Exmark 4500-420 Lawn Mower User Manual

ULTRA VAC QDS
®
LAZER Z® HP MODELS
For Ultra Vac Serial Nos.
790,000 & Higher
Part No. 4500-420 Rev. A
Exmark reserves the right to make changes or
add improvements to its products at any time
without incurring any obligation to make such
changes to products manufactured previously.
Exmark, or its distributors and dealers, accept
no responsibility for variations which may be
evident in the actual specifications of its products
and the statements and descriptions contained
in this publication.
© 2008—Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
2
Contact us at www.Exmark.com.
Printed in the USA
All Rights Reserved
Introduction
CONGRATULATIONS on the purchase of your
Exmark Ultra Vac QDS. This product has been
carefully designed and manufactured to give you
a maximum amount of dependability and years of
trouble-free operation.
This manual contains operating, maintenance,
adjustment, and safety instructions for your Exmark
Ultra Vac QDS.
BEFORE OPERATING YOUR MOWER,
CAREFULLY READ THIS MANUAL IN ITS
ENTIRETY.
Figure 1
1. Model and serial number location
By following the operating, maintenance, and safety
instructions, you will prolong the life of your Ultra
Vac QDS, maintain its maximum efficiency, and
promote safe operation.
Model No.
If additional information is needed, or should you
require trained mechanic service, contact your
authorized Exmark equipment dealer or distributor.
Serial No.
All Exmark equipment dealers and distributors are
kept informed of the latest methods of servicing
and are equipped to provide prompt and efficient
service in the field or at their service stations. They
carry ample stock of service parts or can secure them
promptly for you from the factory.
All Exmark parts are thoroughly tested and inspected
before leaving the factory, however, attention is
required on your part if you are to obtain the fullest
measure of satisfaction and performance.
Whenever you need service, genuine Exmark parts,
or additional information, contact an Authorized
Service Dealer or Exmark Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.
3
Contents
Introduction ........................................................... 3
Safety ..................................................................... 5
Safety Alert Symbol ......................................... 5
Safe Operating Practices .................................. 5
Safety and Instructional Decals ....................... 8
Specifications ....................................................... 10
Model Numbers ............................................ 10
Systems ......................................................... 10
Dimensions................................................... 10
Torque Requirements .................................... 10
Product Overview ................................................ 11
Operation ............................................................. 11
Pre-Start........................................................ 11
Operating Instructions .................................. 11
Transporting ................................................. 14
Maintenance ......................................................... 16
Recommended Maintenance Schedule(s) ........... 16
Periodic Maintenance ....................................... 16
Check Blower Housing/Impeller ................... 16
Check Door Cloth Mesh................................ 16
Lubricate Grease Fittings............................... 17
Check Condition of Belt ................................ 17
Adjustments ..................................................... 18
Cleaning ........................................................... 19
Clean Muffler and Rear Frame Area................ 19
Clean Rear Screen In Hood............................ 19
Clean Blower................................................. 19
Troubleshooting ................................................... 20
4
Safety
Safety
• Never let children or untrained people operate
or service the equipment. Local regulations may
restrict the age of the operator.
Safety Alert Symbol
• The owner/user can prevent and is responsible
for accidents or injuries occurring to himself or
herself, other people or property.
This Safety Alert Symbol (Figure 2) is used both in
this manual and on the machine to identify important
safety messages which must be followed to avoid
accidents
Preparation
This symbol means: ATTENTION! BECOME
ALERT! YOUR SAFETY IS INVOLVED!
• Evaluate the terrain to determine what accessories
and attachments are needed to properly and safely
perform the job. Only use on machines approved
by Exmark.
• Wear appropriate clothing including safety glasses,
substantial footwear, long trousers, and hearing
protection. Do Not operate when barefoot or
when wearing open sandals.
Figure 2
1. Safety alert symbol
The safety alert symbol appears above information
which alerts you to unsafe actions or situations
and will be followed by the word DANGER,
WARNING, or CAUTION.
CAUTION
This machine produces sound levels in
excess of 85 dBA at the operator’s ear and
can cause hearing loss through extended
periods of exposure.
DANGER: White lettering / Red background.
Indicates an imminently hazardous situation which, if
not avoided, Will result in death or serious injury.
Wear hearing protection when operating this
machine.
WARNING: Black lettering / Orange background.
Indicates a potentially hazardous situation which, if
not avoided, Could result in death or serious injury.
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects which can be
thrown by the machine and may cause personal
injury to the operator or bystanders.
CAUTION: Black lettering / Yellow background.
Indicates a potentially hazardous situation which, if
not avoided, May result in minor or moderate injury.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes
general information worthy of special attention.
Operation
• Operate only in daylight or good artificial light,
keeping away from holes and hidden hazards.
Safe Operating Practices
• Never mow with the discharge deflector raised,
removed or altered unless there is a grass
collection system or mulch kit in place and
working properly.
Training
• Read the tractor and Ultra Vac QDS Operator’s
Manuals and other training material. If the
operator(s) or mechanic(s) can not read English
it is the owner’s responsibility to explain this
material to them.
• Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
• All operators and mechanics should be trained.
The owner is responsible for training the users.
5
Safety
Slope Operation
DANGER
Use Extreme caution when mowing and/or turning
on slopes as loss of traction and/or tip-over could
occur. The operator is responsible for safe operation
on slopes.
There are rotating blades in the blower and
under the mower deck. Blade contact can
cause serious operator or bystander injury
or even death.
• Do Not reach into blower unless rotation
indicator has stopped. Disengage PTO,
stop engine, remove key, wait for all
moving parts to stop. Engage parking
brake.
DANGER
Operating on wet grass or steep slopes can
cause sliding and loss of control. Wheels
dropping over edges, ditches, steep banks, or
water can cause rollovers, which may result
in serious injury, death or drowning.
• Never operate mower unless discharge
deflector, entire grass collection system,
or mulch kit is installed.
• Do Not mow slopes when grass is wet.
• Do Not mow near drop-offs or near water.
• Stop engine, wait for all moving parts to stop,
remove key and engage parking brake:
• Do Not mow slopes greater than 15
degrees.
– Before checking, cleaning or working on the
mower.
• Reduce speed and use extreme caution
on slopes.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
damage and make repairs before restarting
and operating the mower).
• Avoid sudden turns or rapid speed
changes.
• Keep the roll bar in the raised and locked
position and use seat belt.
– Before clearing blockages.
– Whenever you leave the mower.
• See inside the back cover to determine the
approximate slope angle of the area to be mowed.
WARNING
• Use a walk behind mower and/or a hand trimmer
near drop-offs, ditches, steep banks or water.
(Figure 3).
Hands, feet, hair, clothing, or accessories can
become entangled in rotating parts. Contact
with the rotating parts can cause traumatic
amputation or severe lacerations.
• Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
• Keep hands, feet, hair, jewelry, or clothing
away from rotating parts.
• Stop the blades, slow down, and use caution when
crossing surfaces other than grass and when
transporting the mower to and from the area to
be mowed.
• Be aware of the mower discharge path and direct
discharge away from others.
6
Safety
Use progressively greater care on slopes as the
hopper fills.
Maintenance and Storage
• Disengage drives, set parking brake, stop engine
and remove key or disconnect spark plug wire.
Wait for all movement to stop before adjusting,
cleaning or repairing.
• Use care when checking blades. Wrap the blade(s)
or wear gloves, and use caution when servicing
them. Only replace damaged blades. Never
straighten or weld them.
• Keep all guards, shields and all safety devices in
place and in safe working condition.
Figure 3
1. Safe Zone-Use the mower here on slopes less than 15
degrees
2. Danger Zone-Use a walk behind mower and/or hand
trimmer on slopes greater than 15 degrees, near
drop-offs and water.
3. Water
• Check all bolts frequently to maintain proper
tightness.
• Frequently check for worn or deteriorating
components that could create a hazard.
• All replacement parts must be the same as
or equivalent to the parts supplied as original
equipment.
• Remove or mark obstacles such as rocks, tree
limbs, etc. from the mowing area. Tall grass can
hide obstacles.
• Watch for ditches, holes, rocks, dips and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
• Be aware that operating on wet grass, across steep
slopes or downhill may cause the mower to lose
traction. Loss of traction to the drive wheels may
result in sliding and a loss of braking and steering.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades
and proceed slowly off the slope.
• Follow the manufacturer’s recommendations for
counter weights to improve stability. Always
install and remove the Ultra Vac QDS, including
counter weights, as instructed. Failure to do so
will cause a reduction in stability or traction. Do
Not operate the mower with only a portion of the
Ultra Vac QDS installed.
• Use extreme care with grass catchers or
attachments. These can change the stability of the
machine and cause loss of control. The stability
and traction of the machine will change as the
Ultra Vac QDS hopper fills with grass clippings.
7
Safety
Safety and Instructional Decals
• Keep all safety signs legible. Remove all grease,
dirt and debris from safety signs and instructional
labels.
• Replace all worn, damaged, or missing safety
signs.
• When replacement components are installed, be
sure that current safety signs are affixed to the
replaced components.
• If an attachment or accessory has been installed,
make sure current safety signs are visible.
• New safety signs may be obtained from
your authorized Exmark equipment dealer or
distributor or from Exmark Mfg. Co. Inc.
• Safety signs may be affixed by peeling off the
backing to expose the adhesive surface. Apply
only to a clean, dry surface. Smooth to remove
any air bubbles.
• Familiarize yourself with the following safety signs
and instruction labels. They are critical to the safe
operation of your Exmark commercial mower.
103-6605
For Units with a Two-Post ROPS Only
1-653554
1-653558
98-5954
103-6604
For Units with a Two-Post ROPS Only
8
Safety
103-3508
9
Specifications
Specifications
Model Numbers
Serial Nos: 790,000 and Higher
LHPUVD4448; LHPUVD4650; LHPUVD5256
w/Ultra Vac QDS
Systems
Bagging System
• Collection Hopper:
– Commercial grade, steel and polyethylene
hopper with rear discharge door, commercial
grade cloth mesh door panel.
– Capacity: 6.7 bushels
• Dump Mechanism: Single motion actuation from
operator’s seat.
• Blower Tube: Fixed, abrasion resistant molded
polyethylene.
• Impeller: 5–bladed, 1/4 inch (6.4 mm) thick
abrasion resistant steel, with vertical axis.
• Impeller bearings: 1 inch (2.5 cm) sealed
non-greaseable bearings.
60.67 inches (154.1 cm)
48 inch Deck
61.73 inches (159.8 cm)
50 inch Deck
64.66 inches (164.2 cm)
52 inch Deck
66.47 inches (168.8 cm)
56 inch Deck
70.85 inches (180.0 cm)
Overall Length:
w/Ultra Vac QDS
44 inch Deck
93.76 inches (283.2 cm)
46 inch Deck
96.69 inches (245.6 cm)
48 inch Deck
93.76 inches (283.2 cm)
50 inch Deck
97.12 inches (246.7 cm)
99.86 inches (253.6 cm)
Torque Requirements
w/Ultra Vac QDS
46 inch Deck
56 inch Deck
Lazer Z HP -220 lb (100 kg), including the front
weight.
Overall Width:
58.47 inches (148.5 cm)
95.00 inches (241.3 cm)
Curb Weight:
Dimensions
44 inch Deck
52 inch Deck
10
Bolt Location
Torque
Impeller Spindle Bottom
Nut
55-60 ft-lb (75-81 N-m)
Impeller Spindle Top Nut
75-80 ft-lb (102-108 N-m)
Operation
Product Overview
Operation
Note: Determine the left and right sides of the
machine from the normal operating position.
Pre-Start
Make sure you understand the controls, their
locations, their functions, and their safety
requirements.
Ensure the blower, door mesh, tube and hopper are
in good condition, properly attached, and latched.
For units above Serial Number 600,000 with Triton
decks: Make sure that the adjustable dog leg baffle is
closed to match the intake into the Ultra Vac Blower.
Figure 4
1. Hood
2. Weight
3. Blower
4. Tube
5. Door
WARNING
If the deck discharge opening and the blower
intake opening do not match correctly, it
will allow objects to be thrown in operator’s
or bystander’s direction. Also, contact with
blade could occur. Thrown objects or blade
contact can cause serious injury or kill you
or bystanders.
Adjust dog leg baffle to match intake
opening.
Refer to the Maintenance section and perform all the
necessary inspection and maintenance steps.
Operating Instructions
Mowing
1. The Ultra Vac QDS blower operates when deck
drive is engaged. Be sure that all persons are clear
of the mower deck before engaging the cutting
blades. Set the throttle to “midway” position. Pull
outward on the PTO switch to the “ROTATE”
position. Accelerate to full throttle to begin
mowing.
2. To disengage the PTO and blower, set the
throttle to “midway” position. Push in on the
PTO switch to the “STOP” position to stop the
cutting blades and blower. The cutting blades will
require a slightly longer amount of time to come
to a complete stop when the blower is installed
on the deck. Verify that all rotation indicators
11
Operation
have stopped before clearing blower assembly or
mower deck
3. To empty the hopper, first shut off deck drive.
Lift up on the handle to open the door and
empty the hopper. If the unit is to be driven
onto a truck or trailer with the hopper full,
always back the unit up the ramp. This will
reduce the chance of rearward tip up. See the
Transporting section for additional information
regarding loading a unit on a truck or trailer.
4. Close and latch the door before continuing
mowing. Do Not engage the cutting blades while
the door is in the open position.
Tips for mowing conditions:
Figure 5
1. Hopper Assembly
2. Tube
3. Blower
• When mowing in areas with sandy soil, use
low lift blades on the cutting deck and higher
cutting heights to minimize wear on the blower
components.
4. Hairpin
5. Clevis Pin
3. Remove the belt cover by loosening the knobs.
• When mowing in wet conditions, such as just after
a rain or in heavy dew, use low lift blades on the
cutting deck to minimize plugging of the blower.
CAUTION
• Maintaining a ground speed that does not pull
down the engine RPM will allow for the highest
productivity and best quality of cut. Bogging the
engine RPM down by going too fast will cause
plugging and quality of cut issues.
The deck sheave will become very hot.
Touching a hot deck sheave can cause severe
burns.
Allow the deck sheave to cool completely
before removing the belt.
• When the hopper gets full, the sound of the
blower will change and there will be slight
blowout from the front right corner of the deck.
Emptying the hopper at this point will minimize
the potential for the tube to plug.
• For units below Serial Number 600,000:
Anti-blowout kits are available for leaf collection.
They help to prevent “chasing” the leaves. To
reduce “plowing” leaves, raise the deck slightly.
• On Triton: Raise front adjustable baffle to
reduce plowing. Lowering front adjustable baffle
may prevent “chasing”. Match discharge opening
to Ultra Vac intake for best performance.
Figure 6
1. Hairpin
2. Chute pivot pin
3. Discharge chute
Bagger Removal for Side Discharge
4. Belt shield
5. Weight
6. Knob
1. Shut off the deck drive, stop engine and wait for
all moving parts to stop. Remove key.
4. Pull the idler release handle and remove the belt
from the upper groove of the deck sheave.
2. Remove the discharge tube by releasing the latch
at the blower. Slide the tube off the blower outlet
and remove the upper end from the hopper.
5. Unlatch the front end of the blower. Pivot the
blower back and lift it off the deck.
12
Operation
6. Install the discharge chute using the chute pivot
pin and hairpin (see Figure 7).
operate the mower with only a portion of the
Ultra Vac installed.
WARNING
Caster or front floor pan weights installed
without bagger may cause loss of traction
and steering control. Loss of control can
result in an accident, which may cause death,
injury, or property damage.
Install caster or front floor pan weights
ONLY when bagger is installed.
Figure 7
Viewed from the right side
1. Hairpin
2. Chute pivot pin
11. The machine can now be used for side discharge
mowing.
3. Discharge chute
Bagger Installation for Bagging
1. Stop engine, remove key, and wait for all moving
parts to stop.
2. Remove hairpin and chute pivot pin. Remove
discharge chute. Pivot pin and hair pin may be
stored in the pivot holes of the discharge chute
during bagging operation.
3. Slide tube ends of hopper assembly into the tubes
of the mount weldment (see Figure 5). Install two
clevis pins through holes in tubes. Retain with
two hair pins.
4. Remove the belt cover on the right side of the
deck (see Figure 6). Install the blower by inserting
the mounting pin into the tube welded to the rear
corner of the deck. Pivot the blower until the
front pin engages the slot in the deck. Adjust the
position of the front pin if necessary to engage
the slot. Use the latch to lock the blower in this
position.
5. Pull the idler release handle and install the belt in
the upper groove of the deck sheave.
6. Install the belt cover using the two knobs.
7. Install the discharge tube assembly by slipping the
upper end into the hood, then sliding the lower
end over the blower discharge opening. Use the
latches to retain the lower end to the blower.
8. For Units Serial Number 600,000 and Higher
with Triton Decks: Adjust position of dog leg
baffle to match the intake of the Ultra Vac blower
baffle adjusted too wide may allow objects to be
thrown from under deck. Baffle adjusted too
narrow may cause plugging issues.
Note: Install chute with the tabs to the rear of
the deck tabs as shown.
WARNING
An uncovered discharge opening will
allow objects to be thrown in operator’s or
bystander’s direction. Also, contact with
blade could occur. Thrown objects or blade
contact can cause serious injury or kill you
or bystanders.
Never operate mower unless discharge
deflector, or entire grass collection system, or
mulch kit is installed.
7. Re-install the plastic belt cover and tighten the
knobs.
8. Remove the hair pins and clevis pins holding the
hopper assembly to the mount weldment.
9. Lift the hopper assembly off the mount.
10. Remove the hairpins and lift the front weights off
of the mount plate.
Note: The removable weights are heavy. Use
care when lifting them. Make sure that you can
hold them securely before lifting them. Use
caution when positioning your hands so that you
Do Not set them down on your hands or fingers.
Note: The portions of the Ultra Vac bagger that
are not bolted to the mower are designed to be
installed or removed in their entirety. Do Not
13
Operation
Transporting
WARNING
Loading a unit on a trailer or truck increases
the possibility of backward tip-over.
Backward tip-over could cause serious injury
or death.
Transporting a Unit
Use a heavy-duty trailer or truck to transport the
machine. Lock brake and block wheels. Securely
fasten the machine to the trailer or truck with straps,
chains, cable, or ropes. Be sure that the trailer or truck
has all necessary lighting and marking as required by
law. Secure a trailer with a safety chain.
• Use extreme caution when operating a
unit on a ramp.
• Use only a single, full width ramp; Do
Not use individual ramps for each side
of the unit.
CAUTION
• If individual ramps must be used, use
enough ramps to create an unbroken
ramp surface wider than the unit.
This unit does not have proper turn
signals, lights, reflective markings, or a
slow moving vehicle emblem. Driving on a
street or roadway without such equipment
is dangerous and can lead to accidents
causing personal injury. Driving on a street
or roadway without such equipment may also
be a violation of State laws and the operator
may be subject to traffic tickets and/or fines.
• Do Not exceed a 15° angle between ramp
and ground or between ramp and trailer
or truck.
• Avoid sudden acceleration while driving
unit up a ramp to avoid tipping backward.
• Avoid sudden deceleration while backing
unit down a ramp to avoid tipping
backward.
Do Not drive a unit on a public street or
roadway.
Loading a Unit
If the unit is to be driven onto a truck or trailer
with the hopper full, always back the unit up the
ramp. This will reduce the chance of rearward
tip up.
Dump contents of hopper before transport Do Not
transport the unit with the hopper full.
Use extreme caution when loading units on trailers or
trucks. One full width ramp that is wide enough to
extend beyond the rear tires is recommended instead
of individual ramps for each side of the unit. The
lower rear section of the tractor frame extends back
between the rear wheels and serves as a stop for
tipping backward. Having a full width ramp provides
a surface for the frame members to contact if the
unit starts to tip backward. If it is not possible to use
one full width ramp, use enough individual ramps to
simulate a full width continuous ramp.
Ramp should be long enough so that the angles
between the ramp and the ground and the ramp and
the trailer or truck Do Not exceed 15°. A steeper
angle may cause mower deck components to get
14
Operation
caught as the unit moves from ramp to trailer or
truck. Steeper angles may also cause the unit to tip
backward. If loading on or near a slope, position
the trailer or truck so it is on the down side of the
slope and the ramp extends up the slope. This will
minimize the ramp angle. The trailer or truck should
be as level as possible.
Important: Do Not attempt to turn the unit
while on the ramp, you may lose control and
drive off the side.
Avoid sudden acceleration when driving up a ramp
and sudden deceleration when backing down a ramp.
Both maneuvers can cause the unit to tip backward.
15
Maintenance
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
WARNING
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could
seriously injure you or other bystanders.
The engine can become very hot. Touching
a hot engine can cause severe burns.
Allow the engine to cool completely before
service or making repairs around the engine
area.
Remove the key from the ignition switch,
engage parking brake, and pull the wire(s)
off the spark plug(s) before you do any
maintenance. Also push the wire(s) aside
so it does not accidentally contact the spark
plug(s).
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
Before each use or daily
•
•
•
•
Check the blower housing/impeller.
Check door cloth mesh.
Clean muffler and rear frame area.
Clean rear screen in the hood.
Every 25 hours
• Lubricate grease fittings.
Every 50 hours
• Check condition of belt.
Yearly or before storage
• Clean blower.
Periodic Maintenance
Check Door Cloth Mesh
Check Blower
Housing/Impeller
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Inspect the bags for wear, tears, or damage.
Service Interval: Before each use or daily
WARNING
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Under normal use the cloth mesh will
deteriorate and wear. Objects could exit
through worn cloth mesh at high speeds.
Thrown objects can cause serious injury or
kill you or bystanders.
2. Inspect for wear or damage daily. Replace or
repair worn parts as needed
Note: When mowing in areas with sandy soil,
use low lift blades on the cutting deck and higher
cutting heights to minimize wear on the blower
components.
Check cloth mesh frequently for tears and
holes. Replace worn cloth mesh.
16
Maintenance
Lubricate Grease Fittings
3. Inspect the belt for damage or wear. Replace belt
with one of the following:
Note: See chart for service intervals.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Lubricate fittings with NGLI grade #2
multi-purpose gun grease.
Refer to the following chart for fitting locations
and lubrication schedule.
Lubrication Chart
Fitting
Locations
1. Idler
Bushings
Initial
Pumps
Number of
Places
Service
Interval
1–2
1
25 Hours
Deck
Part No.
44 inch Deck
1-653332
46 inch Deck
1-653438
48 inch Deck
1-653333
50 inch Deck
103-0866
52 inch Deck
1-653438
56 inch Deck
109-9249
A. To replace belt, remove the belt guide on the
blower (Figure 8)
Check Condition of Belt
Service Interval: Every 50 hours
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
Figure 8
2. Inspect the belt position on the idler arm.
1. Spring loaded idler
2. Impeller sheave
3. Fixed idler
The idler arm may become bent during use or
transport. A bent idler arm could cause the belt
to jump off of the idler and be damaged.
4. Belt guide
5. Deck sheave
A. Make sure the belt cover is installed and run
the blower for one to two minutes.
B. Install the belt onto the blower assembly as
shown.
B. Shut off the deck drive, stop engine and wait
for all moving parts to stop. Remove key.
Remove the belt cover and check to make sure
that the belt is riding near the center of the
flat idler on the idler arm.
C. Reinstall the belt guide removed previously.
C. If the belt is not riding near the center of the
idler, remove the blower, and bend the idler
arm slightly.
D. Reinstall the blower and belt cover and repeat
steps A through C until the belt is positioned
near the center of the idler.
17
Maintenance
Adjustments
Note: The Ultra Vac QDS was adjusted at the
factory to operate properly. However, there are three
basic adjustments that can be made, should your unit
require them:
3. Door opening: After adjusting the hinge links
for door closing, the hinge stops (Figure 10B) can
be adjusted to obtain maximum door opening.
The stop plates should be adjusted so that the
door link contacts them when the upper tube of
the door frame is within 1/4 inch (6.4 mm) ± 1/8
inch (3.2 mm) from the lower lip of the molded
hood. Both left and right stops must make
contact when the door link arm is at this position.
Figure 9
Figure 10
1. Bellcrank arm
2. Upper frame tube
3. Maintain same distance on both sides
1. 1/4 inch (6.4 mm) ± 1/8 inch (3.2 mm)
1. Arm Position: The left and right bellcrank arms
control the timing of the left and right door
opening mechanisms. The ends of these arms
must be positioned equally from the upper frame
tube for proper actuation. Check this distance
with the door closed. If adjustment is necessary,
loosen the allen head clamping screw on the hub
of the right hand arm. Position the arms so that
their ends are the same distance from the upper
frame tube. Tighten the clamping bolt to hold
them in this position (see Figure 9).
2. Door closing: The closing of the door is
controlled by the two hinge links (Figure 10A).
The length of the hinge links can be changed
to provide complete closing of the door and
reasonable force on the handle to latch or unlatch
the door. Lengthen the links to reduce the force.
Shorten the links to increase the force. The left
and right sides must be approximately equal. With
the door closed, both links should be slightly tight
to minimize rattling.
18
Maintenance
Cleaning
Clean Muffler and Rear
Frame Area
Service Interval: Before each use or daily
Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
WARNING
Operating engine parts, especially the
muffler, become extremely hot. Severe burns
can occur on contact and debris, such as
leaves, grass, brush, etc. can catch fire.
• Allow engine parts, especially the muffler,
to cool before touching.
• Remove accumulated debris from muffler
and engine area.
• Install and maintain in working order a
spark arrester before using equipment
on forest-covered, grass-covered,
brush-covered unimproved land.
Clean Rear Screen In Hood
Service Interval: Before each use or daily
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Open door and remove clippings that are stuck
to the screen.
Clean Blower
Service Interval: Yearly or before storage
Grass build up may cause problems with the impeller
when the unit is put back into operation.
1. Stop engine, wait for all moving parts to stop, and
remove key. Engage parking brake.
2. Remove grass buildup from around the impeller
before placing it in storage.
19
Troubleshooting
Troubleshooting
Important: It is essential that all operator safety mechanisms be connected and in proper operating
condition prior to mower use.
When a problem occurs, Do Not overlook the simple causes. For example: starting problems could be
caused by an empty fuel tank.
The following table lists some of the common causes of trouble. Do Not attempt to service or replace major
items or any items that call for special timing or adjustment procedures (such as valves, governor, etc.). Have
this work done by your Engine Service Dealer.
Note: When disconnecting electrical connectors Do Not pull on the wires to separate the connectors.
Problem
Possible Cause
Corrective Action
1. Cutting blade(s) is/are bent or unbalanced.
1. Install new cutting blade(s).
2. Blade mounting bolt is loose.
3. Loose blower pulley or pulley assembly.
4. Blower impeller blades are bent.
2. Tighten the blade mounting bolt.
3. Tighten the appropriate pulley.
4. Contact an Authorized Service Dealer.
Blower drive belt snaps or breaks frequently.
1. Idler arm is out of alignment.
1. Correct the alignment of the idler arm.
Excessive grass blowout from the deck.
1. Hopper is full.
1. Dump more frequently.
2. Plugged screen in bagger hood.
2. Remove debris, leaves or grass clippings
from the screen.
3. Drive slower at full throttle.
4. Install new blower belt.
5. Locate and remove plugged debris.
6. Use lower lift blade.
Abnormal vibration.
3.
4.
5.
6.
Blower and tubes plug too frequently.
Ground speed is too fast.
Blower belt is worn, loose, or broken.
Plugged tube or blower.
Conditions are dry.
1. Hopper is too full.
1. Dump more frequently
2. Ground speed is too fast.
3. Grass is too wet.
4. Grass is too long.
2. Drive slower at full throttle.
3. Cut grass when it is dry.
4. Cut grass more frequently or at higher cut
height.
5. Remove debris, leaves, or grass clippings
from the screen.
6. Install new belt.
5. Plugged screen in bagger hood.
6. Blower drive belt is worn, loose, or
broken.
7. Blower is plugged.
7. Use low lift blades in wet conditions.
1. Plugged blower.
1. Remove debris, leaves, or grass clippings
from the blower impeller.
2. Impeller not aligned.
2. Contact an Authorized Service Dealer.
Plowing leaves.
1. Deck is too low.
1. Units below Serial Number
600,000: Raise the deck slightly.
Triton: Raise the front adjustable baffle.
Chasing leaves.
1. Blowout from deck.
1. Units below Serial Number 600,000:
Install an anti-blowout kit–contact
an Authorized Service Dealer.
Triton: Lower the front adjustable
baffle. Match discharge opening to Ultra
Vac intake.
Blower components show signs of wear
and/or air cleaners and cooling fins are dirty.
1. Sand or dry conditions.
1. Use low lift blades on the cutting
deck and higher cutting heights.
Clean air cleaners and cooling fins
frequently.
Blower impeller does not spin freely.
20
Exmark Commercial Attachments and Accessories
1 Year Limited Warranty
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 on these products and found by us
(in the exercise of our reasonable discretion) to be defective in
factory materials or workmanship for a period of one year.
Owner’s Responsibilities
The Exmark attachment or accessory, including any defective
part, must be returned to an authorized Exmark service dealer
within the warranty period. This warranty extends only to
commercial attachments and accessories 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 or other operational
instructions provided by Exmark. Such routine maintenance,
whether performed by a dealer or by you, is at your expense.
This warranty applies to Exmark commercial attachments and
accessories sold in the U.S. 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.
Warranty Exceptions
• Bags, Belts and Tires
General Conditions
The sole liability of Exmark and Exmark Warranty Company
with respect to this warranty shall be repair or replacement of
defective components as set forth herein. Neither Exmark
nor Exmark Warranty Company shall be liable for any
incidental or consequential loss or damage.
Warranty Period
90 days
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.
• 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 attachment or accessory or other than as
recommended in the operator's manual or other operational
instructions provided by Exmark.
Such damages include but are not limited to:
• Expenses related to gasoline, oil or lubricants.
• Travel time, overtime, after hours time or other
extraordinary repair charges or charges 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 attachment
or accessory.
All implied warranties of merchantability (that the
product is fit for ordinary use) and fitness for use (that the
product is fit for a particular purpose) are limited to the
duration of the express warranty.
Some states do not allow exclusions of incidental or
consequential damages, or limitations on how long an
implied warranty lasts, so the above exclusions and
limitations may not apply to you.
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. or Canada customers may
also call 402-223-6375.
This warranty gives you specific legal rights, and you may
also have other rights which vary from state to state.
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
service@exmark.com
G4500-433
21
Service Record
Date:
Description of Work Done:
22
Service Done By:
23
SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS
MID-MOUNT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
OPERATOR CONTROLLED DISCHARGE
FULL SUSPENSION SEAT
ROLL OVER PROTECTION SYSTEM (ROPS)
DECK LIFT ASSIST KIT
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
TURF STRIPER
12V POWER PORT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
OUT-FRONT RIDING ACCESSORIES AND OPTIONS
CUSTOM RIDE SEAT SUSPENSION SYSTEM
SNOW BLADE
DUAL-TAIL WHEEL
SNOWBLOWER
FLOOR PAN EXTENDER
SUN SHADE
HITCH KIT
TRASH CONTAINER
LIGHT KIT
ULTRA VAC COLLECTION SYSTEM
MICRO-MULCH SYSTEM
ULTRA VAC QUICK DISPOSAL SYSTEM
ROLL OVER PROTECTION SYSTEM (ROPS)
WEATHER CAB
WALK-BEHIND ACCESSORIES AND OPTIONS
GRASS CATCHER
TURF STRIPER
MICRO-MULCH SYSTEM
STANDON
Place Model No. and Serial No.
Label Here (Included in the Literature
Pack) or Fill in Below
Date Purchased
Model No.
Serial No.
© 2008 Exmark Mfg. Co., Inc.
Industrial Park Box 808
Beatrice, NE 68310
All Rights Reserved
Part No. 4500-420 Rev. A
(402) 223-6300
Fax (402) 223-5489
Printed in the USA
www.exmark.com