Exmark 116-9360 User manual

FormNo.4501-494RevA
InstallationInstructions
MuleDriveDamperRetrotKit
KitNo.116-9360
ForSerialNo.600,000–312,999,999
WARNING
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Proposition65Warning
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causecancer,birthdefects,orreproductiveharm.
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ThisSafetyAlertSymbol(Figure1)isusedbothinthis
instructionsheetandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoidaccidents
Thissymbolmeans:ATTENTION!BECOMEALERT!
YOURSAFETYISINVOLVED!
Figure1
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Thesafetyalertsymbolappearsaboveinformationwhich
alertsyoutounsafeactionsorsituationsandwillbefollowed
bythewordDANGER,WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.Indicatesan
imminentlyhazardoussituationwhich,ifnotavoided,Will
resultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.Indicates
apotentiallyhazardoussituationwhich,ifnotavoided,Could
resultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.Indicates
apotentiallyhazardoussituationwhich,ifnotavoided,May
resultinminorormoderateinjury.
Thismanualusestwootherwordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.
WARNING
Whilemaintenanceoradjustmentsarebeingmade,
someonecouldstarttheengine.Accidentalstarting
oftheenginecouldseriouslyinjureyouorother
bystanders.
Removethekeyfromtheignitionswitch,engage
parkingbrake,andpullthewire(s)offthespark
plug(s)beforeyoudoanymaintenance.Alsopush
thewire(s)asidesoitdoesnotaccidentallycontact
thesparkplug(s).
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
©2012—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
www.Exmark.comOriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*4501-494*A

LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ItemPartNo.DescriptionQtyItemPartNo.DescriptionQty
1116-9285Asm-TensionerArmW/Bearing19116-9280Damper-MuleBeltDrive1
2109-8754Spacer210109-6658Nut-Nyloc3/8-16Flg5
3109-8866Bushing,Plastic2113231-31Bolt-Carriage3/8-16x21/22
4104-8301Nut-Nyloc3/8-16Flg2123231-5Bolt-Carriage3/8-16x13/41
5323-12Screw-HH3/8-16x21/21133231-7Bolt-Carriage3/8-16x21/41
6116-6316Spring-Extension114116-9359-03Bracket-DamperMntUpper1
7116-0932Dampener,Sleeve115323-6Screw-HH3/8-16x12
8116-9300Spacer216103-5858Decal,Grease1
Figure2
2

InstallationInstructions
1.Makesureallmovingpartshavestopped,parkingbrake
isengaged,andthekeyhasbeenremoved.
2.Removeandretainrearbumperanditsmounting
hardware.
3.Loosenthemuledriveidlerpulleyontherighthand
sideoftheunitsoitcanslideupwardintheslot.
4.Placeawrenchonthe3/8inchnutinthecenterofthe
springloadedidlerpulleyandapplyupwardpressure
torelievethebelttension.
Note:1/2inchbreakerbarwitha9/16inchsocket
worksbest.
5.Carefullyremovethebeltfromtheidlerpulleygroove,
andSLOWLYreleasethespringpressure.
6.Removeanddiscardthespringanditsmounting
hardware.
7.Removethemuledriveidlerassemblyfromtheunit.
Retainthemuledriveidlermountingbolt,nut,bushing,
andtwoshields(referenceFigure3).
Figure3
1.Idlermountingbolt4.Discard
2.Shield5.Idlerpulley
3.Nut6.Bushing
8.Removethepulleyfromtheidlerarm.Inspecttheidler
pulleyandbushing,ifingoodconditionremoveand
retain;otherwiseanewpulleyand/orbushingmustbe
installed.Discardallothermuledrivecomponents.
9.Placetheupperdampenermountbracketontorear
faceoftheenginemountbracketandalignasshown
inFigure4.Marktheholelocationsanddrilltwo
.406inchdiameterholesintherearfaceoftheengine
mountbracket.Attachtheupperdampenermount
bracketusingtwo3/8-16x1inchhexboltsandtwo
3/8inchnylocnuts.
Figure4
1.Enginemountbracket4..57inches(14.5mm)
2.Upperdampenermount
bracket
5.Holes
3.Alignthesesurfaces
10.Relocatethegroundcablesfromthelowerengine
mountplatescrewtotheupperscrew(seeFigure5).
Figure5
1.Upperdampenermount
bracket
3.Upperscrew
2.Groundcables
11.Installtheidlerpulleyandbushingontothenew
tightenerarmusing3/8-16x13/4inchcarriagebolt
and3/8inchangednylocnut.
12.Installthenewtightenerarmassemblyontheframe
re-usingthemuledrivemountingbolt,nut,andtwo
shieldsthatwereretainedinstep7.
13.Slidethedampenersleeveontotheextensionspring.
Using3/8-16x21/4inchboltand3/8inchnylocnut,
3

assemblethebushing,spacer,andextensionspring
ontothetightenerarmassemblyasshowninFigure2.
14.Securetheupperspringhooktotheframeusing
3/8-16x21/2inchbolt,spacer,bushing,and3/8inch
nylocnutasshowninFigure2.
15.Attachthelowerendofthedampenertotheoutside
holeinthetightenerarmassemblyusing3/8-16x2
1/2inchcarriagebolt,spacer,and3/8inchanged
nutasshowninFigure2.
Note:Besuretoinstallthedamperwiththerodend
downforproperoperation.
16.Attachtheupperendofthedampertothebracket,
installedinstep9,using3/8-16x21/2inchcarriage
bolt,spacer,and3/8inchnutasshowninFigure2.
17.Usingthesametechniquefromstep4,extendthe
springandslipthebeltbackintothepulleygroove.
Makesurethebeltispositionedinallthepulley
grooves.Slowlyreleasethespring.Adjustthebelt
tensionpertheMuleDriveBeltTensionAdjustment
section.
MuleDriveBeltTension
Adjustment
Note:Adjustthemulebeltdrivetensioninitiallyandthen
aftertherstvehours.
Self-tensioningidler,adjustasfollows:
1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.
2.Ontheleftsideoftheenginedecksupport,checkthe
locationoftheboltheadinthecenterofthespring
loadedpulley.Thetopoftheboltshouldbeatthe
bottomoftheupperalignmentholeasshownin
Figure6.Itisnecessarytoadjustthebelttensionwhen
thecenteroftheboltheadisatorbelowthecenterof
thebottomalignmenthole.
Figure6
1.Frontofunit2.Locatethetopofthebolt
withthebottomofthe
upperalignmenthole
3.Whenadjustmentisnecessary,loosentheidlerpulley
ontheright-handsidesoitcanmoveupanddownin
theslot.
Placeawrenchonthe3/8inchnutinthecenterof
thespringloadedpulleyandapplyupwardpressureto
relievetensiononthespring(1/2inchdrivebreaker
barand9/16inchsocketworksbest).
Repositiontheadjustingpulleytowardsthebottomof
theslot.
Note:Wheninstallinganewbelt,itisnecessarytoreposition
therightadjustingpulleyupwardintheslotinordertoplace
thespringloadedpulleyinthecorrectlocation(reference
step2).
Figure7
1.Springidlerpulley
2.Frontofunit
3.Rightsideidlerpulley(adjustable)
4