel 2. Blade control...
Page 22 - Driving Forward or Backward; Forward
Operation 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 cra...
Page 23 - Backward; To stop, push the motion control levers to neutral.; Stopping the Machine; Move the deck height adjuster pin to the desired
Operation Backward 1. Move the levers to the center, unlocked position.2. To go backward, slowly pull the motion control levers rearward (Figure 12). To go straight, apply equal pressure to bothmotion control levers (Figure 12). To turn, release the pressure on the motioncontrol lever toward the dir...
Page 24 - For Maximum Deck Flotation,; Positioning the Seat
Operation the predetermined cut height by slowly decreasingfoot pressure allowing the foot lever to travelrearward. Adjusting the Anti-ScalpRollers It is recommended to change the anti-scalp rollerposition when the height of cut has changed. 1. Stop the machine and move the drive levers to the neutr...
Page 25 - Adjusting the Height; Always push the machine by hand.; To Push the Machine
Operation Figure 17 1. Bolt 3. Nut 2. Spring 4. Additional mountingholes Up to five springs can be secured to the seat box witha nut and bolt, see Figure 17. Refer to your Parts Manual for spring and hardwarepart numbers. Adjusting the Motion ControlLevers Adjusting the Height The motion control lev...
Page 26 - Loosen the knob by turning counterclockwise.; To Operate the Machine; Side Discharge; Transporting a Unit; CAUTION
Operation Figure 19 1. Front of the machine. 5. Lever position forpushing the machine 2. Rotate bypass releaseknob counterclockwise 6. Rotate bypass releaseknob clockwise 3. Lever position foroperating the machine. 7. Release lever 4. Pull lever in this direction 4. Loosen the knob by turning counte...
Page 27 - Do Not attempt to turn the unit; Operating Tips
Operation WARNING Loading a unit on a trailer or truck increasesthe possibility of backward tip-over.Backward tip-over could cause serious injuryor death. • Use extreme caution when operating aunit on a ramp. • Use only a single, full width ramp; DoNot use individual ramps for each sideof the unit. ...
Page 28 - Cutting Speed; To improve cut quality, use a slower ground speed.; Avoid Cutting Too Low
Operation Cutting Speed To improve cut quality, use a slower ground speed. Avoid Cutting Too Low If the cutting width of the mower is wider than themower you previously used, raise the cutting heightto ensure that uneven turf is not cut too short. Long Grass If the grass is ever allowed to grow slig...
Page 29 - Maintenance
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. Accidentalstarting of the engine could seriously injure you or other bystanders. Remove the key...
Page 30 - Raising the Seat; Periodic Maintenance; Lubrication; Greasing the Bearings
Maintenance Important: Refer to your Engine Operator’s Manual for additional maintenance procedures. PremaintenanceProcedures Raising the Seat Make sure the motion control levers are locked inthe neutral position. Lift the seat forward until thelanyard is tight. The following components can beaccess...
Page 31 - Connect a grease gun to each fitting (Figure 21; Engine Maintenance; Servicing the Air Cleaner; Service Interval: Before each use or daily; Operating the engine with loose or damaged
Maintenance Figure 22 Located on the back of the seat. 1. Read the instructionsbefore servicing orperforming maintenance 4. Check oil level. 2. Grease idler pivots. 5. Check hydraulic oil leveland refer to Operator’smanual for furtherinstructions. 3. Time interval. 6. Check tire pressure. 4. Connect...
Page 32 - Servicing Paper Element; Servicing the Engine Oil; Changing the Oil and Filter; Service Interval: After the first 5 hours
Maintenance Servicing Paper Element Service Interval: Every 25 hours (May need more often underextremely dusty or dirtyconditions.) Every 100 hours/Yearly(whichever comesfirst)—Replace the aircleaner element. 1. Remove the air cleaner cover (Figure 23). 2. Remove the air cleaner element with the int...
Page 33 - Checking
Maintenance 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operatingposition. 4. Clean the area around the drain plug and on the machine frame. Place a pan underneath machinedirectly below the drain hole in the frame asshown in Figure 26 and Figure 27. F...
Page 34 - Service Interval: After the first 200 hours
Maintenance Checking the Hydraulic OilLevel Service Interval: Before each use or daily Check expansion tank and if necessary add MOBIL 115W-50 synthetic motor oil to the FULL COLD line Figure 29 1. Engine 2. Expansion tank Change the HydraulicSystem Filter Service Interval: After the first 200 hours...
Page 35 - Servicing the Spark Plug; Service Interval: Every 200 hours/Every 2; Removing the Spark Plug; Checking the Spark Plug; Never clean the spark plug.; Installing the Spark Plug; Cleaning the Blower Housing
Maintenance Servicing the Spark Plug Service Interval: Every 200 hours/Every 2 years (whichever comesfirst) Every 500 hours—Replacethe spark plug. As stated in the maintenance intervals, remove thespark plug, check condition, and reset the gap orreplace with a new plug as necessary. The spark plug i...
Page 36 - Fuel System Maintenance; Replacing the Fuel Filter
Maintenance Important: Operating the engine with a blocked grass screen, dirty or plugged cooling fins,and/or cooling shrouds removed, will causeengine damage due to overheating. Fuel System Maintenance Replacing the Fuel Filter Service Interval: Every 100 hours/Yearly (whichever comes first) DANGER...
Page 37 - Removing the Battery; Charging the Battery; Removing the Battery
Maintenance Charging the Battery Removing the Battery WARNING Battery terminals or metal tools could shortagainst metal machine components causingsparks. Sparks can cause the battery gassesto explode, resulting in personal injury. • When removing or installing the battery,Do Not allow the battery te...
Page 38 - Installing the Battery
Maintenance VoltageReading PercentCharge MaximumChargerSettings ChargingInterval 12.6 orgreater 100% 16 volts/7amps NoChargingRequired 12.4 – 12.6 75–100% 16 volts/7amps 30 Minutes 12.2 – 12.4 50–75% 16 volts/7amps 1 Hour 12.0–12.2 25–50% 14.4 volts/4amps 2 Hours 11.7–12.0 0–25% 14.4 volts/4amps 3 H...
Page 39 - To replace a fuse, pull out on the fuse to remove it; Drive System Maintenance; Mower Maintenance; Replace a worn or damaged blade.; Inspecting the Blades; Sharpening the Blades; Checking for Bent Blades; Rotate the blades until the ends face forward
Maintenance 2. Remove cover as shown in Figure 36. 3. To replace a fuse, pull out on the fuse to remove it Drive System Maintenance Checking the Tire Pressure Service Interval: Every 25 hours/Monthly (whichever comes first) Maintain the air pressure in the front and rear tires asspecified. Uneven ti...
Page 40 - Removing the Blades; Removing the Blades
Maintenance Figure 39 1. Blades front to rear 3. Measure here 2. Outside cutting edges 2. Rotate the opposite ends of the blades forward. 3. Measure from a level surface to the cutting edge of the blades at the same position as in step 1.The difference between the dimensions obtainedin steps 1 and 3...
Page 41 - Installing the Blades; The curved part of the blade; Inspecting the Belts; Service Interval: Every 25 hours; Replacing the Mower Belt; Be careful when removing the belt.
Maintenance Figure 41 1. Sharpen at original angle 2. Check the balance of the blade by putting it on a blade balancer (Figure 42). If the blade stays in ahorizontal position, the blade is balanced and canbe used. If the blade is not balanced, file somemetal off the end of the sail area only (Figure...
Page 42 - Leveling the Mower Deck; Checking the Tire Pressure; Adjusting the Blade Slope
Maintenance 6. Route the new belt around the engine pulley and mower pulleys. 7. Pull the idler pulley in the direction shown in Figure 43 and route the belt onto the idler pulley. 8. Install the belt covers over the outside spindles. Leveling the Mower Deck The mower blades must be level from side ...
Page 44 - Removing the Mower Deck; Installing the Mower Deck
Maintenance Removing the Mower Deck 1. Park the machine on a level surface and disengage the blade control switch 2. Move the motion control levers outward to the neutral position, engage parking brake, stop theengine, remove the key, and wait for all movingparts to stop before leaving the operating...
Page 45 - Orient the spring so that the short leg points; The discharge deflector must be
Maintenance Replacing the DischargeDeflector DANGER An uncovered discharge opening could allowthe lawn mower to throw objects in theoperator’s or bystander’s direction and resultin serious injury. Also, contact with the bladecould occur. Never operate the lawn mower unless youinstall a mulch plate, ...
Page 46 - Cleaning
Maintenance Cleaning Washing the Underside ofthe Mower Service Interval: Before each use or daily After each use, wash the underside of the mower toprevent grass buildup for improved mulch action andclipping dispersal. 1. Park the machine on a level surface and disengage the blade control switch. 2....
Page 47 - Storage; Cleaning and Storage
Storage Storage Cleaning and Storage 1. Disengage the blade control switch, move the motion controls outward to the neutral position,engage parking brake, stop the engine, andremove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially theengin...
Page 48 - Troubleshooting; condition prior to mower use.
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 becaused by an empty fuel tank. The followi...
Page 50 - Schematics; Electrical Diagram—Briggs & Stratton
Schematics Schematics Electrical Diagram—Briggs & Stratton TERMINAL I TERMINAL S TERMINAL X TERMINAL Y TERMINAL B TERMINAL A 3. S TA R T POSITION 1. OFF 2 . R UN B + I + S CIRCUIT "MAKE" X + Y NONE B + I + A IGNITION SWITCH TERMINAL CONNECTIONS TERMINAL A V O L T A GE REGUL A T OR TERMIN...
Page 51 - Electrical Diagram—Kohler Command
Schematics Electrical Diagram—Kohler Command TERMINAL I TERMINAL S TERMINAL X TERMINAL Y TERMINAL B TERMINAL A 3. S TA R T POSITION 1. OFF 2 . R UN B + I + S CIRCUIT "MAKE" X + Y NONE B + I + A IGNITION SWITCH TERMINAL CONNECTIONS TERMINAL A V O L T A GE REGUL A T OR TERMINAL B B A TTE R Y T...
Page 54 - Service Record
Service Record Date: Description of Work Done: Service Done By: 54
