Exmark FRCK724, FRCK524, FRCK604 Operator's Manual

ULTRAV AC®QDS

FRONTRUNNERTMMODELS

ForUltraVacSerialNos.
720,000&Higher

PartNo.4500-274Rev.A

Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.

©2006–2008—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310

2

Contactusatwww.Exmark.com.

PrintedintheUSA.

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour
ExmarkUltraVacQDS.Thisproducthasbeen
carefullydesignedandmanufacturedtogiveyou
amaximumamountofdependabilityandyearsof
trouble-freeoperation.

Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
UltraVacQDS.

BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourUltra
VacQDS,maintainitsmaximumefciency,and
promotesafeoperation.

Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.

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

AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready .

Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

3

Contents

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

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

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

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

SafetyandInstructionalDecals.......................8

Specications.......................................................10

ModelNumbers............................................10

Systems.........................................................10

Dimensions...................................................10

TorqueRequirements....................................10

ProductOverview................................................11

Operation.............................................................11

Pre-Start........................................................11

OperatingInstructions..................................11

Transporting.................................................14

Maintenance.........................................................16

RecommendedMaintenanceSchedule(s)...........16

PeriodicMaintenance.......................................16

CheckBlowerHousing/Impeller...................16

LubricateGreaseFittings...............................16

CheckConditionofBelt................................17

Adjustments.....................................................18

Cleaning...........................................................19

CleanMuferandRearFrameArea................19

CleanRearScreenInHopper.........................19

CleanBlower.................................................19

Troubleshooting...................................................20

4

Safety

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.

SafeOperatingPractices

Training

•ReadthetractorandUltraVacQDSOperator’s
Manualsandothertrainingmaterial.Ifthe
operator(s)ormechanic(s)cannotreadEnglish
itistheowner’sresponsibilitytoexplainthis
materialtothem.

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyandsafely
performthejob.Onlyuseonmachinesapproved
byExmark.

•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.

CAUTION

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

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

Operation

•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.

•Nevermowwiththedischargedeectorraised,
removedoralteredunlessthereisagrass
collectionsystemormulchkitinplaceand
workingproperly.

5

Safety

DANGER

Therearerotatingbladesintheblowerand
underthemowerdeck.Bladecontactcan
causeseriousoperatororbystanderinjury
orevendeath.

•DoNotreachintoblowerunlessrotation
indicatorhasstopped.DisengagePTO,
stopengine,removekey ,waitforall
movingpartstostop.engageparking
brake.

•Neveroperatemowerunlessdischarge
deector,entiregrasscollectionsystem,
ormulchkitisinstalled.

•Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

WARNING

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

•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.

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

•Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.

•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.

SlopeOperation

WARNING

Usingasingletailwheelmaycontactthe
collectionsystemandcausedifcultsteering
andreducethemachinestability.Thesingle
tailwheeltiremaycontactthebottomofthe
collectionsystemcausingdifcultsteering .
Asingletailwheelwithacollectionsystem
islessstableandapotentialtip-overcould
causeseriousinjuryordeath.

Operatemachineonlywithadualtailwheel
installed.

UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.

DANGER

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Wheels
droppingoveredges,ditches,steepbanks,or
watercancauserollovers,whichmayresult
inseriousinjury,deathordrowning.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15
degrees.

•Reducespeedanduseextremecaution
onslopes.

•Avoidsuddenturnsorrapidspeed
changes.

•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.

•Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.
(Figure3).

6

Safety

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15
degrees

2.DangerZone-Useawalkbehindmowerand/orhand
trimmerneardrop-offsandwater.

3.Water

•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.

•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.

•Beawarethatlossoftractionmayoccurgoing
downhill.W eighttransfertothefrontwheels
maycausedrivewheelstoslipandcauselossof
brakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.AlwaysinstallandremovetheUltraVac
QDS,includingcounterweights,asinstructed.
Failuretodosowillcauseareductioninstability
ortraction.DoNotoperatethemowerwithonly
aportionoftheUltraVacQDSinstalled.

•Useextremecarewithgrasscatchersor
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.Thestability
andtractionofthemachinewillchangeasthe
UltraVacQDShopperllswithgrassclippings.
Useprogressivelygreatercareonslopesasthe
hopperlls.

MaintenanceandStorage

•Disengagedrives,setparkingbrake,stopengine
andremovekeyordisconnectsparkplugwire.
Waitforallmovementtostopbeforeadjusting,
cleaningorrepairing.

•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplaceblades.Neverstraightenor
weldthem.

•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper
tightness.

•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.

•Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.

7

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
operationofyourExmarkcommercialmower.

1-653558

98-5954

103-2076

103-8444

109-5606

8

Safety

109-5890

9

Specications

Specications

ModelNumbers

SerialNos:720,000andHigher

FRUVD–FitsFrontRunnerwith52,60,or72inchdecks

FRCK524–Completingkitfor52inchdeck

FRCK604–Completingkitfor60inchdeck

FRCK724–Completingkitfor72inchdeck

Note:DualtailwheelsareREQUIREDformaximumstability,clearance,andcapacity .
FRDTWK–Completekittoinstalldualtailwheels
FRDTWA–Partialkittoinstalldualtailwheels,re-usessomecomponentsfromsingletailwheel.

Systems

BaggingSystem

•CollectionHopper:

–Commercialgraderotationallymoldedplastic.

–Capacity:12.0bushels

•DumpMechanism:Manualdumpfromseat

•BlowerTube:Flexible,abrasionresistantEPDM
rubberwithpolypropylenehelix.

•Impeller:5–bladed,1/4inch(6.4mm)thick
abrasionresistantsteel,withverticalaxis.

•Impellerbearings:1inch(2.5cm)sealed
non-greaseablebearings.

Dimensions

OverallWidth:

w/UltraV acQDS

52inchDeck66.85inches(169.8cm)

60inchDeck74.44inches(189.1cm)

72inchDeck87.10inches(221.2cm)

OverallLength:

w/UltraV acQDS

52inchDeck118.21inches(300.3cm)

60inchDeck118.32inches(300.5cm)

72inchDeck121.2inches(307.8cm)

CurbWeight:

52inchDeck

264lb(119kg)

60inchDeck

265lb(120kg)

72inchDeck

265lb(120kg)

TorqueRequirements

BoltLocation

Torque

ImpellerSpindleBottom
Nut

32-40ft-lb(43-54N-m)

ImpellerSpindleT opNut75-80ft-lb(102-108N-m)

10

Operation

ProductOverview

Figure4

1.Blower3.Hopperassembly

2.Flexibletube4.Doorhandle

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Pre-Start

Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.

Ensuretheblower,beltcover,exibletube,hopper,
anddoorareingoodcondition,properlyattached,
andlatched.

RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.

OperatingInstructions

Mowing

1.TheUltraVacQDSbloweroperateswhendeck
driveisengaged.Besurethatallpersonsareclear
ofthemowerdeckbeforeengagingthecutting
blades.Setthethrottleto“midway”position.Pull
outwardonthePTOswitchtothe“ROTATE”
position.Acceleratetofullthrottletobegin
mowing.

2.TodisengagethePTOandblower,setthe
throttleto“midway”position.Pushinonthe
PTOswitchtothe“STOP”positiontostopthe
cuttingbladesandblower.Thecuttingbladeswill
requireaslightlylongeramountoftimetocome
toacompletestopwhentheblowerisinstalled
onthedeck.Verifythatallrotationindicators
havestoppedbeforeclearingblowerassemblyor
mowerdeck

3.Toemptythehopper,rstshutoffdeckdrive.
Liftuponthehandletoopenthedoorandempty
thehopper.Iftheunitistobedrivenontoatruck
ortrailerwiththehopperfull,alwaysbackthe
unituptheramp.Thiswillreducethechanceof
rearwardtipup.SeetheTransportingsection
foradditionalinformationregardingloadinga
unitonatruckortrailer.

4.Closeandlatchthedoorbeforecontinuing
mowing.DoNotengagethecuttingbladeswhile
thedoorisintheopenposition.

Tipsformowingconditions:

11

Operation

•Whenmowinginareaswithsandysoil,use
lowliftbladesonthecuttingdeckandhigher
cuttingheightstominimizewearontheblower
components.

•Whenmowinginwetconditions,suchasjustafter
arainorinheavydew ,uselowliftbladesonthe
cuttingdecktominimizepluggingoftheblower.

•Maintainingagroundspeedthatdoesnotpull
downtheengineRPMwillallowforthehighest
productivityandbestqualityofcut.Boggingthe
engineRPMdownbygoingtoofastwillcause
pluggingandqualityofcutissues.

•Whenthehoppergetfull,thesoundoftheblower
willchangeandtherewillbeslightblowoutfrom
thefrontrightcornerofthedeck.Emptyingthe
hopperatthispointwillminimizethepotential
forthetubetoplug.

BaggerRemovalforSideDischarge

1.Shutoffthedeckdrive,stopengineandwaitfor
allmovingpartstostop.Removekey.

2.Removethedischargetubebyreleasingthelock
pinattheblower.Rotateandpullthetubeaway
fromthebloweroutletadapter(seeFigure5).

Figure5

1.Hopperassembly6.Dischargechutepinand
hairpin

2.Lowerhopperlinks7.Belt

3.Alarm8.Blower

4.Decksheave9.Flexibletube

5.Beltcover

3.Removethebeltcoverbylooseningtherearknob
andremovingthefrontknob.Therearknobdoes

notneedtoberemovedcompletelytoremove
thebeltcover.

CAUTION

Thedecksheavewillbecomeveryhot.
Touchingahotdecksheavecancausesevere
burns.

Allowthedecksheavetocoolcompletely
beforeremovingthebelt.

4.Pulltheidlerreleasehandleandremovethebelt
fromtheuppergrooveofthedecksheave.

5.Unlatchthefrontendoftheblower.Pivotthe
blowerbackandliftitoffthedeck.

6.Installthedischargechuteusingthechutepivot
pinandhairpin(seeFigure6).

Figure6

Viewedfromtherightside

1.Hairpin

3.DischargeChute

2.ChutePivotPin

Note:Installchutewiththetabstotherearof
thedecktabsasshown.

WARNING

Anuncovereddischargeopeningwill
allowobjectstobethrowninoperator’sor
bystander’sdirection.Also,contactwith
bladecouldoccur.Thrownobjectsorblade
contactcancauseseriousinjuryorkillyou
orbystanders.

Neveroperatemowerunlessdischarge
deector,orentiregrasscollectionsystem,or
mulchkitisinstalled.

12

Operation

7.Re-installtheplasticbeltcoverandtightenthe
knobs.

8.Unplugthewiringforthellsensoratthefront
ofthehopper.Secureloosewireharnessby
routinglooseendpartiallybackdownROPStube.

9.Removethehairpinsandclevispinsholdingthe
hopperassemblytotheROPSweldment.

10.Rotatethehopperassemblyrearwarduntilthe
backofthedoorrestsontheground.Remove
thehairpinsholdingthelowerhopperlinksto
thelowerframemount(Figure7).

11.Thebracketboltedtotherearoftheframeatthe
ROPSremainsontheunit

Note:TheportionsoftheFrontRunnerUltra
Vacthatarenotboltedtothemoweraredesigned
tobeinstalledorremovedintheirentirety.Failure
todosowillcauseareductioninstabilityor
traction.DoNotoperatethemowerwithonlya
portionoftheFrontRunnerUltraVacinstalled.

12.Themachinecannowbeusedforsidedischarge
mowing.

BaggerInstallationforBagging

1.Stopengine,removekey ,andwaitforallmoving
partstostop.

2.Removehairpinandchutepivotpin.Remove
dischargechute.Pivotpinandhairpinmaybe
storedinthepivotholesofthedischargechute
duringbaggingoperation.

3.Laythehopperassemblyonthedoorasshownin
(seeFigure7).

Figure7

1.Secureinthislocation

3.Hopperassembly

2.Lowerlinks

4.Installthehopperassemblyontothemountby
rotatingthelowerhopperlinksforwardand
slippingthemoverthepinsofthelowermount
weldment.Securethelowerlinkstothemount
usingthehairpins.

5.Liftandrotatethehopperassemblyupandalign
theupperpinholeswiththeholesintheROPS
mount.InstalltheupperpinsthroughtheROPS
platesandhopperframetubes.Securetheupper
pinswiththeattachedhairpins.

Figure8

1.Rotatehopperassembly2.Hopperassembly

6.Mountthebloweronthedeckbyslidingthe
mountingpinintothetubeattherearrightcorner
ofthedeck.Swingtheblowerclosed.Adjustthe
positionofthefrontpintoengagetheslotinthe
frontofthedeck.Usethelatchtolocktheblower
inthisposition.Adjustthetensiononthelatch
toholdthebloweruptothedeck,yetallowfor
releasebyhand.

7.Removetheplasticbeltcover.Pullthespring
loadedidlerbackandslipthebeltoverthetop
spindledecksheave.

8.Installtheplasticbeltcover.Therearofthecover
isslottedandcanslipbehindtheplasticknobon
thebeltshieldstud.Theplasticknobdoesnot
needtoberemoved.Thefronthorizontalplastic
knobfortheplasticbeltcovermustbeinstalled
afterthecoverhasbeenpositioned.

Thefrontverticalplasticknobontheoriginal
steelbeltcovercanbeusedforplasticbeltcover.

9.Thehopperinlethasribstoengagethespiral
reinforcementoftheexibletube.Usingamarker
orpaintpen,marktheexibletubeapproximately
4inchesfromtheend.Inserttheendofthe
tubeintothehopperinlet,androtateclockwise
toengage.Rotateandthreadthetubeintothe
hopperinletuptothe4inchmark.Itmaybe
easierto“push”thetubeintotheinletratherthan
rotating(Figure9).

13

Operation

Figure9

1.Hopper3.Flexibletube

2.Rotateclockwiseto
engage

10.Slidethelowerendofthetubeassemblyontothe
bloweroutletadapterandrotatetolockinplace.
Installthelockpinthroughthetubeandblower
adapter.

Figure10

1.Lockpin2.Rotatetolock

Note:TheportionsoftheUltraVacthatarenot
boltedtothemoweraredesignedtobeinstalled
orremovedintheirentirety.DoNotoperate
themowerwithonlyaportionoftheUltraVac
installed.

Transporting

TransportingaUnit

Useaheavy-dutytrailerortrucktotransportthe
machine.Lockbrakeandblockwheels.Securely
fastenthemachinetothetrailerortruckwithstraps,
chains,cable,orropes.Besurethatthetrailerortruck
hasallnecessarylightingandmarkingasrequiredby
law .Secureatrailerwithasafetychain.

CAUTION

Thisunitdoesnothaveproperturn
signals,lights,reectivemarkings,ora
slowmovingvehicleemblem.Drivingona
streetorroadwaywithoutsuchequipment
isdangerousandcanleadtoaccidents
causingpersonalinjury.Drivingonastreet
orroadwaywithoutsuchequipmentmayalso
beaviolationofStatelawsandtheoperator
maybesubjecttotrafcticketsand/ornes.

DoNotdriveaunitonapublicstreetor
roadway.

WARNING

Loadingaunitonatrailerortruckincreases
thepossibilityoftip-over.Tip-overcould
causeseriousinjuryordeath.

•Useextremecautionwhenoperatinga
unitonaramp.

•Useonlyasingle,fullwidthramp;Do
Notuseindividualrampsforeachside
oftheunit.

•Ifindividualrampsmustbeused,use
enoughrampstocreateanunbroken
rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp
andgroundorbetweenrampandtrailer
ortruck.

•Avoidsuddenaccelerationwhiledriving
unitonaramp.

LoadingaUnit

Iftheunitistobedrivenontoatruckortrailer
withthehopperfull,alwaysbacktheunitupthe
ramp.Thiswillreducethechanceofrearward
tipup.Useextremecautionwhenloadingunits

ontrailersortrucks.Onefullwidthrampthatis
wideenoughtoextendbeyondthereartiresis
recommendedinsteadofindividualrampsforeach
sideoftheunit.Thelowerrearsectionofthetractor
frameextendsbackbetweentherearwheelsand
servesasastopfortippingbackward.Havingafull
widthrampprovidesasurfacefortheframemembers
tocontactiftheunitstartstotipbackward.Ifitis

14

Operation

notpossibletouseonefullwidthramp,useenough
individualrampstosimulateafullwidthcontinuous
ramp.

Rampshouldbelongenoughsothattheangles
betweentherampandthegroundandtherampand
thetrailerortruckDoNotexceed15°.Asteeper
anglemaycausemowerdeckcomponentstoget
caughtastheunitmovesfromramptotraileror
truck.Steeperanglesmayalsocausetheunittotip
backward.Ifloadingonornearaslope,position
thetrailerortrucksoitisonthedownsideofthe
slopeandtherampextendsuptheslope.Thiswill
minimizetherampangle.Thetrailerortruckshould
beaslevelaspossible.

Important:DoNotattempttoturntheunit
whileontheramp,youmaylosecontroland
driveofftheside.

Avoidsuddenaccelerationwhendrivinguparamp
andsuddendecelerationwhenbackingdownaramp.
Bothmaneuverscancausetheunittotipbackward.

Dumpcontentsofhopperbeforetransport.DoNot

transporttheunitwiththehopperfull.

15

Maintenance

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing
made,someonecouldstarttheengine.
Accidentalstartingoftheenginecould
seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch,
engageparkingbrake,andpullthewire(s)
offthesparkplug(s)beforeyoudoany
maintenance.Alsopushthewire(s)aside
soitdoesnotaccidentallycontactthespark
plug(s).

WARNING

Theenginecanbecomeveryhot.Touching
ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore
serviceormakingrepairsaroundtheengine
area.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Beforeeachuseordaily

•Checktheblowerhousing/impeller.

•Cleanmuferandrearframearea.

•Cleanrearscreeninthehood.

Every25hours

•Lubricategreasettings.

Every50hours

•Checkconditionofbelt.

Yearlyorbeforestorage

•Cleanblower.

PeriodicMaintenance

CheckBlower
Housing/Impeller

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Inspectforwearordamagedaily.Replaceor
repairwornpartsasneeded

Note:Whenmowinginareaswithsandysoil,
uselowliftbladesonthecuttingdeckandhigher
cuttingheightstominimizewearontheblower
components.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.LubricatettingswithNGLIgrade#2
multi-purposegungrease.

Refertothefollowingchartforttinglocations
andlubricationschedule.

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

1.Blower
Housing/
Impeller

——

Daily

16

Maintenance

LubricationChart

Fitting

Locations

Initial

Pumps

Numberof

Places

Service

Interval

2.Idler
Bushings

1–21

25Hours

3.Belts

——

50Hours

4.Mufer/
RearFrame

——

Daily

5.Hopper
Screen

——

Daily

6.Flexible
Discharge
Tube

——

Daily

7.Fill
Sensor

——

Daily

CheckConditionofBelt

ServiceInterval:Every50hours

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Inspectthebeltfordamageorwear.Replacebelt
withoneofthefollowing:

Deck

PartNo.

52inchDeck

109-4948

60inchDeck

103-0866

72inchDeck

103-0867

3.Inspectthebeltpositionontheidlerarm.

Theidlerarmmaybecomebentduringuseor
transport.Abentidlerarmcouldcausethebelt
tojumpoffoftheidlerandbedamaged.

A.Makesurethebeltcoverisinstalledandrun

theblowerforonetotwominutes.

B.Shutoffthedeckdrive,stopengine,wait

forallmovingpartstostopandremovekey .
Engageparkingbrake.Removethebeltcover
andchecktomakesurethatthebeltisriding
nearthecenteroftheatidlerontheidler
arm.

C.Ifthebeltisnotridingnearthecenterofthe

idler,removetheblower,andbendtheidler
armslightly.

Note:Idlerstillneedstoclearthedeck
stiffenerduringoperation.

D.Reinstalltheblowerandbeltcoverandrepeat

stepsAthroughCuntilthebeltispositioned
nearthecenteroftheidler.

FlexibleDischargeTube

ServiceInterval:Asrequired

Inspecttheexibledischargetubeforwearor
damage.

WARNING

Undernormalusetheexibledischargetube
willwear.Objectscouldexitawornexible
dischargetubeathighspeeds.Thrown
objectscancauseseriousinjuryorkillyou
orbystanders.

Checktheexibledischargetubefortears
andholes.Replacewornexibledischarge
tube.

FillSensor

ServiceInterval:Asrequired

Thellsensorislocatedatthefrontofthehopper,
andiswiredintothePTOcircuit.Whengrasslls
thehopperenoughtoblockoneorbothsensors,
analarmwillsound.Thellsensortestingmustbe
madewiththePTOengaged,buttheenginedoes
nothavetoberunning.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Unlatchthedoorandpullthedoorhandle
engagementpintoraisethedoortothetopofthe
hopper(seeFigure13).

3.Reachintothehopperandplaceapieceof
maskingorducttapeovertheLHsensor.

4.Closethedoor.

5.SitintheseatandturnthekeytotheRUN
position,butDONOTSTARTtheunit.

6.PulluponthePTOswitchtoengagepowertothe
clutch;youshouldhearaclickfromtheclutch.

7.Thereisasplitseconddelaybeforethellsensor
alarmwillsound.

8.Repeatsteps2through4toremovethetapefrom
thesensor.

17

Maintenance

Adjustments

Note:TheUltraVacQDSwasadjustedatthefactorytooperateproperly.However,therearethreebasic
adjustmentsthatcanbemade,shouldyourunitrequirethem:

1.Fillsensors:Locatedinsidethehopper,they
soundanalarmwhenthehopperisfull.Theycan
beadjustedforvaryinggrassconditionsthatll
thehopperdifferently(seeFigure11).

Figure11

1.Fillsensor

MovingtheLHsensorupworksbetterinwetter
conditions.

MovingtheLHsensordownworksbetterin
dryerconditions.

2.Latches:Thelatches(Figure12)canbeadjusted.
Withthedoorclosed,thelatchplateshouldbe
setsothatthelatchcamscompletelyengageand
contactthelatchplatesboltedtothedoor.

Figure12

1.Over-centerspring3.Theseveboltsadjust
thelatchcamweldment

2.Whizlocknuts

3.Latchhandlelink:Thelatchhandleneedstobe
abletosnapover-centertokeepthelatchcams
tightagainstthedoorlatchplatesandthedoor
pulledshut.Thelengthofthelatchlinkageis
controlledbythetwowhizlocknutsoneitherside

ofthelatchlink(Figure12).Thewhizlocknuts
shouldbeadjustedsothatreasonableforceon
thehandleisrequiredtoover-centerandlatch
thedoor.DoNotadjustsothattheover-center
springcollapsescompletelywhenthedoorisfully
latched.

18

Maintenance

Cleaning

CleanMuferandRear
FrameArea

ServiceInterval:Beforeeachuseordaily

Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

WARNING

Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.

•Allowengineparts,especiallythemufer,
tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer
andenginearea.

•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,
brush-coveredunimprovedland.

CleanRearScreenInHopper

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Openhopperdoorbyremovingpinsasshown
andremoveclippingsthatarestucktoscreenas
showninFigure13.Screencanberemovedby
removingpinsatrearofscreen.

Figure13

1.Putpinhereforstorage3.Screen

2.Pin

CleanBlower

ServiceInterval:Yearlyorbeforestorage

Grassbuildupmaycauseproblemswiththeimpeller
whentheunitisputbackintooperation.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removegrassbuildupfromaroundtheimpeller
beforeplacingitinstorage.

19

Troubleshooting

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,DoNotoverlookthesimplecauses.Forexample:startingproblemscouldbe
causedbyanemptyfueltank.

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

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

1.Cuttingblade(s)is/arebentorunbalanced.

1.Installnewcuttingblade(s).

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Looseblowerpulleyorpulleyassembly.

3.Tightentheappropriatepulley .

Abnormalvibration.

4.Blowerimpellerbladesarebent.4.ContactanAuthorizedServiceDealer.

Blowerdrivebeltsnapsorbreaksfrequently.

1.Idlerarmisoutofalignment.1.Correctthealignmentoftheidlerarm.

1.Hopperisfull.1.Dumpmorefrequently.

2.Pluggedscreeninbaggerhood.2.Removedebris,leavesorgrassclippings
fromthescreen.

3.Groundspeedistoofast.

3.Drivesloweratfullthrottle.

4.Blowerbeltisworn,loose,orbroken.4.Installnewblowerbelt.

5.Pluggedtubeorblower.5.Locateandremovepluggeddebris.

Excessivegrassblowoutfromthedeck.

6.Conditionsaredry.6.Uselowerliftblade.

1.Hopperistoofull.1.Dumpmorefrequently

2.Groundspeedistoofast.

2.Drivesloweratfullthrottle.

3.Grassistoowet.

3.Cutgrasswhenitisdry.

4.Grassistoolong.4.Cutgrassmorefrequentlyorathighercut
height.

5.Pluggedscreeninbaggerhood.5.Removedebris,leaves,orgrassclippings
fromthescreen.

6.Blowerdrivebeltisworn,loose,or

broken.

6.Installnewbelt.

Blowerandtubesplugtoofrequently.

7.Blowerisplugged.7.Uselowliftbladesinwetconditions.

1.Pluggedblower.1.Removedebris,leaves,orgrassclippings
fromtheblowerimpeller.

Blowerimpellerdoesnotspinfreely.

2.Impellernotaligned.2.ContactanAuthorizedServiceDealer.

Plowingleaves.

1.Deckistoolow.

1.Raisethedeckslightly.

Chasingleaves.

1.Blowoutfromdeck.1.Installananti-blowoutkit–contactan
AuthorizedServiceDealer.

Blowercomponentsshowsignsofwear
and/oraircleanersandcoolingnsaredirty.

1.Sandordryconditions.1.Uselowliftbladesonthecuttingdeckand
highercuttingheights.

20

Conditions and Products Covered

Exmark Mfg. Co. Inc. and its affiliate, Exmark Warranty
Company, pursuant to an agreement between them, jointly
warrant on the terms and conditions herein, that we will repair,
replace or adjust any part manufactured by Exmark and found
by us (in the exercise of our reasonable discretion) to be
defective in factory materials or workmanship for a period of
two years.

This warranty applies to Exmark turf equipment purchased on
or after October 1, 2004 sold in the US or Canada. This
warranty may only be assigned or transferred to a second (or
third) owner by an authorized Exmark dealer. The warranty
period commences upon the date of the original retail
purchase.

 Products Warranty Period

• All Products (except as noted below) 2 years

• All Attachments and Accessories 1 year

• Metro 21 and Metro 26 Series  1 year

• Belts and Tires 90 days

• Battery 1 Year Prorated

• Engine* Warranty is covered by engine manufacturer

* Please refer to the engine manufacturer’s warranty statement
that is included in the literature packet. We are not authorized
to handle warranty adjustments on engines.

This warranty only includes the cost of parts and labor.

Items and Conditions Not Covered

This warranty does not cover the following:

• Pickup and delivery charges to and from any authorized 
 Exmark Service Dealer beyond first warrantable service.

• Any damage or deterioration due to normal use, wear and 
 tear, or exposure.

• Cost of regular maintenance service or parts, such as filters, 
 fuel, lubricants, tune-up parts, and adjustments.

• Any product or part which has been altered or misused or 
 required replacement or repair due to normal wear, 
 accidents, or lack of proper maintenance.

• Any repairs necessary due to use of parts, accessories or 
 supplies, including gasoline, oil or lubricants, incompatible 
 with the turf equipment or other than as recommended in 
 the operator's manual or other operational instructions 
 provided by Exmark.

There are no other express warranties except for engine and
special emission system coverage stated elsewhere herein or
included with the product.

All warranty work must be performed by an authorized
Exmark Service Dealer using Exmark approved replacement
parts.

Instructions for Obtaining Warranty Service

The product must be registered with original proof of purchase
by an Exmark Service Dealer before obtaining any warranty
service.

Contact any Exmark Service Dealer to arrange service at their
dealership. To locate a dealer convenient to you, access our
website at www.exmark.com. U.S. Customers may also call
402-223-6375.

If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:

 Exmark Customer Service Department
 The Exmark Warranty Company
 2101 Ashland Avenue
 Beatrice, NE 68310
 402-223-6375 or
 [e-mail]

Owner’s Responsibilities

The Exmark turf equipment, including any defective part,
must be returned to an authorized Exmark service dealer
within the warranty period. This warranty extends only to turf
equipment operated under normal conditions. You must read
the operator’s manual. You must also properly service and
maintain your Exmark product as described in the operator’s
manual. Such routine maintenance, whether performed by a
dealer or by you, is at your expense.

General Conditions

The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair and replacement
of defective components as set forth herein. Neither Exmark

nor Exmark Warranty Company shall have any liability
for any other cost, loss or damage, including but not
limited to, any incidental or consequential loss or damage.

In particular, we shall have no liability or responsibility for:

• Expenses related to gasoline, oil or lubricants.

• Travel time, overtime, after hours time or other  
 extraordinary repair charges or charge relating to repairs or 
 replacements outside of normal business hours at the place 
 of business of the authorized Exmark Service Dealer.

• Rental of like or similar replacement equipment during the 
 period of any warranty, repair or replacement work.

• Any telephone or telegram charges or travel charges.

• Loss or damage to person or property other than that 
 covered by the terms of this warranty.

• Any claims for lost revenue, lost profit or additional cost as 
 a result of a claim of breach of warranty.

• Attorney's fees.

No Claim of breach of warranty shall be cause for cancellation
or rescission of the contract of sale of any Exmark mower.

Some states do not allow exclusions of incidental or
consequential damages, so the above exclusions and
limitations may not apply to you.

This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.

2-Year Limited Warranty

Exmark Turf Equipment

(For units purchased on or after October 1, 2004)

G006117

21

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

22

23

MI D-MO UNT RIDI NG ACCESSORIES

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES

WALK-BEHIND ACCESSORIES

GRASS CATCHER

LAZERLOCKER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DECK LIFT ASSIST KIT

HITCH KIT

LAZERLOCKER

LIGHT KIT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT RIDING AC CESS ORIE S

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

ROTARY BROOM

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

DatePurchased

ModelNo.

SerialNo.

©2006–2008ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
AllRightsReserved

PartNo.4500-274Rev.A
[phone]
Fax[phone]
PrintedintheUSA.

www.exmark.com