WALK-BEHIND ROTARY BROOM. For Serial Nos. 314,000,000 & Higher Part No Rev. A

Transcription

1 WALK-BEHIND ROTARY BROOM For Serial Nos. 314,000,000 & Higher Part No Rev. A

2 WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Important: The engine in this product is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code (CPRC) Section 4442 to use or operate this engine on any forest-covered, brush-covered, or grass-covered land as defined in CPRC Other states or federal areas may have similar laws. To acquire a spark arrester for your unit, see your Engine Service Dealer. This spark ignition system complies with the Canadian standard ICES-002. Ce système d allumage par ètincelle de vèhicule est conforme à la norme NMB-002 du Canada. The enclosed Engine Owner s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty. Keep this engine Owner s Manual with your unit. Should this engine Owner s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer. 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 Exmark Mfg. Co., Inc. Industrial Park Box 808 Beatrice, NE Contact us at Printed in the USA All Rights Reserved

3 Introduction CONGRATULATIONS on the purchase of your Exmark Walk-Behind Rotary Broom. 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 Walk-Behind Rotary Broom. BEFORE OPERATING YOUR WALK-BEHIND ROTARY BROOM, CAREFULLY READ THIS MANUAL IN ITS ENTIRETY. By following the operating, maintenance, and safety instructions, you will prolong the life of your walk-behind rotary broom, maintain its maximum efficiency, and promote safe operation. Important: To maximize safety, performance, and proper operation of this machine, it is essential that all operators carefully read and fully understand the contents of the Operator s manual provided with the product. Safe operation of Exmark equipment is essential. Failure to comply with the operating instructions or receive proper training may result in injury. Go to for additional safe operation information, such as safety tips, training materials, and Operator s manuals. If additional information is needed, or should you require trained mechanic service, contact your authorized Exmark equipment dealer or distributor. 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. Figure 1 1. Model and serial number location Model No. Serial No. 3

4 Contents Introduction... 3 Safety... 5 Safety Alert Symbol... 5 Safe Operating Practices... 5 Safety and Instructional Decals...10 Specifications...13 Model Numbers...13 Systems...13 Dimensions...13 Torque Requirements...14 Product Overview...15 Operation...15 Controls...15 Pre-Start...16 Operating Instructions...16 Transporting...21 Maintenance...22 Recommended Maintenance Schedule(s)...22 Periodic Maintenance...22 Check Engine Oil Level...22 Check Traction Cable...22 Check for Loose Hardware...23 Change Engine Oil...23 Check Tire Pressures...23 Check Condition Of Belts...23 Lubricate Grease Fittings...23 Check Spark Plug...24 Check Fuel Tank Filter...24 Thread Locking Adhesives...24 Lubricate Hex Shaft...24 Check Broom Cable...24 Check Broom Shaft Shear Pin...24 Adjustments...26 Traction Cable Adjustment...26 Broom Drive Adjustment...26 Wheel Clutch Cable Adjustment...26 Troubleshooting

5 Safety Safety Safety Alert Symbol 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. This symbol means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Figure 2 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. DANGER: White lettering / Red background. Indicates an imminently hazardous situation which, if not avoided, Will result in death or serious injury. WARNING: Black lettering / Orange background. Indicates a potentially hazardous situation which, if not avoided, Could result in death or serious injury. 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. Safe Operating Practices Training Read, understand and follow all instructions on the machine and in the manual(s) before operating this machine. Be thoroughly familiar with the controls and the proper use of the machine. Know how to stop the machine and disengage the controls quickly. If the operator(s) or mechanic(s) can not read English it is the owner s responsibility to explain this material to them; other languages may be available on our website. Never allow children to operate or service the machine. Never allow adults to operate or service the machine without proper instruction. The owner is responsible for training the users. Keep the area of operation clear of all persons, particularly small children. Exercise caution to avoid slipping or falling, especially when operating the machine in reverse. Only adults and mature teenagers should operate the machine, and even mature teenagers should have adult supervision. Be sure a teenager: 1. has read and understands the Operator's Manual and recognizes the risks involved; 2. is sufficiently mature to use caution; and 3. is of sufficient size and weight to operate the controls comfortably and to manage the machine without taking risks. The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property. Preparation Thoroughly inspect the area where the machine is to be used and remove all ropes, wires, boards, and other foreign objects which can be thrown or become entangled in the machine and may cause personal injury to the operator or bystanders. Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by Exmark. Prior to use, evaluate surfaces to be cleaned to ensure proper footing or traction on slippery or wet surfaces. Wear appropriate clothing including safety glasses, dust protection mask, substantial footwear, long trousers, and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts. Wear footwear that will improve footing on slippery surfaces. 5

6 Safety 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. Wear hearing protection when operating this machine. DANGER In certain conditions gasoline is extremely flammable and vapors are explosive. A fire or explosion from gasoline can burn you, others, and cause property damage. Fill the fuel tank outdoors on level ground, in an open area, when the engine is cold. Wipe up any gasoline that spills. Never refill the fuel tank or drain the machine indoors or inside an enclosed trailer. Do Not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 5/8 inch (16 mm) from top of tank. This empty space in the tank allows gasoline to expand. Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by spark. Store gasoline in an approved container and keep it out of the reach of children. Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot. If fuel is spilled, Do Not attempt to start the engine. Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated. Do Not operate without entire exhaust system in place and in proper working condition. DANGER In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage. Always place gasoline containers on the ground away from your vehicle before filling. Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge. When practical, remove gas-powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground. If this is not possible, then refuel such equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle. If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. WARNING Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors has caused cancer in laboratory animals. Failure to use caution may cause serious injury or illness. Avoid prolonged breathing of vapors. Keep face away from nozzle and gas tank/container opening. Keep away from eyes and skin. Never siphon by mouth. Check that the operator presence controls and shields are attached and functioning properly. Do Not operate unless they are functioning properly. Never attempt to make any adjustments while the engine is running (except when specifically recommended by manufacturer). 6

7 Safety Operation 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. WARNING Engine exhaust contains carbon monoxide, which is an odorless deadly poison that can kill you. Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect. Never operate the machine without good visibility or light. Stay alert for hidden hazards or traffic. Always be sure of your footing, and keep a firm hold on the handles. Walk; never run. Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, Do Not operate the machine. Do Not put hands or feet near or under the broom. Exercise extreme caution when operating on roads or crossing gravel drives, walks, or roads. Stay alert for hidden hazards or traffic. Do Not operate on any roof or other elevated surface. After striking a foreign object, stop engine, wait for all moving parts to stop, and remove the spark plug wire(s) and thoroughly inspect the machine for any damage, and repair the damage before restarting and operating the machine. If the machine should start to vibrate abnormally, stop the engine and check immediately for the cause. Vibration is generally a warning of trouble. Never operate the machine with damaged guards, shields, or covers. Always have safety shields, guards, and other devices in place and in proper working condition. Keep children, pets, and all others away from machine during operation. Never direct discharge at bystanders or operate the rotary broom near glass enclosures, automobiles, window wells, drop-offs, and the like without proper adjustment of the sweeping discharge angle. Stop the machine and broom drive before adjusting the broom angle. Do Not overload the machine capacity by attempting to clear snow or debris at too fast a rate. Never operate the machine at high transport speeds on slippery surfaces. Look behind and use care when operating in reverse. Disengage power to the broom when machine is transported or not in use. Do Not change the engine governor setting or overspeed the engine. Park the machine on level ground. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). Before checking, cleaning or working on the machine. After striking a foreign object or abnormal vibration occurs (inspect the machine for damage and make repairs before restarting and operating the machine). Before clearing blockages. Whenever you leave the machine unattended. Park the machine on level ground. Stop engine, wait for all moving parts to stop: Before refueling or adjusting the broom height. WARNING 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. This machine was designed for one operator only. Do Not carry passengers. 7

8 Safety Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. Do Not operate the machine under the influence of alcohol or drugs. Use extreme care when loading or unloading the machine into a trailer or truck. Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision. Broom bristles will melt or burn. Keep away from extreme heat or flame. Clearing a Clogged Broom WARNING The rotating broom could cause serious injury. Always use caution when cleaning the broom. To clear the broom: Park the machine on level ground. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). Sharp objects can become entangled in bristles. Use gloves and caution when cleaning out the broom of foreign objects; not bare hands. Slope Operation Use Extreme caution when operating and/or turning on slopes as loss of traction and/or tip-over could occur. The operator is responsible for safe operation on slopes. DANGER Operating on wet surfaces or steep slopes can cause sliding and loss of control. Loss of control and/or loss of operator's footing could result in a fall with an arm or leg getting under the broom or engine deck which may result in serious injury, death or drowning. Do Not operate near drop-offs or near water. Reduce speed and use extreme caution on slopes. Avoid sudden turns or rapid speed changes. Always keep the traction drive engaged especially when traveling downhill. Do Not operate on slopes greater than 10 degrees. See inside the back cover to determine the approximate slope angle of the work area. When feasible, avoid operating the equipment in wet grass. Progressively greater care is needed as the slope increases. Remove or mark obstacles such as rocks, tree limbs, etc. from the work area. Avoid sudden starts when operating the broom uphill because the machine may tip backwards. Watch for ditches, holes, rocks, dips and rises that change the operating angle, as rough terrain could overturn the machine. Do Not squeeze both wheel clutch levers simultaneously and coast down hills. Tire chains are highly recommended when operating at or below freezing temperatures. Only use chains supplied by Exmark. Use extreme care with attachments. These can change the stability of the machine and cause loss of control. Maintenance and Storage Park machine on level ground. Never allow untrained personnel to service machine. Stop the engine and remove the spark plug wire(s). Wait for all movement to stop before adjusting, cleaning or repairing. Keep engine and engine area free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. These materials can become combustible and may result in a fire. Let engine cool before storing and do not store near flame or any enclosed area where open pilot lights or heat appliances are present. Shut off fuel while storing or transporting. Do Not store fuel near flames or drain indoors. Always refer to the Operator s Manual for important details if the machine is to be stored for an extended period. Keep hands and feet away from moving parts. If possible, Do Not make adjustments with the engine running. Keep all guards, shields and all safety devices in place and in safe working condition. 8

9 Safety Check all bolts frequently to maintain proper tightness. Frequently check for worn or deteriorating components that could create a hazard. WARNING Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine. Unauthorized modifications to the original equipment or failure to use original Exmark parts could lead to serious injury or death. Unauthorized changes to the machine, engine, fuel or venting system, may violate applicable safety standards such as: ANSI, OSHA and NFPA and/or government regulations such as EPA and CARB. 9

10 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 equipment. 1. Grease Reorder part no Fast 3. Slow 2. Forward speeds 4. Reverse speeds Warning stay away from moving parts; keep all guards in place. 1. Thrown object hazard-do Not operate when people and pets are in the area. 2. Warning-Entanglement hazard-stay clear of rotating broom. 10

11 Safety Explosion/Fire hazard Read the Operator s Manual. Stop engine before filling fuel tank. Leave 5/8 inch (16mm) at top of tank for fuel expansion-do Not overfill tank Left turn control-squeeze lever to turn left. 4. Broom drive-squeeze lever to engage; release lever to disengage. 2. Traction drive-squeeze lever to engage; release lever to disengage. 3. Broom angle lever-push down to change angle; release lever to lock angle. 5. Right turn control-squeeze lever to turn right. 11

12 Safety 1. Warning-Read the Operator s Manual. Do Not operate this machine unless you are trained. Stay away from moving parts; keep all guards in place. 2. Thrown object hazard-do Not operate when people and pets are in the area; pick up objects that could be thrown by broom Warning-Stop engine and remove spark plug before adjusting, servicing, or cleaning machine and attachments. Before leaving the operator s position, disengage broom, traction drive, and stop engine. Look behind and to the side before changing directions. Do Not carry passengers. 5. Warning-Entanglement hazard-stay clear of rotating broom. Broom bristles will melt or burn-keep away from extreme heat or flame. Do Not operate on any roof or other elevated surface. 3. Warning-Wear hearing protection. 6. Warning-Do Not operate on slopes greater than 10 degrees. Use extreme caution when operating on slopes; operate across slopes not up and down. 12

13 Specifications Specifications Model Numbers Serial Nos: 314,000,000 and Higher BR270KC36 Systems Engine Engine Specifications: See your Engine Owner s Manual Engine Oil Type: Exmark 4 Cycle Premium Engine Oil RPM: Full Speed: 3600 ±100 RPM (No Load) Fuel System Capacity: 4.3 qt. (4.1 L) Fuel Recommendations: For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). Oxygenated fuel with up to 10% ethanol or 15% MTBE by volume is acceptable. Do Not use ethanol blends of gasoline (such as E15 or E85) with more than 10% ethanol by volume. Performance problems and/or engine damage may result which may not be covered under warranty. Do Not use gasoline containing methanol. Do Not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used. Do Not add oil to gasoline. Fuel Filter: Replaceable In-line Fuel Shut-Off Valve: 1/4 turn increments Operator Controls Motion Control: Placing the speed selector lever and engaging the traction drive lever control the speed and movement of the machine. Steering Control: Separate wheel clutch levers under the handles control the direction of travel of the respective drive wheel. Squeezing both levers at the same time allows the broom to temporarily be placed in neutral. Transmission Front disc with free-wheel steering Speeds: mph (4.8 km/hr) forward mph (2.7 km/hr) reverse. Wheel Drive System Drive wheels are driven through clutched roller chains. Tires and Wheels Drive Pneumatic (Air-Filled) Quantity 2 2 Front Caster Polyolefin Tread X-Trac Smooth Size 15 x x 1 3/8 inches (12.7 x 3.5 mm) Ply Rating 2 Pressure Broom psi ( kpa) Broom Width: 36 inches (91.4 cm) Dimensions Overall Width: 46.5 inches (118.1 cm) Overall Length: 73 inches (185.4 cm) 13

14 Specifications Overall Height: 41.5 inches (105.4 cm) Tread Width: (Outside to Outside of Tires, Widthwise) inches (65.4 cm) Torque Requirements Bolt Location Engine Mounting Nuts Wheel Hub Nuts Torque in-lb (15-19 N-m) ft-lb (11-15 N-m) Curb Weight: 323 lb (146.5 kg) 14

15 Operation Product Overview Operation Note: Determine the left and right sides of the machine from the normal operating position. Controls Choke Control The choke control is the top lever located on the rear LH side of the engine above the fuel shut-off valve. The choke is used to aid in starting a cold engine. Move the lever left to the ON position for a cold start. Do Not run a warm engine with the choke in the ON position. Figure 3 1. Wheel clutch lever 6. Traction drive lever 2. Handle 7. Fuel cap 3. Broom angle lever 8. Broom 4. Broom drive lever 9. Broom height adjustment pin 5. Speed selector lever Throttle Control The throttle control is located on the rear RH side of the engine. The throttle is used to control engine speed. Moving the throttle control to the left will increase engine speed and moving it right will decrease engine speed. Engine On/Off Switch Located on the RH side of the engine. Rotate the switch clockwise to the ON position before starting the engine. Rotate the switch counterclockwise to the OFF position to kill the engine. Fuel Shut-Off Valve The fuel shut-off valve is the lower lever located on the rear LH side of the engine below the choke. The fuel shut-off valve shuts off the flow of fuel when the machine will not be used for a few days, when parking inside a building, and during transport to and from the job. Move the lever to the left to shut off fuel. Move the lever to the right to turn on fuel. Wheel Clutch Levers Located below the RH and LH handles. The wheel clutch levers allow the drive to momentarily disengage to one or both wheels with the traction drive lever still engaged. This allows easier turning and maneuvering the machine (see Figure 4). 15

16 Operation Squeezing both wheel clutch levers simultaneously disengages the drive to both wheels (free-wheeling). This enables you to manually move the machine backward without stopping to shift it into a reverse gear. It also allows you to maneuver and transport the machine more easily when the engine is not running. Figure 4 1. Wheel clutch lever 4. Traction drive lever 2. Handle 5. Speed selector lever 3. Broom angle lever 6. Broom drive lever Broom Drive Lever Located above the RH handle (see Figure 4). To engage the broom, squeeze the lever to the handle. To disengage the broom, release the RH lever. Traction Drive Lever Located above the LH handle (see Figure 4). The traction drive lever controls the forward and reverse motion of the machine. To engage the traction drive, squeeze the lever to the handle. Note: Holding down the traction drive lever against the handle engages the traction drive to both wheels. Speed Selector Lever Located on the main console panel (see Figure 4). The speed selector has six forward and two reverse settings. To change speeds, release the traction drive lever and shift the speed selector lever to the desired setting. The lever locks in a notch at each speed setting. Broom Angle Lever Located on the RH handle (see Figure 4). The broom angle lever allows the broom to rotate and lock 19 degrees to the right or left or straight ahead. Pre-Start Refer to the engine manual to properly position the air cleaner cover for summer and winter operation. Fill fuel tank on level ground. Fuel Recommendations: For best results, use only clean, fresh, unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). Oxygenated fuel with up to 10% ethanol or 15% MTBE by volume is acceptable. Do Not use ethanol blends of gasoline (such as E15, E20, or E85) with more than 10% ethanol by volume. Performance problems and/or engine damage may result which may not be covered under warranty. Do Not use gasoline containing methanol. Do Not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used. Do Not add oil to gasoline. Do Not overfill fuel tank. Fill the fuel tank until the level is 5/8 inch (16 mm) from top of tank. The empty space in the tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system. Make sure you understand the controls, their locations, their functions, and their safety requirements. Operating Instructions Open the Fuel Shut-Off Valve Move the fuel shut-off valve, the lower lever located below the choke, to the right to turn on fuel. Starting the Engine 1. On the RH side of the engine, rotate the engine on/off switch clockwise to the ON position. 2. On the rear LH side of the engine, move the choke lever, the top lever located above the fuel 16

17 Operation shut-off valve, to the left to the ON position. On a warm engine, leave the choke in the OFF position. 3. Place the throttle midway between the SLOW and FAST positions located on rear RH side of the engine. 4. Slowly pull the engine recoil handle until you feel resistance and then stop. Allow the recoil handle to return and then sharply pull it straight out. Allow the rope to return slowly. 5. Allow the engine to warm up for several minutes, move the choke toward the OFF position. Stopping the Engine 1. Bring the unit to a full stop. 2. Place the throttle midway between the SLOW and FAST positions. 3. Allow the engine to run for a minimum of 15 seconds, then turn the engine on/off switch to the OFF position to stop the engine. 4. Wait for all moving parts to stop before leaving the operating position. 5. Close the fuel shut-off valve, located below the choke, by moving it to the left when the machine will not be in use for a few days, when transporting, or when the unit is parked inside a building. Driving the Machine CAUTION If the traction drive is not properly adjusted, the machine may move in the direction opposite of what you intended, causing injury and/or property damage. Carefully check the traction drive and adjust it properly, if necessary. Important: If the machine moves when the traction lever is in the released position, check the traction cable (refer to Check Traction Cable and Traction Cable Adjustment sections in Maintenance) or contact your authorized EXMARK SERVICE DEALER. Driving Forward: 1. Place the speed selector lever to the desired forward position, making sure it locks in the notch (see Figure 5). Figure 5 Note: If the ground speed is too fast, debris or snow will pile up in front of the broom causing the broom to bulldoze instead of sweep. This can damage the bristles and the drive line. 2. Slowly squeeze the LH traction drive lever to the handle (see Figure 6). Note: Holding down the traction drive lever against the handle engages the traction drive to both wheels. Figure 6 3. To stop the traction drive, release the traction drive lever. 4. To move forward, engage the traction drive, slowly squeeze the left hand (traction) lever to the handle (see Figure 7). Momentarily squeezing and releasing the left or right wheel clutch lever allows for steering adjustments to keep the machine going in a straight line, especially in deep snow. To turn right, lift up on the right wheel clutch lever and squeeze it toward the handle. This disengages the drive to the right wheel while the left wheel continues driving, and the machine turns to the right. 17

18 Operation to shift it into a reverse gear. It also allows you to maneuver and transport the machine more easily when the engine is not running. Operating the Broom Figure 7 Note: Similarly, squeezing the left wheel clutch lever turns the machine to the left. When you complete the turn, release the wheel clutch lever, and the drive re-engages both wheels (see Figure 8). Figure 8 DANGER When the machine is in operation, contact with rotating or moving parts will severely injure hands and feet. Before adjusting, cleaning, inspecting, troubleshooting, or repairing the machine, stop the engine and wait for all moving parts to stop. Disconnect the wire from the spark plug and keep it away from the plug to prevent someone from accidentally starting the engine. Stay behind the handles and away from the broom while operating the machine. Keep face, hands, feet, and any other part of your body or clothing away from concealed, moving, or rotating parts. 5. To stop the traction drive, release the traction drive lever. Driving Rearward: 1. Place the speed selector lever to the desired rearward position, making sure it locks in the notch. 2. To move rearward, engage the traction drive, slowly squeeze the left hand (traction) lever to the handle. Momentarily squeezing and releasing the left or right wheel clutch lever allows for steering adjustments to keep the machine going in a straight line. To turn right, squeeze the right wheel clutch lever toward the handle. This disengages the drive to the right wheel while the left wheel continues driving, and the machine turns to the right. Note: Similarly, squeezing the left wheel clutch lever turns the machine to the left. Squeezing both wheel clutch levers simultaneously disengages the drive to both wheels. This enables machine to be moved rearward without stopping WARNING Contact with a rotating broom can result in serious personal injury or death to the operator or bystanders. To remove an obstruction from the broom; refer to Clearing a Clogged Broom. Do Not operate the machine if the broom drive lever is not functioning properly. Contact your authorized EXMARK SERVICE DEALER. WARNING The rotating broom can throw stones and other foreign objects, causing serious personal injury to the operator or to bystanders. Keep the working area clear and free of all objects that the broom could pick up and throw. Keep all children and pets away from the area of operation. 18

19 Operation CAUTION When the broom is engaged, it may drive the unit in the reverse direction. If the broom height is adjusted too low, the machine may move more forcefully in the reverse direction, causing injury and/or property damage. Carefully check the broom height and adjust it properly or contact your authorized EXMARK SERVICE DEALER. 1. Set the engine throttle to the FAST position. 2. Place the speed selector lever into the desired position and slowly squeeze the LH traction drive lever. Important: Make sure the traction drive is engaged before operating the broom; otherwise the broom may drive the unit in the reverse direction. 3. To engage the broom, slowly squeeze the right hand (broom) lever to the handle (Figure 9). 2. With the engine running, with the throttle set midway between SLOW and FAST. Engage the broom and allow the broom to sweep for approximately 30 seconds. 3. Disengage the broom and stop the engine. 4. Wait for all moving parts to stop before leaving the operating position. 5. Turn the engine on/off switch to the OFF position. 6. Make sure the area swept equals the length of the broom and 2-4 inches ( mm) maximum width. Figure 10 Figure inches ( mm) maximum width 2. Length of broom 3. Swept area If the engine slows down under a load or the wheels slip, shift the machine into a lower gear. If the front of the machine rides up, shift the machine into a lower gear. If the front continues to ride up, lift up on the handles. 4. To stop the broom, release the right hand lever. Checking the Sweeping Path A broom sweeps with the tips of its bristles. When too much down pressure is applied, the broom is no longer using its tips; the broom is now working with the sides of the bristles (like a mop). This limits the flicking action of the bristles, sweeping effectiveness, and can decrease broom life. 1. Drive to a flat dusty area and stop the machine. 7. Adjust the broom height if necessary. Adjusting the Broom Height 1. Drive to a flat dusty area and stop the machine. 2. Disengage the broom and stop the engine. 3. Wait for all moving parts to stop before leaving the operating position. 4. Turn the engine on/off switch to the OFF position. 5. To adjust the broom height, remove and retain the pin from the adjuster sleeve and caster wheel tube. 19

20 Operation the broom can rotate 19 degrees to the right or left or straight ahead. 5. Once the broom is positioned, release the broom angle lever. Release the left wheel clutch lever and make sure the broom is locked into place. Clearing a Clogged Broom WARNING The rotating broom could cause serious injury. Always use caution when cleaning the broom. Figure Caster wheel tube 3. Pin 2. Positions to achieve 1/8 4. Adjuster sleeve inch (3 mm) increments 6. Raise or lower the caster wheel tube to achieve the sweep area as stated in Checking the Sweeping Path. Select any hole combination that is in alignment to place and latch the retaining pin; match the same position on the other side. 7. For fine tuning adjustments, slide the adjuster sleeve one pin hole location up or down on the caster wheel tube to adjust the broom height in 1/8 inch (3 mm) increments (reference Figure 11). Repeat for the other caster wheel. To raise the broom in 1/8 inch (3 mm) increments, slightly raise the adjuster sleeve and insert the pin into the next pin hole below the current hole used. To lower the broom in 1/8 inch (3 mm) increments, slightly lower the adjuster sleeve and insert the pin into the next pin hole above the current hole used. 8. Once the desired height is reached, secure the pin on each caster wheel. Recheck the sweeping area. Adjusting Broom Side Angle 1. Disengage the broom and stop the engine. 2. Wait for all moving parts to stop. 3. Push the lever down using the RH thumb (see Figure 4). 4. Squeeze the left wheel clutch lever to the handle and push the broom housing to the desired angle; If the broom becomes clogged, stay in the operating position and release the left hand traction drive lever. While engaging the broom, push down on the handles to raise the front of the machine a few inches (centimeters) off the pavement. Then lift the handles quickly to bump the front of the machine on the pavement. Repeat if necessary. If you cannot unclog the broom by bumping the front of the machine: Park the machine on level ground. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). Sharp objects can become entangled in bristles. Use gloves and caution when cleaning out the broom of foreign objects; not bare hands. Preventing Freeze-up In snowy and cold conditions, some controls and moving parts may freeze. Do Not use excessive force when trying to operate frozen controls. If you have difficulty operating any control or part, start the engine and let it run for a few minutes. After using the machine, let the engine run for a few minutes to prevent moving parts from freezing. Engage the broom to clear any remaining snow from inside the housing. Stop the engine and wait for all moving parts to stop, and remove the spark plug wire(s). Remove all ice, snow, or other debris from the machine. Reconnect spark plug wire(s). With the engine switch in the OFF position, pull the recoil 20

21 Operation starter handle several times to prevent the recoil starter from freezing up. Transporting Transporting a Unit WARNING Loading the machine onto a trailer without strong enough or properly supported ramps could be dangerous. The ramps could collapse causing the unit to fall, which could cause injury. Use proper ramps that are secured to the truck or trailer. Keep feet and legs out from under the unit when loading and unloading. If necessary, use assistance when loading. Use full width ramps when loading the machine. Be sure the fuel shut-off valve is closed during transport. Use a heavy duty trailer to transport the machine. Place the machine in either a forward or reverse gear then block wheels. Securely fasten the machine to the trailer with straps, chains, cables, or ropes. If possible, both front and rear straps should be directed down and outward from the machine. Be sure that the trailer has all necessary lighting and marking as required by law and use safety chains. 21

22 Maintenance Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval After the first 2 hours After the first 5 hours Before each use or daily Every 50 hours Every 100 hours Every 160 hours Yearly Maintenance Procedure Check the traction cable. Check the broom cable. Change the engine oil. Check the engine oil level. Check for loose hardware. Check fuel tank filter Check the broom shaft shear pin. Check the tire pressures. Check the condition of the belts. Change the engine oil. (May need more often under severe conditions.) Grease the broom angle lock pin. Check the spark plug. Check the traction cable. Lubricate hex shaft. Check the broom cable. thereafter Periodic Maintenance Check Engine Oil Level Service Interval: Before each use or daily 1. Stop engine and wait for all moving parts to stop. Make sure unit is on a level surface. 2. Check with engine cold. 3. Clean area around dipstick. Remove dipstick and wipe oil off. Reinsert the dipstick according to the engine manufacturer's recommendations. Remove the dipstick and read the oil level. 4. If the oil level is low, wipe off the area around the oil fill cap, remove cap and fill to the FULL mark on the dipstick. Exmark 4-Cycle Premium Engine Oil is recommended; refer to the Engine Owner's manual for an acceptable alternative. Do Not overfill. Important: Do Not operate the engine with the oil level below the LOW (or ADD ) mark on the dipstick, or over the FULL mark. Check Traction Cable Service Interval: After the first 2 hours Yearly 1. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). 2. With the traction lever disengaged, check the pin in the elongated slot in the left side of the machine above the tire (see Figure 12). There should be a gap of 1/4 inch (6 mm) from the front of the slot to the front edge of the pin. If adjustment is necessary, see Adjusting Traction Cable. 22

23 Check Tire Pressures Service Interval: Every 50 hours Maintenance 1. Stop engine, wait for all moving parts to stop, and leave engine switch in the OFF position. 2. Check tire pressure in drive tires. 3. Inflate drive tires to psi ( kpa). Figure Pin 2. 1/4 inch (6 mm) Check for Loose Hardware Service Interval: Before each use or daily 1. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). 2. Visually inspect machine for any loose hardware or any other possible problem. Tighten hardware or correct the problem before operating. Change Engine Oil Service Interval: After the first 5 hours Every 100 hours (May need more often under severe conditions.) 1. Stop engine, wait for all moving parts to stop. 2. Disconnect the wire from the spark plug. 3. Drain oil while engine is warm from operation. 4. The oil drain is located on the left side of the engine. Place pan under drain fitting to catch oil. Remove oil drain plug. Allow oil to drain and replace oil drain plug. 5. Clean around oil fill cap and remove cap. Fill to specified capacity and replace cap. Use oil recommended in the Check Engine Oil Level section. Do Not overfill. 6. Start the engine and check for leaks. Stop engine and recheck oil level. 7. Wipe up any spilled oil from engine deck mounting surfaces. Check Condition Of Belts Service Interval: Every 50 hours 1. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). 2. Remove belt cover and engine shield to check belt condition. Lubricate Grease Fittings Note: See chart for service intervals. 1. Stop engine, wait for all moving parts to stop, and leave engine switch in the OFF position. 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. Broom Angle Lock Pin Initial Pumps Number of Places Service Interval * hours 23

24 Maintenance Check Spark Plug Service Interval: Every 160 hours Remove spark plug, check condition and reset the gap, or replace with a new plug. See Engine Owner's Manual. Check Fuel Tank Filter Service Interval: Before each use or daily See Engine Owner's Manual. Thread Locking Adhesives Thread locking adhesives such as Loctite 242 or Fel-Pro, Pro-Lock Nut Type are used on the following fasteners: Sheave retaining bolt in end of engine crankshaft. All set screws. Lubricate Hex Shaft Service Interval: Yearly Important: Do Not get oil on the rubber wheel or the aluminum friction drive plate because the traction drive will slip (Figure 13). 1. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). 2. Remove the belt cover and engine shield. 3. Move the speed selector lever to Position R2. 4. Dip a long, clean, small tipped paint brush in automotive engine oil and lightly lubricate hex shaft. Rock the machine forward and rearward to rotate the hex shaft. 5. Move the speed selector lever to Position Lubricate the other end of the hex shaft. 7. Move the speed selector lever forward and rearward a few times. 8. Install the belt cover and engine shield. Check Broom Cable Service Interval: After the first 2 hours Yearly thereafter 1. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). 2. Remove the belt cover and engine shield. 3. With the broom lever disengaged, ensure the gap between the broom clutch assembly and the tab is 1/8 inch (3.2 mm). If the broom is not properly adjusted, see Broom Drive Adjustment. Figure Broom clutch assembly 3. 1/8 inch (3.2 mm) 2. Tab 1. Aluminum friction drive plate Figure Hex shaft Check Broom Shaft Shear Pin Service Interval: Before each use or daily 1. Move the machine to a level surface. 2. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). 3. Check the shear pin located on the broom shaft on either side of the gear box. 24

25 Maintenance Figure Nut 2. Shear pin 4. If the shear pin is damaged, remove the pin and replace only with pin recommended by Exmark. Secure the pin with a nut. Check Broom Segments Service Interval: As required 1. Move the machine to a level surface. 2. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s). 3. Raise the broom by resetting the caster positions. 4. On both sides of the unit, remove and retain the outer bearing housing hardware. 5. Manually pull the power unit rearward to remove the broom assembly from the unit. 6. Support the splined shaft on either side of the gearbox. 7. Stand the broom core assembly on end so removable end retainer plate is facing upward. Figure Hardware 4. Support shaft 2. End retainer plate 5. Alignment fingers 3. Broom segment 8. Remove and retain the hardware from the end retainer plate. 9. Remove the damage broom segment(s). Install the new segment(s) by staggering the metal ring alignment fingers as shown in Figure 16. Important: Damage may occur to the broom assembly if the broom segments are not properly installed. 10. Reinstall the broom assembly to the unit. Important: Make sure the bearing setscrews are tightened before operating the broom. 25

26 Maintenance Adjustments Traction Cable Adjustment If the machine does not drive in the forward or reverse speeds or it drives when you release the traction lever, adjust the traction cable. With the traction lever disengaged, check the pin in the elongated slot in the left side of the machine above the tire. There should be a gap of 1/4 inch (6 mm) from the front of the slot to the front edge of the pin reference Figure 12. If the left hand (traction) cable is not properly adjusted, do the following steps: 1. Loosen the jam nut. 2. Loosen or tighten the turnbuckle to adjust the pin until it is the proper gap from the front edge of the slot. 3. Tighten the jam nut (Figure 17). Figure Jam nut 2. Turnbuckle Figure Jam nut 2. Turnbuckle 2. Loosen or tighten the turnbuckle that adjusts the tension on the cable (Figure 18). 3. Adjust the turnbuckle until the gap between the broom clutch assembly and the tab is 1/8 inch (3.2 mm) (see Figure 14). 4. Tighten the jam nut. 5. If the broom cable is properly adjusted but a problem remains, contact an Authorized Service Dealer. Wheel Clutch Cable Adjustment 1. Squeeze the lever fully, then check the gap between the bottom of the handle and the wheel clutch lever end. Broom Drive Adjustment If the broom cable is not properly adjusted (see Check Broom Cable section), do the following steps: 1. Loosen the jam nut (Figure 18). Figure 19 Note: The gap should be approximately the thickness of a pencil (1/4 inch or 6 mm). If it is greater, loosen the cable clamp nut, slide the cable jacket up slightly, tighten the cable clamp nut, and check the gap again. 2. Repeat step 1 for other cable. 26

27 Troubleshooting Troubleshooting Important: It is essential that all operator safety mechanisms be connected and in proper operating condition prior to 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 of adjustments 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 Engine will not start, starts hard, or fails to keep running Engine loses power. Broom does not clean surface. Broom does not rotate. 1. Fuel tank is empty. 1. Fill the fuel tank. 2. Fuel shutoff valve is closed. 2. Open the fuel shutoff valve. 3. The throttle and choke are not in the correct position. 3. Be sure the throttle control is midway between the SLOW and FAST positions, and the choke is in the ON position for a cold engine or the OFF position for a warm engine. 4. Dirt in fuel valve. 4. Clean fuel valve screen and cup. 5. Blocked fuel cap vent. 5. Clean fuel cap vent. 6. Dirt, water, or stale fuel is in the fuel 6. Contact an Authorized Service Dealer. system. 7. Air cleaner is dirty. 7. Clean or replace the air cleaner element. 8. Faulty spark plug. 8. Clean, adjust or replace spark plug. 9. Spark plug wire is not connected. 9. Check the spark plug wire connection. 1. Engine load is excessive. 1. Reduce the ground speed or aeration depth. 2. Air cleaner is dirty. 2. Clean or replace the air cleaner element. 3. Oil level in crankcase is incorrect. 3. Check oil level in crankcase. 4. Dirt in fuel tank filter. 4. Clean the fuel tank filter. 5. Dirt, water, or stale fuel is in the fuel 5. Contact an Authorized Service Dealer. system. 1. Incorrect broom height. 1. Adjust broom height. 2. Tire pressure in drive tires not correct. 2. Adjust tire pressure in the drive tires. 3. Cleaning too much debris at one time. 3. Slow down and clear smaller areas of debris. 1. Broom is clogged. 1. Unclog broom. 2. Broom drive lever is not engaged. 2. Engage broom drive lever. 3. Broom drive belt slipping. 3. Adjust or replace belt. 4. Broken belt. 4. Replace belt. 5. Broken shear pin. 5. Replace shear pin. Machine pulls left or right. 1. Tire pressure in drive tires not correct. 1. Adjust tire pressure in the drive tires. Machine does not drive. 1. Drive belt is worn, loose or broken. 1. Install new belt. 2. Drive belt is off a pulley. 2. Replace or adjust belt. 27

28 Troubleshooting Problem Possible Cause Corrective Action Abnormal vibration. Broom does not stop when drive lever is released. 1. Loose or damaged broom assembly 1. Tighten hardware. Replace broom assembly or contact an Authorized Service Dealer. 2. Engine mounting bolts are loose. 2. Tighten the engine mounting bolts. 3. Loose engine pulley or idler pulley. 3. Tighten the appropriate pulley. 4. Engine pulley is damaged. 4. Contact an Authorized Service Dealer. 5. Belt is damaged. 5. Install new belt. 6. Chains are not properly tensioned. 6. See Drive Chain Tension Adjustment in Adjustments section. 1. Broom drive belt out of adjustment. 1. Check broom drive adjustment. Broom wears out prematurely. 1. Incorrect broom height. 1. Adjust broom height. Speed selector difficult to move or frozen in place. 1. Hex shaft needs lubrication. 1. Lubricate hex shaft. 28

29 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. This warranty applies to Exmark commercial equipment 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 Warranty Period Bags, Belts and Tires 90 days Battery 1 Year Prorated Engine * * The Engine warranty is covered by the engine manufacturer. Please refer to the engine manufacturer s warranty statement that is included in the literature packet. 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 including standard service items such as blades, brushes, cutting teeth, tines, bushings, bearings, chains, or sprockets. 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 as set forth in the maintenance section of the operator s manual. Any repairs necessary due to use of parts, accessories or supplies, including gasoline, oil or lubricants, incompatible with the 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. 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 U.S. or Canada customers may also call Exmark Commercial Equipment 1 Year Limited Warranty 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 or service@exmark.com Owner s Responsibilities If your product requires warranty service it must be returned to an authorized Exmark service dealer within the warranty period. This warranty extends only to 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 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. 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 mower. 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. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. G _E 29

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