Exmark Quest Bagger Manual

QUEST®BAGGER
SetupInstructions
ForSerialNos.790,000&Higher
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.Partnumbersnotshownareavailableonthedealer
extranet.
DealerPack
Part#DescriptionQty.Use
—WarrantyRegistrationReminderFillouttheonlinewarrantyregistration
form.
LiteraturePack
Part#DescriptionQty.Use
—Manual,Operator’s1
—Manual,Parts1Readbeforeoperatingthemachine.
ModelandRecommendedBaggerBlades
ModelNumber
116–1084:Fits42,48,and52inchQuestdecks.
RecommendedHighLiftBlades
116-1202—Fits42inchQuestdecks
109-6391—Fits48inchQuestdecks
109-6392—Fits52inchQuestdecks
Thesebladesarerecommendedtoobtainmaximumairowtothebag.
©2009—ExmarkMfg.Co.,Inc.
P .O.Box808
Beatrice,NE68310
PartNo.4500-440Rev.B
PrintedintheUSA
AllRightsReserved

AssemblyDiagrams
KeyQtyDescription
11Asm,HoodBagger
21Tube,Upper
31Asm,LowerTube
41Rod,WeightLock
51Weight,Bagger35#
610Nut,Nyloc3/8-16Flg
72Screw,ButtonHead3/8-16x1
81Asm,BracketandBumpers
94Plate,Stiffener
104Bolt,Carriage3/8-16x5
112Plate,Stiffener
122Tube,Hitch
131Wld,Hitch
144Bolt,Carriage3/8-16x3
152Asm,Bag
162Nut,Nyloc1/4-20Flg
172Screw,1/4-20x3/4
181Bafe,Discharge(42&52inch)
191Bkt,BootMount
205Bolt,Carriage5/16-18x3/4(42inch)
1Bolt,Carriage5/16-18x3/4(48inch)
3Bolt,Carriage5/16-18x3/4(52inch)
211Asm,BaggerMount
225Nut,Nyloc5/16-18Flg(42inch)
1Nut,Nyloc5/16-18Flg(48inch)
3Nut,Nyloc5/16-18Flg(52inch)
23▲3Blade,Highlift(48&52inch)
2Blade,Highlift(42inch)
241Clamp
251Bafe,Center(42inch)
264Nut,Nyloc1/4-20Flg
273Weight
284Screw,HH1/4-20x13/8
▲Bladesarenotincluded.
2

Figure1
*42&52inchdeckonly.
■42inchdeckonly.
3

Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin
thissetupinstructionsandonthemachinetoidentify
importantsafetymessageswhichmustbefollowedto
avoidaccidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituationsandwill
befollowedbythewordDANGER,WARNING,or
CAUTION.
DANGER:Whitelettering/Redbackground.Indicates
animminentlyhazardoussituationwhich,ifnotavoided,
Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,ifnot
avoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,ifnot
avoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizesgeneral
informationworthyofspecialattention.
InstallingtheWeightsUnderthe
Footrest—42InchDeckOnly
Installthree7lbweights(item27)tothebottomofthe
footrestusingfour1/4-20x13/8bolts(item28)and
four1/4nylocnuts(item26)asshowninFigure3.
Note:Theseweightscanstaymountedtotheunit
whenthebaggerisremoved.
Figure3
InstallingtheRemovableWeight
—AllUnits
WARNING
Thefrontweightinstalledwithoutthebagger
maycauselossoftractionandsteeringcontrol
oranunstableconditionwhichcouldresultin
injuryordeath.
Installthefrontweightonlywhenthebagger
isinstalled.
Note:Theremovableweightisheavy.Usecarewhen
liftingit.Makesurethatyoucanholditsecurelybefore
liftingit.Usecautionwhenpositioningyourhandsso
thatyouDoNotsetitdownonyourhandsorngers.
1.Attachtheweightsupportassembly(item8)tothe
frontpanelfootrestwithtwo3/8-16x1inchbutton
headscrews(item7)andtwonylocnuts(item6)as
showninFigure4.
Figure4
4

Note:Ifyourmowerdoesnothavemountingholes
onthefootrest,positionthebackoftheweight
supportassemblyonthecrossbarunderthefoot
rest.Centertheweightsupportassemblyandmark
thetwomountingholesonthelipofthefootrest.
Drillholesusinga13/32inchdrillbit.Installweight
supportassemblyasstatedinstep1.
2.Thelockrod(item4)hasakeyononeend.Slidethe
lockrodthroughtheweightsupportassembly,notch
intheweightandtheovalholeintheframebracket.
3.Rotatethelockrodtosecureitintoplace.
Note:Theweightsupportassemblycanstaymounted
totheunitwhenthebaggerandweightareremoved.
InstallingtheHitchBracket
1.Removethetwo3/8-16inchcarriageboltsatthe
rearofeachframerail.Retainforreuseifthebagger
isremoved.
2.Installthetwo3/8-16x5inchcarriagebolts(item
10)throughtheholesontheframeasshownin
Figure5.Placetwostiffeners(item9)onthetop
andbottomofthebaggertube(item12)andinstall
oncarriagebolts.Fastenwithtwonylocnuts(item
6);leaveloosetoaidinstallation.Repeatprocedure
forotherside.
Figure5
3.Aligntheholesinthebaggertube(item12)withthe
baggerhitch(item13).Fastenwithhardwareand
stiffenerasshowninFigure5;leaveloosetoaidin
installation.
4.Tightenallhardware.
InstallingtheHoodandBags
WARNING
Operatingthemowerwiththebaggerinstalled
andthefrontweightremovedmaycauseloss
oftractionandsteeringcontroloranunstable
conditionwhichcouldresultininjuryordeath.
Installthebaggeronlywhenthefrontweight
isinstalled.
1.Installthebaggermountassembly(item21)onto
tothehoodassembly(item1)usingtwo1/4-20x
3/4inchscrews(item17)andnylocnuts(item16)as
showninFigure6.
2.Installthemountassemblyontothehitch(item13).
Figure6
CAUTION
Ifyouremovethespring-loadedhoodwhenit
isclosed(inthedownposition),thehoodmay
suddenlyyopenandyouorsomeoneelsemay
bebruised,pinched,orinjuredinanotherway.
Alwaysopen(raise)thehoodbeforeyouremove
orinstallitonthequick-attachbracket.
3.Installthebags(item15)byslidingthebagframe
hooksontotheretainingbrackets(seeFigure7).
5

Figure7
4.Lowerthehoodontothebags.
InstallingtheBootMountBracket
andTubes
1.Removethedischargedeectorfromthedeck.
Retainallcomponentsforreuseifthebaggeris
removed.
2.Installthebootmountbracket(item19)ontothe
deckframeusingthe5/16-18x3/4inchcarriage
bolt(item20)andnylocnut(item22)asshownin
Figure8.Bracketmaystayonwhenconvertingto
sidedischargemode.
Figure8
3.Insertthetabonthelowertubeassemblyintothe
bootmountbracketasshowninFigure8.
4.Usethelatch(itemAFigure8)onthelowertube
assembly(item3)tolockthebrackettothedeck.
Adjustthetensiononthelatchtoholdthebracket
uptothedeck,yetallowforreleasebyhand.
5.Sliportwisttheuppertube(item2)intojunction
tubeofthehood.
6.Slidetheuppertubeontothelowertubeandfasten
withclamp(item24)(Figure8).
Note:Applyagrease/lubricantonthelowertube
tohelpwithassembly.
AdjustingtheHoodHinge
Ifthehooddoesnotstayopenwiththeuppertube
installed,tightenthepivothardwareuntilitdoes.
InstallingtheDischargeBafe—42
and52InchDecksOnly
1.RemovefastenersinthedeckasshowninFigure9.
Retainforreuseifthedischargebafeisremoved.
Figure9
UndersideofDeckShown
2.Installthedischargebafe(s):
•52inchdecks:
Installouterdischargebafe(item18)usingthe
hardwareshowninFigure9.Discarditem25
anditshardware.
Note:ForSerialNumbers803,785andlower,
lineuptheholeintheouterdischargebafe
withtheholeinthetopofthedeck.Drillahole
intothesideofthedeckandmountasshown
inFigure9.
•48inchdecks:
Discardbothbafesandhardware.
•42inchdecks:
Removeandretainthehardwareandweight
underthebottomofthedeck.Installthecenter
bafe(item25)andtheouterdischargebafe
(item18)usingthehardwareshowninFigure9.
Note:Thebafe(s)canstayonthemachinewhileside
discharging.
InstallingtheBaggerBlades
Note:Originalequipmentbladescanbeused;however
highliftbladesarerecommendedforbestperformance.
6

WARNING
Incorrectinstallationofthebladeor
componentsusedtoretainthebladecausethe
bladetocomelooseandcouldseriouslyinjure
orkillyouorbystanders.
AlwaysinstalltheoriginalExmarkblades,
washersandbladeboltsasshown.
ForMowerSerialNumbers719,999and
Lower
1.Installthebladeontothespindleshaft(Figure10).
Important:Thecurvedpartoftheblademust
bepointingupwardtowardtheinsideofthe
mowertoensurepropercutting.
Figure10
1.Blade4.Bladebolt
2.Bushing5.Sailareaofblade
3.Springdiscwasher6.Orientationofwashers
2.Holdthebladeendusingaragorthickly-padded
glove(orplaceawrenchonthetopsheavenut).
Installthebushing,twospringdiskwashers(cupped
sidetowardtheblade)andbladebolt(Figure10).
3.Torquethebladeboltto45-55ft-lb(61-75N-m).
Refertomoweroperator’smanualforblademaintenance.
ForMowerSerialNumbers720,000and
Higher
1.Installthebladeontothespindleshaft(Figure11).
Important:Thecurvedpartoftheblademust
bepointingupwardtowardtheinsideofthe
mowertoensurepropercutting.
Figure11
1.Blade3.Boltandwasherassembly
2.Washer
2.Holdthebladeendusingaragorthickly-padded
glove(orplaceawrenchonthetopsheavenut).
Installthewasherandbladeboltandwasher
assembly.
3.Torquethebladeboltto45-55ft-lb(61-75N-m).
Note:Refertomoweroperator’smanualforblade
maintenance.
FillingOuttheProduct
Registration
Fillouttheonlinewarrantyregistrationform.
7