Exmark ARX440CKC24000 Operator's Manual

Download

STAND-ON

AERATOR

24INCHMODEL

ForSerialNos. 402,082,300&Higher

PartNo.4503-596Rev.B

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemical

orchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:ItisaviolationofCaliforniaPublic ResourceCodeSection4442or4443touse oroperatetheengineonanyforest-covered, brush-covered,orgrass-coveredlandunlessthe engineisequippedwithasparkarrester,as denedinSection4442,maintainedineffective workingorderortheengineisconstructed, equipped,andmaintainedforthepreventionof re.

Toacquireasparkarresterforyourmachine,seeyour EngineServiceDealer.

ForallmodelsthatdonothaveExmarkengines, pleaserefertotheenginemanufacturer's informationincludedwiththemachine.

FormodelswithExmarkengines,refertothis manualforinformation.

Thegrossornethorsepower(ortorque)of thisenginewaslaboratoryratedbytheengine manufacturerinaccordancewiththeSociety ofAutomotiveEngineers(SAE)J1940orJ2723. Asconguredtomeetsafety,emission,and operatingrequirements,theactualengine horsepower(ortorque)onthisclassofmachine willbesignicantlylower.

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkAerator.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark aerator.

BEFOREOPERATINGYOURAERATOR, CAREFULLYREADTHISMANUALINITS ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety instructions,youwillprolongthelifeofyouraerator, maintainitsmaximumefciency,andpromotesafe operation.

Important:Tomaximizesafety,performance, andproperoperationofthismachine,itis essentialthatalloperatorscarefullyreadand fullyunderstandthecontentsoftheOperator’s manualprovidedwiththeproduct.Safe operationofExmarkequipmentisessential. Failuretocomplywiththeoperatinginstructions orreceivepropertrainingmayresultininjury.

Gotohttp://www.Exmark.comforadditional safeoperationinformation,suchassafetytips, trainingmaterials,andOperator’smanuals.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

g231322

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Forcompletewarrantydetails,see http://www.Exmark.com.Youmayalsocall us402-223-6375torequestawrittencopyofthe product’swarranty.

Ifadditionalinformationisneeded,orshould yourequiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor.

AllExmarkequipmentdealersanddistributorsare keptinformedofthelatestmethodsofservicing andareequippedtoprovidepromptandefcient serviceintheeldorattheirservicestations.They carryamplestockofservicepartsorcansecurethem promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals......................10

Specications........................................................14

Systems..........................................................14

Dimensions....................................................15

TorqueRequirements.....................................15

ProductOverview.................................................16

Operation..............................................................16

Controls.........................................................16

Pre-Start.........................................................20

OperatingInstructions...................................20

Transporting..................................................23

Maintenance..........................................................25

RecommendedMaintenanceSchedule(s)............25

PeriodicMaintenance........................................26

CheckEngineOilLevel..................................26

CheckBatteryCharge.....................................26

CheckTines...................................................28

ChecktheSafetyInterlock..............................29

CheckforLooseHardware.............................30

ServiceAirCleaner.........................................30

ChangeEngineOil.........................................30

CheckAuxiliaryHydraulicOilLevel................30

CheckHydraulicTransmissionOil

Level..........................................................30

CheckTirePressures......................................31

CheckConditionandTensionOf

Belts...........................................................31

CheckConditionOfChains............................31

CheckConditionOfSprockets.......................31

LubricatingtheChains....................................31

LubricatingtheGreaseFittings.......................31

CheckSparkPlug...........................................32

ChangeAuxiliaryHydraulicReservoirFluid

andFilter....................................................32

ChangeHydraulicTransmissionFiltersand

Fluid..........................................................32

CheckTransmissionOutputShaftNut

TorqueSpecication...................................33

CheckWheelHubBoltTorque

Specication...............................................33

CheckTransmissionMountBolt

Torque.......................................................33

CheckSparkArrester(ifequipped)..................34

ThreadLockingAdhesives..............................34

Adjustments......................................................35

AuxiliaryPumpDriveBeltAdjustment...........35

TransmissionDriveBeltTension....................35

DriveWheelChainTension

Adjustment................................................35

TineDriveChainAdjustment.........................35

AdjustingtheParkingBrake............................35

MotionControlLinkageAdjustment..............36

MotionControlTrackingAdjustment.............36

Return-to-UpSpringAdjustment....................37

Cleaning............................................................38

CleanEngineandExhaustSystem

Area...........................................................38

RemoveEngineShroudsandClean

CoolingFins...............................................38

CleanDebrisFromMachine...........................38

WasteDisposal...............................................38

Troubleshooting....................................................39

Schematics............................................................41

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents.

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

SafetyAlertSymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Indicatesanimminentlyhazardous

situationwhich,ifnotavoided,Willresultindeathor seriousinjury.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate anaerator,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator's Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

g000502

3.isofsufcientsizeandweighttooperate thecontrolscomfortablyandtomanagethe aeratorwithouttakingrisks.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

WARNING:Indicatesapotentiallyhazardous situationwhich,ifnotavoided,Couldresultindeath orseriousinjury.

CAUTION:Indicatesapotentiallyhazardous situationwhich,ifnotavoided,Mayresultinminor ormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)cannot readthismanualitistheowner’ sresponsibilityto explainthismaterialtothem;otherlanguagesmay beavailableonourwebsite.

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Wearappropriateclothingincludingsafetyglasses, substantialslip-resistantfootwear,andhearing protection.Longhair,looseclothingorjewelry maygettangledinmovingparts.

CAUTION

Thismachineproducessoundlevelsinexcess of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.

Wearhearingprotectionwhenoperatingthis machine.

•Inspecttheareawheretheequipmentistobe usedandremoveallrocks,toys,sticks,wires, bones,andotherforeignobjectswhichcanbe thrownbythemachineandmaycausepersonal injurytotheoperatororbystanders.

•Markandavoidhiddenobjectssuchassprinkler heads,undergroundwires/cables,invisiblefences, etc.topreventdamagetothesesystemswhen aerating.

Safety

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevelground, inanopenarea,whentheengineiscold. Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Fillthefueltanktothebottomoftheller neck.Theemptyspaceinthetankallows gasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengine oremissionsystem.

•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyspark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine.Never removethecapofthefueltankoradd fuelwhenengineisrunningorwhenthe engineishot.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitegasolinevapors.Areor explosionfromgasolinecanburnyouand othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.Do Notuseanozzlelockopendevice.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

•Checkthattheoperatorpresencecontrols, safetyswitches,andshieldsareattachedand functioningproperly.DoNotoperateunlessthey arefunctioningproperly.

Safety

Operation

WARNING

Operatingengineparts,especiallythemufer, becomeextremelyhot.Severeburnscanoccur oncontactanddebris,suchasleaves,grass, brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,to coolbeforetouching.

•Removeaccumulateddebrisfrommuferand enginearea.

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcankill you.

DoNotrunengineindoorsorinasmallconned areawheredangerouscarbonmonoxidefumes cancollect.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea, DoNotoperatethemachine;seekshelter.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.

•Neveroperatethemachinewithdamagedguards, shields,orcovers.Alwayshavesafetyshields, guards,switchesandotherdevicesinplaceandin properworkingcondition.

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Parkmachineonlevelground.Stopengine,wait forallmovingpartstostop,removekeyand engageparkingbrake:

–Beforechecking,cleaningorworkingonthe

machine.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemachinefor damageandmakerepairsbeforerestarting andoperatingthemachine).

–Beforeclearingblockages.

–Wheneveryouleavethemachine.

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

WARNING

Hands,feet,hair,clothing,oraccessoriescan becomeentangledinrotatingparts.Contact withtherotatingpartscancausetraumatic amputationorseverelacerations.

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesinplace andworkingproperly.

•Keephands,feet,hair,jewelry,orclothing awayfromrotatingparts.

•NEVERcarrypassengers.DONOToperate themachinewhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhen makingturns.Lookbehindandtothesidebefore changingdirections.

•Raisethetines,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemachinetoandfromthework area.

•DoNotoperatethemachineundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

•Slopesareamajorfactorrelatedtolossofcontrol androlloveraccidents,whichcanresultinsevere injuryordeath.Theoperatorisresponsiblefor safeslopeoperation.Operatingthemachineon anysloperequiresextracaution.Beforeusingthe machineonaslope,theoperatormust:

–Reviewandunderstandtheslopeinstructions

inthemanualandonthemachine.

–Evaluatethesiteconditionsofthedayto

determineiftheslopeissafeformachine operation.Usecommonsenseandgood judgmentwhenperformingthisevaluation. Changesintheterrain,suchasmoisture,can quicklyaffecttheoperationofthemachine onaslope.

•Operateacrossslopes,neverupanddown.Avoid operationonexcessivelysteeporwetslopes.

Safety

•Identifyhazardsatthebaseoftheslope.Do notoperatethemachineneardropoffs,ditches, embankments,waterorotherhazards.The machinecouldsuddenlyrolloverifawheelgoes overtheedgeortheedgecollapses.Keepasafe distance(twicethewidthofthemachine)between themachineandanyhazard.Useawalkbehind machineorahandheldtooltooperateinthese areas.

•Useextracarewhileoperatingwithaccessories orattachments.Thesecanchangethestabilityof themachineandcausealossofcontrol.Follow directionsforcounterweights.

•Ifyoulosecontrolofthemachine,stepoffand awayfromthedirectionoftravelofthemachine.

MaintenanceandStorage

•Raisethetines,settheparkingbrake,stopengine andremovekeyordisconnectsparkplugwire. Waitforallmovementtostopbeforeadjusting, cleaningorrepairing.

•Keepengineandengineareafreefromexcessive greaseoroilandotherdebriswhichcan accumulateintheseareas.Thesematerialscan becomecombustibleandmayresultinare.

•Letenginecoolbeforestoringanddonotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

Figure3

1.SafeZone—Usethemachinehere

2.DangerZone-Useawalkbehindmachineorahand heldtoolneardropoffs,ditches,embankments,water orotherhazards.

3.Water

4.W=widthofthemachine

5.Keepasafedistance(twicethewidthofthemachine) betweenthemachineandanyhazard.

•Avoidstarting,stoppingorturningthemachine onslopes.Avoidmakingsuddenchangesinspeed ordirection;turnslowlyandgradually.

•Donotoperateamachineunderanyconditions wheretraction,steeringorstabilityisinquestion. Beawarethatoperatingthemachineonwetgrass, acrossslopesordownhillmaycausethemachine tolosetraction.Lossoftractiontothedrive wheelsmayresultinslidingandalossofbraking andsteering.Themachinecanslideevenifthe drivewheelsarestopped.

•Removeormarkobstaclessuchasditches,holes, ruts,bumps,rocksorotherhiddenhazards.Tall grasscanhideobstacles.Uneventerraincould overturnthemachine.

g222486

•Parkmachineonlevel,hardground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

•Disconnectbatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthe negativeterminalrstandthepositivelast. Reconnectpositiverstandnegativelast.

•Usecarewhencheckingandservicingtines.Wrap thetine(s)orweargloves,andusecautionwhen servicingthem.Onlyreplacedamagedtines. Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts. Ifpossible,donotmakeadjustmentswiththe enginerunning.

•Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugcharger beforeconnectingordisconnectingfrombattery. Wearprotectiveclothinganduseinsulatedtools.

Safety

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

•Ventilatewhenchargingorusingbattery inanenclosedspace.

•Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately.

WARNING

Removingstandardoriginalequipmentparts andaccessoriesmayalterthewarranty,traction, andsafetyofthemachine.Failuretouseoriginal Exmarkpartscouldcauseseriousinjuryor death.Makingunauthorizedchangestothe engine,fuelorventingsystem,mayviolateEP A andCARBregulations.

Replaceallpartsincluding,butnotlimitedto, tires,belts,tines,andfuelsystemcomponents withoriginalExmarkparts.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjuryorgangrenemay result.

•Ifequipped,makesureallhydraulicuid hosesandlinesareingoodconditionandall hydraulicconnectionsandttingsaretight beforeapplyingpressuretohydraulicsystem.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

CAUTION

Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagementof components.Sparkscouldcauseanexplosion ormovingpartscouldaccidentallyengage causingpersonalinjury.

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

•Usecardboardorpaper,notyourhands,to ndhydraulicleaks.

•Beforeperforminganyworkonthehydraulic system:

–Safelyrelieveallpressureintheground drivehydraulicsystembyplacingthemotion controlleversinneutralandshuttingoffthe engine.

–Safelyrelieveallpressureintheauxiliary hydraulicsystembyshuttingofftheengine, turningtheignitionswitchtothe“ON” position,andpressingthetineground engagementswitch.Oncethetineshave loweredtotheground,releasethetineground engagementswitchandturntheignition switchtothe“OFF”position.

Safety

SafetyandInstructionalDecals

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe backingtoexposetheadhesivesurface.Apply onlytoaclean,drysurface.Smoothtoremove anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialaerator.

115-4212

1.Hydraulicoillevel3.Warning—donottouch thehotsurface.

2.ReadtheOperator's

Manual.

117–2718

120-9570

1.Warning—stayawayfrommovingparts,keepallguards

andshieldsinplace.

decal115-4212

decal121-6150

121-6150

1.Cuttinghazardofhandandfoot–stayawayfrommoving parts.

decal117-2718

decal121-6161

121–6161

1.Entanglementhazard,belt—stayawayfrommoving parts;keepallguardsinplace.

decal120-9570

Safety

decal135-3183

135-3183

121–6163

1.Presstolowerthetines.2.Releasetoraisethe tines.

1.Bypassleverpositionfor pushingthemachine.

3.Bypassleverpositionfor operatingthemachine.

2.Readtheinstructions

decal121-6163

beforeservicingor performingmaintenance.

g211619

HourMeter/TineEngagementDisplay

1.Parkingbrake4.Depthsettinglock

2.Tinegroundengagement footswitchlockout

3.Tinedownposition

5.SeeOperator’smanual foroperatingconditions code

135-2016

1.Electronictinedepth-decrease

2.Electronictinedepth-increase

3.Pressandhold1secondtoturnon—tineground engagementfootswitchunlock

4.Pressandhold1secondtoturnoff—tineground engagementfootswitchlock

decal135-2016

Safety

STOP

LB KG

135-2013

decal135-2013-1

135-2013

1.Operatorweightadjustment

5.Throttle—slow9.Parkingbrake—engage

2.Increase6.Engine—on10.Parkingbrake—release

3.Decrease7.Engine—start

4.Throttle—fast8.Engine—off

135-2014

1.Fast6.Wheelsandtinesrotatewhen

2.Slow7.Warning—readtheOperator’s

3.Neutral

4.Reverse

5.Wheelsandtinesrotatewhen movingforward

movingbackward

Manual.

8.Warning—keepbystandersasafe distanceawayfromthemachine.

9.Warning—Cutting/dismemberment hazardofhandorfoot;tines—stay awayfrommovingparts;keepall guardsinplace.

10.Warning—Donotoperatethe machineunlessyouaretrained.

decal135-2014b

11.Thrownobjecthazard—pickup debrisbeforeoperatingthemachine.

12.Warning—shutofftheengine, engagetheparkingbreak,and removetheignitionkeybefore leavingthemachine.

13.Tippinghazard–DoNotoperatethe machineneardrop-offs.

14.Tippinghazard–DoNotturnsharply whiletravelingfast;slowdownand turngradually.

15.Tippinghazard–DoNotusesplit ramps;usefullwidthrampstoload amachinefortransport.

Safety

135-3685

1.Readandunderstandtheoperator’smanualbefore servicingthismachine.

2.Cleanandoilchainsandcheckchaintension(2x)every8 hours

3.Seeengineowner’smanualforservice8.Checkhydraulicoillevel(2x)(Onlyuserecommended

4.Checkauxiliarypumpdrivebelttensionevery50hours9.Checkauxiliaryhydraulictank(OnlyuseAW-32hydrooil)

5.Greasefrontcasterwheelbearings(2x)every100hours10.Greasetineshaftbearings(4x)every25hours

6.Greasebeltidlerpivotevery100hours

7.Checktirepressure-23psi(2x)every50hours

hydrooil)every50hours

every50hours

decal135-3685

Specications

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•EngineOilType:Exmark4–CyclePremium EngineOil

•RPM:FullSpeed:3800±100RPM(NoLoad)

FuelSystem

•Capacity:1.9gal.(7L)

•FuelRecommendations:

–Forbestresults,useonlyclean,fresh,unleaded

gasolinewithanoctaneratingof87orhigher ((R+M)/2ratingmethod).

–Oxygenatedfuelwithupto10%ethanolor

15%MTBEbyvolumeisacceptable.

–DoNotuseethanolblendsofgasoline(such

asE15orE85)withmorethan10%ethanol byvolume.Performanceproblemsand/or enginedamagemayresultwhichmaynotbe coveredunderwarranty.

–DoNotusegasolinecontainingmethanol.

OperatorControls

•SteeringandMotionControl

–Separatelevers,oneachsideoftheconsole,

controlspeedanddirectionoftravelofthe respectivedrivewheels.

–Steeringiscontrolledbyvaryingtheposition

oftheleversrelativetoeachother.

•TineGroundEngagement:Engagesthetines withtheground.

•ParkingBrakeLever:Engagestheparkingbrake.

•TineDownPressureControl:Adjuststinedown pressure.

•ElectronicDepthControl:Adjustsactualtine depthelectronically.

Transmission

•Twointegratedhydrostatictransmissions:Hydro GearZT3100.

•HydraulicOilCapacity:78oz.(2.3L)per transmission

•HydraulicFilterisreplaceablecartridgetype

•Speeds:

–0-7.0mph(11.3km/hr)forward.

–0-4.0mph(6.4km/hr)reverse.

–DoNotstorefueleitherinthefueltankor

fuelcontainersoverthewinterunlessafuel stabilizerisused.

–DoNotaddoiltogasoline.

•FuelShut-OffValve:1/4turn

ElectricalSystem(ElectricStart)

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:Kohler,10amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuse:20ampmainfuse

SafetyInterlockSystem

Enginewillnotstartunlesstheparkbrakeisengaged.

WheelandTineDriveSystem

Drivewheelsandtheoutsideaerationtinesare driventhroughrollerchainsbythetwohydrostatic transmissions.

Specications

TiresandWheels

Drive

Pneumatic (Air-Filled)

Quantity

Tread

Size16.5x4.50-8113x4.00-6

PlyRating

Pressure

TurfSaverSmooth

23psi (159kPa)

Aeration

AerationWidth:24inches(61.0cm)

Tines:Qty:36

CoreDepth:.5-5inches(1.3-12.7cm)

Holespersquarefoot:4.6

TorqueRequirements

FrontCaster

Semi-Pneumatic

BoltLocation

EngineMountingBolts

WheelLugNuts

WheelHubBolt27-33ft-lb(37-45N-m)

TransmissionOutput ShaftNuts

TineShaftNut

WheelAxleBolt135-165ft-lb

TransmissionBracket Bolts(4xwithspacers)

Torque

27-33ft-lb(37-45N-m)

85-105ft-lb(115-142 N-m)

211-260ft-lb (286-352N-m)

(183-224N-m)

38-48ft-lb (52-65N-m)

Dimensions

OverallWidth:

35.5inches(90.2cm)

OverallLength:

68.6inches(173.2cm)

OverallHeight:

51.0inches(129.5cm)

TreadWidth:(OutsidetoOutsideof Tires,Widthwise)

35.5inches(90.2cm)

CurbWeight:

856lb(388kg)

Operation

ProductOverview

Figure4

1.Platform

2.Parkbrakelever5.Fuelcap

3.Enginecontrols

4.Motioncontrollevers

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

MotionControlLevers

Themotioncontrollevers,locatedoneachsideofthe topconsole,controltheforwardandreversemotion ofthemachine.

Movingtheleversforwardorbackwardturns thewheelonthesamesideforwardorreverse respectively.Wheelspeedisproportionaltothe amounttheleverismoved.

g231324

Important:Thetinesarerotatingwhenthe motioncontrolleversaremovedoutofthe neutralposition.

Figure5

1.LHMotioncontrollever5.Forward

2.RHMotioncontrollever6.Neutral

3.Frontreferencebar

4.Frontofunit8.Rearreferencebar

7.Reverse

ChokeControl

Locatedonthecontrolconsole(blackknob)(see Figure6).

Thechokeisusedtoaidinstartingacoldengine. Pullingthechokeknobupwardwillputthechoke inthe“ON”positionandpushingthechokeknob downward,willputthechokeinthe“OFF”position.

g223330

Operation

DoNotrunawarmenginewithchokeinthe“ON” position.

Pullleverrearwardtoengagethebrake.

Pushtheleverforwardtodisengagethebrake.

Whenparkingonasteepslope,thewheelsmustbe chockedorblockedinadditiontothebrakebeing engaged.Theunitmustbetieddownandbrake engagedwhentransporting.

IgnitionSwitch

Locatedontherightsideofthecontrolconsole.

Theignitionswitchisusedtostartandstopthe engine.Theswitchhasthreepositions“OFF”,“ON” and“START”.Insertkeyintoswitchandrotate clockwisetothe“ON”position.Rotateclockwiseto thenextpositiontoengagethestarter(keymustbe heldagainstspringpressureinthisposition).Allow thekeytoreturntothe“ON”positionimmediately aftertheenginestarts.

Figure6

1.Tinegroundengagement footswitch

2.Operatorweight adjustmentcontrol

3.Multi-functionswitch

4.LHMotioncontrollever10.Parkbrake

5.Frontreferencebar

6.Throttle

7.Choke

8.RHMotioncontrollever

9.Hourmeter

11.Ignitionswitch

ThrottleControl

Locatedonthecontrolconsole(redlever)(see Figure6).

Thethrottleisusedtocontrolenginespeed.Moving thethrottleleverforwardwillincreaseenginespeed andmovingthethrottlelevertotherearwilldecrease enginespeed.Movingthethrottleforwardintothe detentisfullthrottle.

g231368

g008610

Figure7

1.Off3.Start

2.On

Note:Tostarttheengine,theparkingbrakemust beengaged.(Itisnotnecessaryfortheoperatorto beontheplatform.)

HourMeter/TineEngagementDisplay

Locatedtotheleftoftheignitionswitchonthe controlconsole.

•Thehourmetermonitorsanddisplaysengine hours.

ParkBrakeLever

Locatedontherightsideoftheignitionswitchon thecontrolconsole.

Thebrakeleverengagesaparkingbrakeinthe transmissions.

Operation

Therearetwowaystoactivatethedisplay .

1.Tapthemulti-functionswitcheitherupordown todisplaythetineengagementmeter.

2.Steponthetinegroundengagementfootswitch.

Ahighernumberonthestatusbarincreasesthe lengthoftheaerationplugandalowernumber decreasesit.

Note:Ifthepluglengthisnotdesiredlength,the machinemayneedtobeadjustedtoaccommodate

g211730

Figure8

HourMeterDisplay

fortheweightoftheoperator(refertotheOperator WeightAdjustmentControlsectionformore

information).

1.LCDIndicators/Informationscreen

2.Hourdisplay

3.LEDstatuslight

Hoursaredisplayedwhenthekeyisofforwhen themachineisrunning.Hoursarenotdisplayed whenthemachineisaerating.

Note:TheLCDindicatorwillappearinthepark brakesettingwhenitmeetsthe“safetostart” mode(parkbrakeengaged).

•Thetineengagementdisplaymonitorsand displaystheelectronictinedepthsetting.

Note:RefertotheHourMeter/TineEngagement User’sGuidefordetailedinformationexplaining

theOperatorinterfaceallowinguserstoaccess information,resetcounters,modifysystemsettings, andtroubleshoottheequipment.

LEDStatusLights

Locatedontherightsideofthehourmeter/tine engagementdisplay.

TheLEDismulti-coloredtoindicatethesystem statusandislocatedontherightsideofthepanel.

•SolidGreen—indicatesnormaloperating activity.

•BlinkingRed—indicatesafaultisactive.

•SolidRed—indicatesmaintenanceisrequired.

Note:RefertotheHourMeter/TineEngagement User’sGuideformoreinformation.

Multi-FunctionSwitch

TineEngagementDisplay

1.LCDIndicators/Informationscreen

2.Tinedepthstatusbar

3.Tinedepthsettingindicator

4.LEDstatuslight

Figure9

Locatedtotheleftofthehourmeter/tineengagement display.

g211731

Thisswitchallowstheoperatorto:

•increase/decreasethedepthofaerationplug.

•lockorunlockthetinedepthsetting.

•lockorunlocktheTineGroundEngagement FootSwitch.

FuelShut-OffLever

LocatedundertheaircleaneronthefrontRHside.

Thefuelshut-offleverisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays,

duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Rotatethehandlecounterclockwisetoopen;rotate clockwiseto90°toclose.

DriveWheelReleaseValves

WARNING

Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck,which couldresultinseriousinjuryordeath.

Stopengine,removekey,allowallthemoving partstostopbeforeaccessingthedrivewheel releasevalves.

Operation

g211754

Figure10

WARNING

Theengineandhydraulicdriveunitscanbecome veryhot.T ouchingahotengineorhydraulic driveunitscancausesevereburns.

Allowtheengineandhydraulicdriveunitsto coolcompletelybeforeaccessingthedrivewheel releasevalves.

Locatedontheleftandrightsidesabovethe transaxles.

Duringnormaloperatingconditions,thewasher ontheleverispositionedoutsidetheslots.Ifthe machinehastobepushedbyhand,thevalvesmust beinthe“released”position(seeFigure10).

1.Leverpositionfor operatingthemachine

2.Washeroutsideofslot

3.Leverpositiontopush themachine

4.Washerinsideslot

Toreleasethedrivewheels,movethelevertothe largeropeningoftheslot,pushitinuntilthewasher isinsidetheframe,thenmovetheleverbacktothe narrowportionoftheslot.Repeatthisoneachside ofthemachine.

Releasetheparkingbrake.Themachineisnowable tobepushedbyhand.

DoNottowmachine.

Toresetthedrivesystembacktotheoperating position:movethelevertothelargeropeningof theslot,pulloutwarduntilthewasherisoutsideof theframe,thenmovetheleverbacktothenarrow portionoftheslot.Repeatthisoneachsideofthe machine.

TineGroundEngagementFoot Switch

Keephandsandfeetawayfromthetines.Ensure thatthetinesareaisclearofanyobstructions beforeloweringit.

Theswitchislocatedontheoperatorplatform.

Tolowerthetinesintotheground,standonthetine groundengagementswitch.TheLEDilluminates inthehourmeter/tineengagementdisplaywhen thetineengagementisactivated.Toraisethetines, removeyourfootfromtheswitch.

Operation

Thisswitchcanbelockedout(disabled)withthe multi-functionswitch.

•Tapandholdthebottomoftheswitchtooverride andlockout(disable)thefootswitch.TheLED illuminatesinthehourmeter/tineengagement display.Usethisfeaturewhentransportingthe aerator.

•Tounlock,tapandholdthetopofthe multi-functionswitchuntiltheLEDlight disappears.

Note:Thelockoutfeatureisengagedeachtimethe engineisswitchedoff.

OperatorWeightAdjustmentControl

Locatedontheleftsideofthecontrolconsole(see Figure6).

Thisfeaturetakesintoaccounttheweightofthe operatorsothatthecorrectaeratingpressureandplug lengthisachievedandtomaximizelateralmachine stability.Rotatingthecontrolcounterclockwise decreasesthepressureandrotatingitclockwise increasesit(SeeAdjustingtheOperatorWeight ControlSetting).

OperatingInstructions

OpentheFuelShut-OffValve

Rotatethelevercounterclockwisetoopen.

StartingtheEngine

1.Leavethemotioncontrolleversinneutraland engagetheparkingbrake.

2.Setthethrottletothe“FAST”position.

3.Onacoldengine,pullthechokeknobupward intothe“ON”position.Onawarmengine,leave thechokeinthe“OFF”position.

4.Turnignitionswitchtothe“START”position. Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine continuouslyformorethantensecondsata time.Iftheenginedoesnotstart,allowa60 secondcool-downperiodbetweenstarting attempts.Failuretofollowtheseguidelines canburnoutthestartermotor

Enginemaybedifculttostartin temperaturesunder30°F(-1°C).

Note:Eachoperatormustadjustthesystempressure sothatthedrivetireslightlytouchtheground.

Important:Keepthedrivetiresonthegroundat alltimestomaximizelateralmachinestability.

Pre-Start

Fillfueltankonlevelground.SeeFuel RecommendationsintheSpecicationssectionfor

additionalgasolineinformation.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe tankallowsgasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineoremission system.

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

5.Ifthechokeisinthe“ON”position,gradually returnchoketothe“OFF”positionastheengine warmsup.

LoweringtheTines

DANGER

Therotatingtinesundertheenginedeckare dangerous.Tinecontactcancauseseriousinjury orkillyou.

DoNotputhandsorfeetundertheunitwhen theengineisrunning.

1.Disengagetheparkingbrake.Setthrottleto “FAST”position.

2.Thelockoutfeatureisengagedeachtimethe engineisswitchedoff.T ounlock,tapandhold thetopofthemulti-functionswitchuntilthe LEDlightdisappears.

3.Taptheswitchoncetodisplaythetineengagement depthsetting;adjustifnecessary.

Operation

4.Lowerthetinesbypressingonthetineground engagementfootswitch.TheLEDindicator shouldilluminateunderthetinedownposition onthehourmeter.

5.Standontheswitchandmovethemotioncontrol leversforwardtoaerate.

Note:Thefootrockerbar,locatedbehindthe tinegroundengagementfootswitch,canbe adjustedforoperatorcomfort.Toadjust,loosen thefootrockerbarhardware,slidethebarforward orrearward,andretightenhardware.

Locking/UnlockingtheTineDepth Setting

Thesettingscanbelockedtoensurethetinedepth isnotinadvertentlychangedbytheoperatororleft unlocked.

•Toactivatethedepthlock:turntheignitionkey from“OFF”to“ON”vetimes(stopatthe “ON”).Usethemulti-functionswitchtoadjust thetinedepthtothedesiredsetting.Pressand holdthemulti-functionswitchdownforone secondtolock.

•Toinactivatethedepthlock:turntheignition keyfrom“OFF”to“ON”vetimes(stopatthe “ON”).Pressandholdthemulti-functionswitch upforonesecondtounlock.

Switchthekeytothe“OFF”or“START”position whenyouarenished.

AdjustingtheOperatorWeight ControlSetting

adjustmentcontrolcounterclockwisetolower themachineuntilthetirestouchtheground.

•Ifthetinesarenottouchingtheground, rotatetheoperatorweightadjustmentcontrol clockwiseuntilthetineslowerandtouchthe ground(butnotraisethemachine).

Important:Keepthedrivetiresonthe groundatalltimestomaximizelateral machinestabilityandaerationquality .

5.Releasethetinegroundengagementfootswitch.

AdjustingtheTineDepthSetting

Tapthemulti-functionswitchupordowntosetthe aerationdepth.Tapthebottomofthemulti-function switchtoincreasethetinedepthtoremovealonger plug.Tapthetopoftheswitchtodecreasethetine depthtoremoveashorterplug.

Note:Tinedepthadjustmentscannowbemade withthemulti-functionswitchonly.Theidealplug depthis2.5–3inches(6.4–7.6cm).Adjustcontrolsto adapttothesoilconditions.

RaisingtheTines

Toraisethetines:

•Removeyourfootfromthetineground engagementfootswitch

•Theignitionkeyisswitchedfromthe“ON” positiontothe“OFF”position.

Important:Thetinesarerotatingwhenthe motioncontrolleverismovedoutoftheneutral position.

1.Withthetinesraised,drivetheaeratortoa hard,atsurface(suchasconcrete)andstopthe aerator,butleaveitrunning.

2.Setthrottletothe“FAST”positionanddisengage theparkbrake.

3.Usethemulti-functionswitchtosetthetinedepth to3.0(seeAdjustingtheTineDepthSetting section.

4.Pressandholdthetinegroundengagementfoot switchtolowerthetines.

•Ifthemachineraisesandthegroundtiresare nolongertouching,rotatetheoperatorweight

StoppingtheEngine

1.Movethemotioncontrolleversbacktothe neutralpositionandbringtheunittoafullstop.

2.Liftyourfootoffofthetinegroundengagement footswitchcontroltoraisethetines.

3.Activatethetineengagementfootswitchlockout.

4.Placethethrottlemidwaybetweenthe“SLOW” and“FAST”positions.

5.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

6.Engagetheparkingbrake.

Operation

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingtheengine.

8.Closethefuelshut-offvalvewhenthemachine willnotbeinuseforafewdays,when transporting,orwhentheunitisparkedinside abuilding.

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioningone levertoomuchaheadoftheother.Operatormay losecontrolofthemachine,whichmaycause damagetothemachineorinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

g016672

Figure12

Important:Tobeginmovement(forwardor

backward),thebrakelevermustbedisengaged (pushedforward)beforethemotioncontrol leverscanbemoved.

Figure11

1.LHMotioncontrollever5.Forward

2.RHMotioncontrollever6.Neutral

3.Frontreferencebar

4.Frontofunit

7.Reverse

DrivingForward

Toturnleftorright,pullthemotioncontrollever backtowardneutralinthedesiredturndirection. Thetinescanbeinthedownpositionwhen makinggradualturns.

Tomakezeroturns,liftyourfootoffofthetine engagementfootswitchcontroltoraisethetines. Theheadwillraiseinonesecond.

Important:DoNotmakeazeroturnwhen thetinesaredownasturftearingwillresult.

Themachinewillmovefasterthefartherthe motioncontrolleversaremovedfromtheneutral position.

g223330

4.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

DrivinginReverse

1.Movethemotioncontrolleverstotheneutral operateposition.

2.Tomoverearwardinastraightline,slowlymove bothleversrearwardwithequalpressure.

1.Makesurethemotioncontrolleversareinthe neutralposition.

2.Releasetheparkingbrake.

3.Tomoveforwardinastraightline,moveboth leversforwardwithequalpressure.

Important:DoNotdriveinreversewhenthe tinesaredownasturftearingwilloccur.

Figure13

Operation

g016673

g231460

Figure14

Toturnleftorright,releasepressureonthe motioncontrollevertowardthedesiredturn direction.

Tomakezeroturns,liftyourfootoffofthetine groundengagementfootswitchtoraisethetines. Theheadwillraiseinhalfsecond.

Important:DoNotmakeazeroturnwhen thetinesareinthedownposition.

3.Tostop,positionbothmotioncontrolleversin theneutraloperateposition.

AdjustingtheFrontReference/Speed ControlBar

Adjustthefrontreference/speedcontrolbarfor desiredmaximumforwardspeed.

1.Stopthemachineandmovethemotioncontrol leverstotheneutralposition.

2.Loosentheboltsonbothsidesofthecontrol towerbylooseningthetwonutsoneachside (fourtotal)oftheconsole(seeFigure14).

1.Twonuts

2.Frontreference/speed controlbar

3.Movethebarforwardtoobtainthefastestspeed.

Movethebarbackwardtoobtaintheslowest speed.

4.Onbothsides,tightenthenutsandbolts.

Important:Makesurethenutsandboltsare tightsothefrontreference/speedcontrolbar doesnotmoveduringoperation.

Transporting

TransportingaUnit

Useaheavy-dutytrailerortrucktotransportthe machine.Lockbrakeandblockwheels.Besure thefuelshut-offvalveisclosed.Securelyfastenthe machinetothetrailerortruckwithstraps,chains, cable,orropes.Ifpossible,bothfrontandrear strapsshouldbedirecteddownandoutwardfrom themachine.Onlyusethefourdesignatedtie-down locationsonthemachine-twoontheleftsideandtwo ontheright(see).Besurethatthetrailerortruckhas allnecessarylightingandmarkingasrequiredbylaw . Secureatrailerwithasafetychain.

Operation

Figure15

Leftsideshown

1.Tie-downlocation

CAUTION

Thisunitdoesnothaveproperturnsignals, lights,reectivemarkings,oraslowmoving vehicleemblem.Drivingonastreetorroadway withoutsuchequipmentisdangerousand canleadtoaccidentscausingpersonalinjury. Drivingonastreetorroadwaywithoutsuch equipmentmayalsobeaviolationofStatelaws andtheoperatormaybesubjecttotrafctickets and/ornes.

wideenoughtoextendbeyondthereartiresis recommendedinsteadofindividualrampsforeach sideofthemachine.Withtheplatformup,afull widthrampprovidesasurfacetowalkonbehindthe machine.Ifitisnotpossibletouseonefullwidth ramp,useenoughindividualrampstosimulateafull widthcontinuousramp.

Asteeprampanglemaycausecomponentstoget

g212139

caughtasthemachinemovesfromramptotraileror truck.Steeperanglesmayalsocausethemachineto tipbackward.Ifloadingonornearaslope,position thetrailerortrucksoitisonthedownsideofthe slopeandtherampsextendsuptheslope.Thiswill minimizetherampangle.Thetrailerortruckshould beaslevelaspossible.

Important:DoNotattempttoturnthemachine whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp andsuddendecelerationwhenbackingdowna ramp.Bothmaneuverscancausethemachinetotip backward.

DoNotdriveaunitonapublicstreetorroadway.

WARNING

Loadingamachineonatrailerortruckincreases thepossibilityofbackwardtip-over.Backward tip-overcouldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatinga machineonaramp.

•Useonlyasingle,fullwidthramp;DoNotuse individualrampsforeachsideofthemachine.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthanthemachine.

•Avoidsuddenaccelerationwhiledriving machineuparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking machinedownaramptoavoidtipping backward.

LoadingaMachine

Useextremecautionwhenloadingmachineson trailersortrucks.Onefullwidthrampthatis

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

Maintenance

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecouldseriously injureyouorotherbystanders.

Removethekeyfromtheignitionswitch,engage parkingbrake,andpullthewire(s)offthespark plug(s)beforeyoudoanymaintenance.Also pushthewire(s)asidesoitdoesnotaccidentally contactthesparkplug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthetransmissionoutputshaftnuttorquespecication.

•Checkthewheelhubbolttorquespecication.

•Checktransmissionmountbolttorque.

•Changetheauxiliaryhydraulicreservoirlteranduid.

•Changethehydraulictransmissionlteranduid.

WARNING

Theenginecanbecomeveryhot.Touchingahot enginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheenginearea.

Beforeeachuseordaily

Every25hours

Every50hours

Every80hours

Every100hours

Every160hours

•Checktheengineoillevel.

•Checkthetines.

•Checkforloosehardware.

•Checktheconditionandtensionofthechains.

•Checktheconditionofthesprockets.

•Lubricatethechains.

•Cleantheengineandexhaustsystemarea.

•Cleanthegrassanddebrisbuild-upfromthemachine.

•Greasethefrontwheelbearings.

•Greasetineshaftbearings.

•Greasetransmissionoutputshaftangedbearings.

•Greasehydrooutputshaftangedbearings.

•Checktheauxiliaryhydraulicoillevel.

•Checkthehydraulictransmissionoillevel.

•Checkthetirepressures.

•Checktheconditionandtensionofthebelts.

•Checksparkarrester(ifequipped).

•Removeengineshroudsandcleancoolingns.

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Checkthesparkplug.

Maintenance

MaintenanceService

Interval

Every250hours

Every500hours

Monthly

Yearly

MaintenanceProcedure

•Replacetheprimaryaircleanerelement—checksecondaryaircleanerelement;replaceif dirty.(Mayneedmoreoftenundersevereconditions.SeetheEnginemanualforadditional information.)

•Changetheauxiliaryhydraulicreservoirlteranduid.

•Changethehydraulictransmissionlteranduid.

•Replacethesecondaryaircleanerelement.(Mayneedmoreoftenundersevereconditions. SeetheEnginemanualforadditionalinformation.)

•Checkthebatterycharge.

•Greasebeltidlerpivot.

•Greasefrontcasterhubs.

•Checkthetransmissionoutputshaftnuttorquespecication.

•Checkthewheelhubbolttorquespecication.

•Checktransmissionmountbolttorque.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Cleanareaarounddipstick.Removedipstick andwipeoiloff.Reinsertthedipstickaccording totheenginemanufacturer'srecommendations. Removethedipstickandreadtheoillevel.

4.Iftheoillevelislow,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Exmark4-CyclePremium EngineOilisrecommended;refertotheEngine Owner'smanualforanappropriateAPIrating andviscosity .DoNotoverll.

Important:DoNotoperatetheenginewiththe oillevelbelowthe“LOW”(or“ADD”)markon thedipstick,oroverthe“FULL”mark.

CheckBatteryCharge

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof timewithoutrechargingthemwillresultinreduced performanceandservicelife.Topreserveoptimum batteryperformanceandlife,rechargebatteriesin storagewhentheopencircuitvoltagedropsto12.4 volts.

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Checkthevoltageofthebatterywithadigital voltmeter.Locatethevoltagereadingofthebatteryin thetableandchargethebatteryfortherecommended timeintervaltobringthechargeuptoafullcharge of12.6voltsorgreater.

Important:Makesurethenegativebatterycable isdisconnectedandthebatterychargerusedfor chargingthebatteryhasanoutputof16voltsand 7ampsorlesstoavoiddamagingthebattery(see chartforrecommendedchargersettings).

Maintenance

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

14.4volts/2 amps

RecommendedJump StartingProcedure

ServiceInterval:Asrequired

1.Checktheweakbatteryforterminalcorrosion (white,green,orblue“snow”),itmustbecleaned offpriortojumpstarting.Cleanandtighten connectionsasnecessary.

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

Charging Interval

No Charging Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

shortlengthstoreducevoltagedropbetween systems.Makesurethecablesarecolorcodedor labeledforthecorrectpolarity.

CAUTION

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe electricalsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

Note:Thefollowinginstructionsareadapted fromtheSAEJ1494Rev .Dec.2001–Battery BoosterCables–SurfaceVehicleRecommended Practice(SAE–SocietyofAutomotive Engineers).

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

Note:Besuretheventcapsaretightandlevel. Placeadampcloth,ifavailable,overanyvent capsonbothbatteries.Besurethevehiclesdo nottouchandthatbothelectricalsystemsare offandatthesameratedsystemvoltage.These instructionsarefornegativegroundsystemsonly.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe enginemayoccur.

DANGER

Jumpstartingaweakbatterythatiscracked, frozen,haslowelectrolytelevel,oran open/shortedbatterycell,cancausean explosionresultinginseriouspersonalinjury.

DoNotjumpstartaweakbatteryifthese conditionsexist.

2.Makesuretheboosterisagoodandfullycharged leadacidbatteryat12.6voltsorgreater.Use properlysizedjumpercables(4to6AWG)with

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure16.

Maintenance

CAUTION

Raisingtheunitforserviceormaintenance relyingsolelyonmechanicalorhydraulic jackscouldbedangerous.Themechanicalor hydraulicjacksmaynotbeenoughsupport ormaymalfunctionallowingtheunittofall, whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic

g012785

Figure16

jacksforsupport.Useadequatejackstands orequivalentsupport.

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

5.Connecttheblacknegative(–)cabletotheother terminal(negative)oftheboosterbattery.

6.MAKETHEFINALCONNECTIONON THEENGINEBLOCKOFTHESTALLED VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK.

7.Startthevehicleandremovethecablesinthe reverseorderofconnection(theengineblock (black)connectionisthersttodisconnect).

3.Removeandretainthetwoboltsfromtherear coverpanel.

4.Removerocksandotherdebrisfromthetines.

5.Inspectthetinesandreplaceasrequired.

CheckTines

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lifttherearoftheunitandsupportusingjack standsorequivalentsupport.

Maintenance

ChecktheSafetyInterlock

Important:Itisessentialthattheoperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortouse.

Note:Ifmachinedoesnotpassanyofthesetests,DoNotoperate.ContactanAuthorizedServiceDealer.

ChecktheNormalEngineStartingCircuit

System

ParkingBrakeOutcome

EngagedStartershouldcrank

StateofSystem

CheckEngineStartingCircuitChart

Note:IntheCheckEngineStartingCircuitChart,thestateofsystemitemthatisboldisbeingchecked.

System

ParkingBrakeOutcome

Disengaged

StateofSystem

Startershouldnotcrank

Maintenance

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every250hours—Replace

theprimaryaircleaner element—check secondaryaircleaner element;replaceifdirty. (Mayneedmoreoften undersevereconditions. SeetheEnginemanualfor additionalinformation.)

Every500hours— Replacethesecondary aircleanerelement.(May needmoreoftenunder severeconditions.See theEnginemanualfor additionalinformation.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.SeetheEngineOwner'sManualformaintenance instructions.

ChangeEngineOil

ServiceInterval:Aftertherst5hours

Every100hours(May needmoreoftenunder severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Theoildrainplugislocatedontheleftsideof theengine.

Placepanundermachinetocatchoil.Removeoil drainplug.Allowoiltodrainandreplaceoildrain plug.Torqueplugto13ft-lb(18N-m).

4.ReplacetheoillterpertheEngineOwner's Manual.Cleanaroundtheoillterandcarefully removethelterbyunscrewingit.Makesureno

oildrainsontothebeltdrivesthroughtheholesin theenginedeck.Beforethenewlterisinstalled, applyathincoatingofExmark4–CyclePremium EngineOilonthesurfaceoftherubberseal. Turnlterclockwiseuntilrubbersealcontacts thelteradapter,thentightenlteranadditional 2/3to3/4turn.

5.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

6.UseoilrecommendedintheCheckEngineOil Levelsection.DoNotoverll.Starttheengine andcheckforleaks.Stopengineandrecheckoil level.

7.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

CheckAuxiliaryHydraulic OilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop, andremovekey.Engageparkingbrake.

2.Cleanareaaroundhydraulicreservoircapand removecap.Oillevelshouldbetothetopofthe bafeinsidethetank.Ifnot,addoil.UseAW -32 hydrooil.Replacehydraulicreservoircapand tightenuntilsnug.DoNotovertighten.

Note:Thebafeislabeled“HOT”and “COLD”.Theoillevelvarieswiththe temperatureoftheoil.The“HOT”levelshows thelevelofoilwhenitisat225°F(107°C).The “COLD”levelshowstheleveloftheoilwhen itisat75°F(24°C).Filltotheappropriatelevel dependinguponthetemperatureoftheoil.For example:Iftheoilisabout150°F(65°C),llto halfwaybetweenthe“HOT”and“COLD”levels. Iftheoilisatroomtemperature(about75°F (24°C)),llonlytothe“COLD”level.

CheckHydraulic TransmissionOilLevel

ServiceInterval:Every50hours

1.Stopengineandwaitforallmovingpartstostop, andremovekey.Engageparkingbrake.

2.Withtheunitcold,checktheexpansiontankand ifnecessaryaddExmarkPremiumHydroOilto theFULLCOLDline.

Maintenance

CheckTirePressures

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto22-24psi(152-165kPa).

4.Semi-pneumaticcastertiresdonotneedtobe inated.

CheckConditionandTension OfBelts

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktheauxiliarypumpdrivebeltconditionand tension;beltshouldbesnug.SeeAuxiliaryPump DriveBeltAdjustmentintheAdjustments section.

3.Checkconditionofthetransmissiondrivebelt.

1.Shutofftheengine,waitforallmovingpartsto stop,andremovethekey.Engagetheparking brake.

2.Lifttherearofthemachineandsupportusing jackstandsorequivalentsupport.

CAUTION

Raisingthemachineforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing themachinetofall,whichcouldcauseinjury.

Donotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

3.Starttheengineandmovethrottlecontrolahead to1/2throttleposition.Disengagetheparking brake.

WARNING

CheckConditionOfChains

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checkthechainsonbothsidesoftheunitfor propertension.Thechainsshouldbeableto moveupanddown1/4-1/2inch(6-12mm).

3.IfchainspoporsnapseeDriveChain

TensionAdjustmentorTineDriveT ension AdjustmentintheAdjustmentssection.

CheckConditionOf Sprockets

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Inspectsprocketsforwearandreplaceasrequired.

LubricatingtheChains

ServiceInterval:Beforeeachuseordaily

Important:Donotlubricatethechainswith

penetratingoilorsolvents.Useanoilorchain lubricant.

Theenginemustberunningandthedrive wheelsmustbeturningsothatadjustments canbeperformed.Contactwithmovingparts orhotsurfacesmaycausepersonalinjury.

Keepyourngers,hands,andclothingclear ofrotatingcomponentsandhotsurfaces.

4.Withtheenginerunning,slowlymovethemotion controlleversforwardandlubricateallfour chains.

5.Checktheconditionandtensionofthechains (seeCheckConditionofChains).

LubricatingtheGrease Fittings

Note:Seethechartbelowforserviceintervals.

1.Shutofftheengine,waitforallmovingpartsto stop,andremovethekey.Engagetheparking brake.

2.LubricatethettingswithNLGIgradeNo.2 multi-purposegrease.

Refertothefollowingchartforttinglocations andlubricationschedule.

LubricationChart

Maintenance

LubricationChart(cont'd.)

Fitting

Locations

1.FrontWheel CasterHubs

2.TineShaft Bearings

3.BeltIdler Pivot

Initial

Pumps

Numberof

Places

Service

Interval

Yearly

25hours

Yearly

Important:Applyathincoatofoilonthe surfaceoftherubberseal.

Turnlterclockwiseuntilrubbersealcontactsthe lteradapter,thentightenthelteranadditional 2/3to3/4turn.

5.Reinstallthehoseandtorqueto37ft-lb(50N-m).

6.AddA W-32hydrooiluntilthelevelreachesthe “coldllline”locatedonthereservoirtank.Start engineandraiseandlowerthetines.Lowerthe tinestothegroundandrellthereservoirtothe “coldllline”.

ChangeHydraulic TransmissionFiltersand Fluid

ServiceInterval:Aftertherst100hours

Every250hoursthereafter

1.Stopengine,waitforallmovingpartstostop,and removekeyorsparkplugwire(s).Engageparking brake.

CheckSparkPlug

ServiceInterval:Every160hours

Removethesparkplug,checkconditionandreset gaps,orreplacewithanewplug.SeeEngineOwner's Manual.

ChangeAuxiliaryHydraulic ReservoirFluidandFilter

ServiceInterval:Aftertherst100hours

Every250hoursthereafter

1.Stopengine,waitforallmovingpartstostop,and removekeyorsparkplugwire(s).Engageparking brake.

2.Carefullycleanareaaroundthefrontofthe auxiliarypumpandllcap;alsocleanaroundthe lter.Itisimportantthatnodirtorcontamination enterhydraulicsystem.

3.Unscrewthesuctionhosefromthepumptting, cleanaroundthepumptting,andallowoilto drain.

4.Unscrewtheltertoremoveandallowoilto drain.

2.Placeacatchpanbetweenthetransmissions.

3.Removethetwodrainplugs,locatedatthebottom ofeachtransmission,tofullydraintheoil.

4.Locatethetwoltersunderthetransmissions.

5.Carefullycleanareaaroundlters.Itisimportant thatnodirtorcontaminationenterhydraulic system.

6.Unscrewlterstoremoveandallowoiltonish drainingfromdrivesystem.

Important:Beforereinstallingnewlters, applyathincoatofExmarkPremiumHydro Oilonthesurfaceoftheltersrubberseal.

Turntheltersclockwiseuntilrubberseal contactsthelteradapterthentightenthelter anadditional3/4to1fullturn.

7.Reinstallthetwodrainplugs.

8.Removetheventplugoneachtransmissionand llthroughexpansionreservoir,whenoilcomes outofventreinstallplug.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

Maintenance

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

Torqueplugsto180in-lb(20N-m).Continueto addExmarkPremiumHydroOiluntilitreaches theFULLCOLDlineontheexpansionreservoir.

9.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

ChangeInterval

250Hours

CAUTION

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminantsintothesystem.

CheckTransmission OutputShaftNutTorque Specication

ServiceInterval:Aftertherst5hours

Yearlythereafter

Torquethenutonthetransmissionoutputtapered shaftto211-260ft-lb(286-352N-m).

CheckWheelHubBolt TorqueSpecication

ServiceInterval:Aftertherst5hours

Yearlythereafter

Torquethewheelhubboltto27-33ft-lb(37-45N-m).

Note:DoNotuseanti-seizecompoundonthe wheelhub.

10.Startengineandmovethrottlecontrolaheadto 1/2throttleposition.Disengageparkingbrake.

WARNING

Enginemustberunninganddrivewheels mustbeturningsomotioncontroladjustment canbeperformed.Contactwithmovingparts orhotsurfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

A.Withtheenginerunning,slowlymovethe

directionalcontrolinbothforwardand reversedirections(5to6times).Checktheoil level,andaddoilasrequiredafterstopping theengine.

B.ItmaybenecessarytorepeatstepA.untilall

theairiscompletelypurgedfromthesystem. Whenthetransaxleoperatesatnormalnoise levelsandmovessmoothlyforwardand reverseatnormalspeeds,thenthetransaxle isconsideredpurged.

Note:DoNotchangethehydraulicsystemoil (exceptforwhatcanbedrainedwhenchanginglter andremovingthedrainplugs),unlessitisfelttheoil hasbeencontaminatedorbeenextremelyhot.

CheckTransmissionMount BoltTorque

ServiceInterval:Aftertherst5hours

Yearlythereafter

Torquethefourtransmissionboltsto41-51ft-lb (56-69N-m)(referenceFigure17).

Note:DoNotuseanti-seizecompoundonthe wheelhub.

g233601

Figure17

1.Transmissionbolt

Maintenance

CheckSparkArrester

(ifequipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresult inpersonalinjuryorpropertydamage.

DoNotrefuelorrunengineunlesssparkarrester isinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacearrester.

4.Ifpluggingofthescreenisobserved,remove arresterandshakelooseparticlesoutofthe arresterandcleanscreenwithawirebrush(soak insolventifnecessary).Reinstallarresteron exhaustoutlet.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242” or“Fel-Pro,Pro-LockNutType”areusedonthe followingfasteners:

Sheaveretainingboltinendofenginecrankshaft.

Allsetscrews.

Maintenance

Adjustments

Note:Shutoffengine,waitforallmovingpartsto stop,engageparkingbrake,andremovekeybefore servicing,cleaning,ormakinganyadjustmentsto theunit.

CAUTION

Raisingtheunitforserviceormaintenance relyingsolelyonmechanicalorhydraulic jackscouldbedangerous.Themechanicalor hydraulicjacksmaynotbeenoughsupportor maymalfunctionallowingtheunittofall,which couldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstandsor equivalentsupport.

AuxiliaryPumpDriveBelt Adjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Totightenbelt,loosenboth3/8inchnutson auxiliarypump.Slidepumpoutwardinslotsand retightennuts.

3.Whenproperlyadjusted,thebeltshouldhave1/2 inch(1.3cm)ofdeectionwiththreepoundsof forceonthebeltmidwaybetweentheauxiliary pumpandenginepulley .

3.Checkthechainsoneachsideoftheidler sprocket,onbothsidesofthemachine,forproper tension.Thechainsshouldbeabletomoveup anddown1/4-1/2inch(6-12mm).

4.Toadjust,loosentheidlerboltandpushupon thesprockettotensionthechain.

Note:DoNotovertightenthechain.

5.Recheckthechaintensionandtightentheidler bolt.

TineDriveChainAdjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lifttherearofthemachineandsupportusing jackstandsorequivalentsupport.

3.Checkthechainsoneachsideoftheidler sprocket,onbothsidesofthemachine,forproper tension.Thechainsshouldbeabletomoveup anddown1/4-1/2inch(6-12mm).

4.Toadjust,loosentheidlerboltandpushupon thesprockettotensionthechain.

Note:DoNotovertightenthechain.

5.Recheckthechaintensionandtightentheidler bolt.

AdjustingtheParkingBrake

TransmissionDriveBelt Tension

Note:Noadjustmentsarerequiredforbelttension.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Installthenewbelt.

3.Makesuretheidlerarmandpulleycanmove freely.

DriveWheelChainTension Adjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lifttherearofthemachineandsupportusing jackstandsorequivalentsupport.

Iftheparkingbrakedoesnotholdsecurely ,an adjustmentisrequired.

1.Parkthemachineonalevelsurface.

2.Shutoffengineandwaitforallmovingpartsto stop.

3.Checktheairpressureinthedrivetires.Ifneeded, adjusttotherecommendedination;referto CheckTirePressuresection.

4.Disengagetheparkbrake.

5.Loosentheadjustmentnutonthebrakecable bracketundertheconsole.

6.Adjustbothcableconduitsdownward approximately1/8–1/4inch(3–6mm).See Figure18.

Maintenance

Figure18

1.Adjustmentnut

7.Tightenthecableadjustmentnutandengagethe parkbrake.

8.Checktheparkbrake;repeatsteps5through7if necessary.

MotionControlLinkage Adjustment

1.Parkthemachineonalevelsurface.

2.Shutoffengineandwaitforallmovingpartsto stop.

3.Pushthecontrolleversallthewayforwardtothe frontreferencebar.

Ifeitherofthecontrolleverscontactthe referencebar,allowthecontrolleverstoreturn toneutral.Loosenthetwojamnutsonthe RHhexadjustmentlinkage.Notethatone jamnutisaright-handthreadandtheotheris left-hand.Turnthehexadjustmentlinkageuntil therecommendedgapisachieved.Retightenthe jamnuts.Repeatthisstepuntilthereis1/8-1/4 inch(3–6mm)gapbetweentheRHcontrollever andthefrontreferencebar.Oncethegapis achieved,proceedwithstep4.

g233407

Figure19

1.Hexadjustmentlinkagejamnut

4.Allowthecontrolleverstoreturntoneutral. TurntheLHhexadjustmentlinkuntilthemotion controlleversareapproximatelyevenwitheach other.

5.Repeatsteps3and4forothermotioncontrol linkage.

MotionControlTracking Adjustment

Ifthemachinetravelsorpullstoonesidewhenthe motioncontrolleversareinthefullforwardposition, adjustthetracking.

1.Pushbothcontrolleversforwardthesame distance.

2.Checkifthemachinepullstooneside.Ifitdoes, stopthemachineandsettheparkingbrake.

3.LoosenthelocknutsontheRHmotioncontrol linkage(asviewedfromtherearofthemachine. PushtheRHcontrolleverforwardandrotatethe adjustmentroduntilthereis1/8-1/4inch(3–6 mm)gapbetweentheRHcontrolleverandthe frontreferencebar.

4.SeeAdjustingtheFrontReference/Speed ControlBarinOperation.Placethefront reference/speedcontrolbarinthemaximum forwardposition.

g231567

5.RotatetheadjustmentrodontheLHsideofthe machine(asviewedfromtherearofthemachine —seeFigure20).

Figure20

Maintenance

g233418

1.Adjustmentrod

6.Lookingdowntowardstheadjustmentrod— rotateitcounterclockwise,in1/4turnincrements, toincreasespeedorclockwisetodecreasespeed.

7.Drivethemachineandcheckthefullforward tracking.

8.Repeatsteps5through7untildesiredtracking isobtained.

Return-to-UpSpring Adjustment

WARNING

Springshavestoredenergy.Overtighteningthe springsmaycausethespringstofailwhichcan causeseriousinjuryordeathanddamagetothe machineandproperty.

Makesurespringsareproperlyadjustedand/or replacedasspeciedintheOperator'smanual.

g233568

Figure21

1.1.38inch(35mm)

Important:Thespringsmustbereplaceditthe gapislessthan1.13inches(29mm).

Alwaysreplacebothreturn-to-upsprings.This preventsunevenloadingandpossibledamageto themachine.

Checkthegapbetweenthespringbracketandthe endofthespringasshowninFigure21.Thegap shouldmeasure1.38inch(35mm).Adjustmentis madebyturningtheboltatthefrontofeachspring (clockwisewillshortenthegap,counter-clockwise willlengthenthegap).

Maintenance

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundenginecoolingair intakeandexhaustsystemareacancauseengine, exhaustarea,andhydraulicsystemtooverheat whichcancreatearehazard.

Cleanalldebrisfromengineandexhaustsystem area.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screen,aroundengineshrouding,andexhaust systemarea.

3.Wipeupanyexcessivegreaseoroilaroundthe engineandexhaustsystemarea.

guards,aroundthefueltank,aroundengineand exhaustarea.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid,which ispoisonousandcancausesevereburns. Swallowingelectrolytecanbefatalorifittouches skincancausesevereburns.

•Wearsafetyglassestoshieldeyes,andrubber glovestoprotectskinandclothingwhen handlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwithwater andcalladoctorimmediately .

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every80hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removecoolingshroudsfromengineandclean coolingns.Alsocleandust,dirt,andoilfrom externalsurfacesofenginewhichcancause impropercooling.

3.Makesurecoolingshroudsareproperlyreinstalled. Operatingtheenginewithoutcoolingshroudswill causeenginedamageduetooverheating.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanoffanyoil,debris,orgrassbuild-uponthe machineandaeratordeck,especiallyunderchain

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

Ifabatteryisbeingreplacedoriftheunitcontaining thebatteryisnolongeroperatingandisbeing scrapped,takethebatterytoalocalcertiedrecycling center.Ifnolocalrecyclingisavailablereturnthe batterytoanycertiedbatteryreseller.

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortouse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor itemsoranyitemsthatcallforspecialtimingofadjustmentsprocedures(suchasvalves,governor,etc.).Have thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank.

Enginewillnotstart,startshard,orfailsto keeprunning

1.Brakeswitchnotoperatingproperly.

2.Batterydoesnothaveafullcharge.

3.Electricalconnectionsarecorroded,loose orfaulty.

4.Fuseisblown.4.Replacetheblownfuse.

5.Relayorswitchisdefective.5.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Thethrottleandchokearenotinthe correctposition.

4.Ambienttemperatureistoolow.

5.Dirt,water,orstalefuelisinthefuel system.

6.Aircleanerisdirty .

Electricalconnectionsarecorroded,loose orfaulty.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

9.Faultysparkplug.

10.

Sparkplugwireisnotconnected.

1.Checkthebrakeswitchandreplaceas necessary.

Chargethebattery.SeeCheckBattery

ChargeandRecommendedJump StartingProceduresectionsin

Maintenance.

3.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Besurethethrottlecontrolismidway betweenthe“SLOW”and“F AST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.

4.Placemachineintoawarmerenvironment untilhydroandengineoilwarms.

5.ContactanAuthorizedServiceDealer.

6.Cleanorreplacetheaircleanerelement.

7.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

9.Clean,adjustorreplacesparkplug. Checkthesparkplugwireconnection.

10.

Enginelosespower.

1.Engineloadisexcessive.1.Reducethegroundspeedoraeration

Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

Coolingnsandairpassagesforthe engineareplugged.

5.Dirt,water,orstalefuelisinthefuel system.

depth.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

Removetheobstructionsfromthe coolingnsandairpassages.

5.ContactanAuthorizedServiceDealer.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Engineoverheats.

Machinepullsleftorright(withleversfully forward).

Machinedoesnotdrive.

Abnormalvibration.

Tinesdonotraise.

1.Engineloadisexcessive.1.Reducethegroundspeedoraeration

2.Oillevelinthecrankcaseislow .

3.Coolingnsandairpassagesforthe engineareplugged.

1.Tirepressureindrivetiresnotcorrect.1.Adjusttirepressureinthedrivetires.

2.Trackingneedsadjustment.

1.Driveorpumpbeltisworn,looseor broken.

2.Driveorpumpbeltisoffapulley.2.Changethebelt.

1.Tine(s)is/arebent.

2.Tinemountingboltisloose.2.Tightenthetinemountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulleyoridlerpulley .

5.Enginepulleyisdamaged.5.ContactanAuthorizedServiceDealer.

6.Beltisdamaged.6.Installnewbelt.

7.Chainsarenotproperlytensioned.

1.Return-to-upspringsarenotproperly adjusted.

2.Return-to-upspringsaredamaged.

3.Shortinharness.

depth.

2.Addoiltothecrankcase.

3.Removetheobstructionsfromthe coolingnsandairpassages.

SeeMotionControlLinkage AdjustmentinAdjustmentssection.

1.Changethebelt.

1.Installnewtine(s).

4.Tightentheappropriatepulley.

SeeDriveWheelChainTension

AdjustmentandTineDriveChain AdjustmentinAdjustmentssection.

SeeReturn-to-UpSpringsAdjustment intheAdjustmentssection.

2.Replacesprings.

3.ContactanAuthorizedServiceDealer.

Tinesdonotengagetheground.

1.Electronicdepthcontrolissettooshallow .1.Increaseelectronicdepthcontrolsetting.

2.Tinedownpressuresettingistoolow .2.Increasetinedownpressure.

3.Harness/switchisdamaged.

4.Auxiliaryreservoirislowonoil.4.Addoiltoreservoir.

5.Parkbrakeisengaged.5.Disengagetheparkbrake.

6.Tinegroundengagementswitchislocked out.

3.ContactanAuthorizedServiceDealer.

6.Unlocktinegroundengagementswitch.

BT01

TERMINAL +

TERMINAL -

BATTERY

IGNITION SWITCH

SW01

RUN

START

OFF

P07

FUSE BLOCK

34576

P06

DIS01

FUEL-HOUR METER

B+

SEN A IN

SW PWR

KEY S

START SIG

FOOT

PARK BRAKE

TINE DOWN OUT

TINE UP OUT

DOWN IN

SEN B IN

UP IN

GND-S/D

GND

CAN LO

CAN HI

P08

121420

512

P08

1611131519

SW03

BRAKE SWITCH

P11

GREEN/BROWN

GREEN/GRAY

WHITE/TAN

WHITE/BLACK

BLUEBLUE

BLUE

RED/WHITE

WHITE/BLUE

F01 15A

ACC'Y

F02 20A

MAIN

STARTER RELAY

K03

ACC SIGNAL

ACC PWR

GND

CAP01

ACC'Y

P01

CAN HI

CAN LO

PWR -SW

PWR - FUSED

GND

CAP02

SERVICE PORT

P09

12345

SP01

RED

ORANGE/RED

BLACK

SP02

RED

SP03

RED/GREEN

SP04

ORANGE

BLUE/RED BLUE/RED

SP05

BLUE

BLUE/BLACK

RED/WHITE

BLACK

WHITE/BROWN

BLACK

RED/WHITE

RED/GREEN

VIOLET/RED

BLACK

VIOLET/BLACK

GREEN

YELLOW

BLACK

RED/WHITE

RED/GREEN

BLACK

YELLOW/WHITE

RED/GREEN

RED

BLACK

BLUE/YELLOW

J01

J02

SW02

FOOT SWITCH

P10

B+

REG

START

MAG

ENGINE - KOHLER

ENG01

BLACK

ENG

GND

IGNITION

MODULES

FLYWHEEL

ALT

REG VIOLET

P05

J05

J03

J04

J06

P02

PWR

GND

CHANNEL A4CHANNEL B

S04

DOWN

(ON)-OFF-(ON)

P12

13468

P12

Relief

Valve

Manifold Assembly

L02

P03

Sol A-

P04

Sol B-

P03

Sol A+

P04

Sol B+

QUADRATURE SENSOR

SEN01

Schematics

ElectricalSchematic

g231578

Schematics

HydraulicSchematic

g243786

MI D-MOUNT RIDING AC CESSORI ES AND OPTIONS

EXMARK ACCESSORIES AND OPTIONS*

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT RIDI NG ACCESS ORIES A ND OPTI ONS

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

*Some accessories and options not available for some models.

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

ModelNo.EngineSerialNo.(E/No)

SerialNo.

Pack)orFillinBelow

DatePurchased

EngineModelNo.andSpec.No.

www.exmark.com

PartNo.4503-596Rev.B (402)223-6375 Fax(402)223-5489 PrintedintheUSA

*4503-596*B

Exmark ARX440CKC24000 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual