Ventrac 4200 Series Operator'S Manual Download | Manualshive

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Service - 44

MAINTENANCE CHART

M

AINTENANCE

C

HECKLIST

- V

ENTRAC

4200

POWER

UNIT

WITH

K

AWASAKI

ENGINE

This sheet is a checklist for tracking service and maintenance for the 4200 power unit and Kawasaki engine.

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Summary of Contents for 4200 Series

Page 1: ...OPERATOR S MANUAL VENTRAC 4200 Serial 2929 Revised 06 11 14 09 10051 Rev 02 ...

Page 2: ...ealer _________________________________________________________________ Dealer Address __________________________________________________________ __________________________________________________________ Dealer Phone Number ____________________________________________________ Dealer Fax Number ______________________________________________________ Model A ______________________ Serial B _________...

Page 3: ...6108 Electric PTO Remote 70 4078 Wheel Extensions 70 4098 Two N One Front Hitch 70 2001 Cab 70 2006 ES220 Spreader 39 55500 SS300 Salt Spreader 70 2011 SS575 Salt Spreader 70 2010 Attachments Item Description Part Number Attachments Item Description Part Number Aerator with Open Spoon Tine 39 55490 Stump Grinder 39 55300 Aerator with Slitter Slicer Tine 39 55492 Terra Rake 52 39 55431 Aerator with...

Page 4: ...Interlock Systems 17 OPERATIONAL CONTROLS PAGE 18 Operational Control Locations 19 Power Take Off PTO Switch A 19 Ignition Key Switch B 19 Throttle C 19 Glow Plug Indicator Light D 19 Tachometer Hour Meter E 19 Volt Gauge F 19 Engine Coolant Temperature Gauge G 19 Engine Oil Pressure Warning Light H 20 Seat Belt Light I 20 Light Switch J 20 12 Volt Switches K L 20 Engine Coolant High Temp Alarm M ...

Page 5: ... Accessory 26 Operating On Slopes 26 Towing or Pushing the Power Unit 27 SERVICE PAGE 28 Cleaning General Maintenance 28 Service Maintenance 28 Lubrication Locations 29 Checking Hydraulic Oil Level 30 Checking Rear Transaxle Oil 30 Changing Hydraulic Oil and Filter 30 Servicing Closed Loop Hydrostatic Drive Circuit 30 Checking Engine RPM 31 Checking Engine Oil Level 31 Changing Engine Oil and Filt...

Page 6: ...T PAGE 43 Maintenance Schedule Ventrac 4200 power unit with Kawasaki engine 43 Maintenance Checklist Ventrac 4200 power unit with Kawasaki engine 44 Maintenance Schedule Ventrac 4200 power unit with Vanguard 3LC engine 45 Maintenance Checklist Ventrac 4200 power unit with Vanguard 3LC engine 46 TROUBLESHOOTING PAGE 47 Engine 47 Electrical 48 Hydraulic 49 Power unit 49 SPECIFICATIONS PAGE 50 Electr...

Page 7: ...aintain and service your power unit It is divided into sections for convenient reference of the appro priate section You must read and understand the operator s manual for each piece of Ventrac equipment you own Read ing the operator s manual will help you become familiar with each specific piece of equipment Under standing the operator s manual will help you as well as others avoid personal injur...

Page 8: ...ughout this manual Right Hand and Left Hand is determined as if sitting on the power unit seat facing forward SIGNAL WORD DEFINITIONS Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word is limited to the most extreme cases Ind...

Page 9: ...Keep all safety decals legible Remove all grease dirt and debris from safety decals and instructional labels If any decals are faded illegible or missing contact your dealer promptly for replacements When new components are installed be sure that current safety decals are affixed to the replacement components A A B B F F I I E E J J ...

Page 10: ...pper Dash General Safety 00 0175 1 D Lower Dash High Low Shift Safety 00 0176 1 E Warning Moving Parts 00 0216 1 F Warning Read Owners Manual 00 0217 1 G Warning Pinching Points 00 0218 2 H Warning Avoid Injury 00 0219 1 I Warning Safety Alteration 00 0220 1 J Warning Hearing PPE 00 0291 1 C C F F E E B B A A D D I I H H G G J J ...

Page 11: ...rn or missing parts Be sure guards and shields are in proper working condition and are secured in place Make all necessary adjustments before operating machine Some pictures in this manual may show shields or covers opened or removed in order to clearly illustrate any instructions Under no circumstance should the machine be operated without these devices in place Alterations or modifications to th...

Page 12: ...run the engine in a building without adequate ventilation Do not touch the engine or the muffler while the engine is running or immediately after stopping the engine These areas may be hot enough to cause a burn Do not change the engine governor settings or over speed the engine Operating engine at excessive speed may increase the hazard of personal injury To reduce the hazard of fire keep the bat...

Page 13: ... safely be controlled on slopes Transport machine with attachment lowered or close to the ground to improve stability While operating on slopes drive in an up and down direction when possible If turning is necessary while driving across slopes reduce speed and turn slowly in the downhill direction Assure a sufficient supply of fuel for continuous operation A minimum of one half tank of fuel is rec...

Page 14: ... Operating engine at excessive speed may increase the hazard of personal injury Springs may contain stored energy Use caution when disengaging or removing springs and or spring loaded components An obstruction or blockage in a drive system or moving rotating parts may cause a buildup of stored energy When the obstruction or blockage is removed the drive system or moving rotating parts may move sud...

Page 15: ...ydraulic fluid escaping under high pres sure can penetrate the skin causing serious injury If hydraulic fluid is injected into skin seek immediate medical attention Hydraulic system may contain stored energy Before performing maintenance or repairs on the hydraulic system remove attachments engage parking brake disengage weight transfer system if equipped shut off engine and remove ignition key To...

Page 16: ...e harm CALIFORNIA PROPOSITION 65 Battery Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Roll Over Protective Structure Your power unit is equipped with a Roll Over Protective Structure ROPS Certified seat belt anchor OSHA 1928 51 Certified ROPS roll ba...

Page 17: ...Circuit Operator Interlock Sit on the seat With the key in the off position press the top portion of the PTO switch to activate the PTO The PTO clutch should NOT engage With the PTO switch still in the on position turn the key switch to the on position The PTO clutch should NOT engage Press the bottom portion of the PTO switch to turn the switch off Press top portion of the PTO switch to activate ...

Page 18: ... E F F G G H H K K L L I I J J C C GG GG FF FF EE EE DD DD Z Z X X AA AA CC CC BB BB Y Y N N O O P P U U R R Q Q M M V V Under Seat Under Seat W W Lower Rear Frame Tunnel Lower Rear Frame Tunnel T T S S U U OPERATIONAL CONTROLS ...

Page 19: ... POWER TAKE OFF PTO SWITCH A Depressing the top of the PTO switch engages the electric clutch to provide power to the front attach ment Depressing the bottom part of the switch will disengage the clutch and apply the clutch brake to stop the attachment Note The PTO will shut off automatically if the operator leaves the power unit seat To restart first return to the seat then disen gage and re enga...

Page 20: ...aintain Neutral assist is recommended when learning the operation of your Ventrac loading unloading attaching and removing attachments and whenever the operator is working in tight areas or is unsure of the power unit s response to the task being performed Position 3 Easy shift position In this position the S D L A control lever is in an easy shift mode This position is designed for experienced op...

Page 21: ...l for the power unit and consists of two parts The primary lever X controls the Speed Direction of power unit Lift of the hitch arms The secondary lever Y controls the Auxiliary hydraulic circuit S Speed The amount of forward or backward movement of this lever controls the ground speed of the power unit D Direction The forward or backward movement of the lever controls the direction of the power u...

Page 22: ...ard position while service is per formed under the seat To secure tip the seat forward lift up the seat prop and insert the end into the wide portion of the seat plate slot Move the seat prop to the narrow portion of the slot to prevent accidental release To release move the seat prop to the wide portion of the slot Tip the seat forward while guiding the seat prop out of the slot Lower the seat pr...

Page 23: ...glow plug indicator light goes out the engine is ready to start and must be started within a few seconds or glow plug preheating cycle may need repeat ed No preheat is required when the engine is at operating temperature 4 Turn the key to the start position and hold to engage starter Release key when engine starts Note If engine fails to start refer to trouble shooting section 5 The engine and hyd...

Page 24: ... and set weight transfer to the off position 3 Lower the attachment to the ground and place the primary S D L A lever in the float position 4 Shut off engine 5 Disengage the PTO belt tension lever 6 Remove the attachment belt from the PTO drive pulley of the power unit 7 Move the secondary S D L A lever left and right to release pressure from the auxiliary hydraulic circuit and disconnect the hydr...

Page 25: ...eight from the attachment to the front wheels of the power unit The operator can select different transfer rates by adjust ing the right and left weight transfer chains To set the weight transfer raise the front hitch to its maximum height Weight Transfer Weight Transfer Chain Chain Weight Transfer Weight Transfer Chain Lock Chain Lock Lift the weight transfer chain link out of the chain lock slot...

Page 26: ...SORY Certain attachments require a 12 volt auxiliary out let Plug the attachment s 12 volt power cord into the 12 volt 4 pin plug located above the front auxiliary quick couplers Two switches are used to control the actions of the 12 volt kit A momentary on off on is used for controlling movement that is only used for a brief time The on off switch is used to activate equipment or select different...

Page 27: ...red to the power unit from the attachment while operating on slopes See Weight Transfer section Always operate carefully and in a manner that does not compromise safety Always wear seat belt Refer to following illustrations for power unit capabil ity with different equipment options 30 degrees maximum forward reverse 20 degrees max with out dual wheels or wheel extensions 25 degrees max with 3 whe...

Page 28: ...is power unit is critical to keep the power unit in a safe and reliable operat ing condition Follow the Maintenance Schedule at the end of the service section For convenience a Frequent Service Reference Chart has been placed on the power unit under the hood as shown in the picture below Throughout the Service Section different access points are referred to Below is a list of shields and covers th...

Page 29: ...ivot points and bearings use only one pump of grease Grease Spray Lube SERVICE Front Hitch Center Pivot Lift Cylinder Drive Shaft U Joint 3 Point Hitch Pivot Cylinder Seat Rails Steering Cylinder Connector Link Rear Serial 2929 3398 Serial 3399 Steering Cylinder Connector Link Front Serial 2929 3398 Serial 3399 Lithium Complex NLGI 2 type grease ...

Page 30: ... cold 1 Park power unit on a level surface 2 Engage parking brake and shut off engine 3 Remove the oil fill plug from the transaxle and check to see if oil is even with the bottom of the oil fill hole 4 Oil Fill Plug Oil Fill Plug If oil level is low add HydroTorq XL synthetic hydraulic oil until level with bottom of oil fill hole CHANGING HYDRAULIC OIL AND FILTER Hydraulic oil and filters should ...

Page 31: ...d on the left side of the engine Wipe dipstick with a clean cloth 6 Vanguard Vanguard Engine Engine A A Kawasaki Kawasaki Engine Engine A A Install dipstick back into the engine and remove again B B C C 7 Check oil level Level should be between the Full B and Add C on the dipstick 8 NOTE if oil is low add small amounts of oil to bring the oil level no higher than level B on the dip stick 9 If oil ...

Page 32: ...OID ENGINE DAMAGE When removing the air filter element an open ing directly to the internal parts of the engine is created Be sure that nothing falls into the canister that could make its way into the engine Have the new filter element ready to install immediately after the old element has been removed ATTENTION Avoid damage to your engine Improper service to the engine air filter can result in se...

Page 33: ...Owner s Manual for proper service intervals 10 Clean the paper element by tapping gently to remove dust Do not wash paper filter element Do not oil foam filter element Do not use pressurized air to clean paper filter element 11 Install the paper element and wing nut 12 Reinstall the foam element over the paper element 13 Reinstall the air filter cover 14 Close engine hood FILLING THE FUEL TANK 1 D...

Page 34: ...g Drain fuel into an approved nonmetallic con tainer Disconnect negative battery cable before working on the fuel system Changing In line Fuel Filter Gasoline Engines 1 Turn the fuel shut off valve to the OFF position 2 Remove the rear frame tunnel cover Vanguard gas only 3 Locate the fuel filter inside the rear frame tun nel area Vanguard or at the right base of the engine Kawasaki 4 Loosen the h...

Page 35: ...it on a level surface 2 Engage parking brake and shut off engine 3 Remove ignition key from switch 4 Allow engine to cool 5 Open engine hood 6 Check belt for excessive wear cracks or damage 7 Check for proper tension Apply 20 lbs of pres sure to the belt between the alternator and the water pump The belt should deflect 3 8 to 1 2 Adjust if belt is to tight or to loose ADJUSTING ALTERNATOR BELT TEN...

Page 36: ... power unit on a level surface 2 Engage parking brake and shut off engine 3 Remove ignition key from switch 4 Tilt the seat plate forward and prop in place 5 Disconnect the negative battery cable A 6 Disconnect the positive battery cable B A A B B 7 Loosen fastener C and remove battery clamp 8 C C Slide battery out of battery compartment Installing 1 Slide battery into battery compartment 2 Instal...

Page 37: ...le to a metal part of the disabled power unit s engine block away from battery 5 Start the engine of the disabled power unit and run the power unit for several minutes 6 Carefully disconnect the booster cables in the reverse order negative cable first and then the positive cable CHANGING THE HEADLIGHT BULB AVOID PERSONAL INJURY The headlight bulb contains gases under pres sure The bulb may shatter...

Page 38: ...UIT FUSE SIZE A Headlights Taillights Tach Light 15 B Alternator Optional Accessories 5 C Gauges Signal Lights 5 D Rear Auxiliary 15 E Engine Supply 15 F Engine Module Preheat Optional Acc 5 G Fuel Pump 5 H Start and PTO Circuits 15 Not used on all models 1 Park power unit on a level surface 2 Engage parking brake and shut off engine 3 Remove ignition key from switch 4 Open engine hood 5 Identify ...

Page 39: ...gine overheating do not exceed more then 50 antifreeze in cooling system CHECKING COOLING SYSTEM 1 Park power unit on a level surface 2 Engage parking brake and shut off engine 3 Remove ignition key from switch 4 Allow engine to cool 5 Open engine hood to access the radiator and the radiator coolant recovery bottle 6 Locate the coolant recovery bottle just in front of the air cleaner Vanguard or i...

Page 40: ...f the engine Kawasaki 8 B B A A Flush the cooling system FLUSHING THE COOLING SYSTEM 1 Park power unit on a level surface 2 Engage parking brake and shut off engine 3 Remove ignition key from switch 4 Drain system Add one can of radiator flush can be purchased at any auto parts store and fill with clean water 5 Install radiator cap 6 Start engine and run until it reaches operating temperature 160 ...

Page 41: ...Engage parking brake and shut off engine 3 Remove ignition key from switch and allow en gine to cool 4 Open engine hood 5 Rotate the belt tension lever down to release tension on the PTO belt 6 Vanguard only Remove the nut from the clutch rod A and remove rod from power unit frame 7 A A B B Vanguard only Locate the clutch plug B and disconnect plug from power unit wire harness 8 Lift up on the PTO...

Page 42: ...ck stands 3 Do not attempt to adjust the neutral position with the power unit wheels on the ground During the adjustment process the power unit could begin to move Lift the power unit off the ground and secure with jack stands to prevent the power unit from moving This also allows neutral to be easily determined when any tire rotation stops Start the power unit and adjust engine speed to approxima...

Page 43: ...Service 43 MAINTENANCE CHART MAINTENANCE SCHEDULE VENTRAC 4200 POWER UNIT WITH KAWASAKI ENGINE This sheet is a guide for recommended service and maintenance for the 4200 power unit and Kawasaki engine ...

Page 44: ...Service 44 MAINTENANCE CHART MAINTENANCE CHECKLIST VENTRAC 4200 POWER UNIT WITH KAWASAKI ENGINE This sheet is a checklist for tracking service and maintenance for the 4200 power unit and Kawasaki engine ...

Page 45: ...ice 45 MAINTENANCE CHART MAINTENANCE SCHEDULE VENTRAC 4200 POWER UNIT WITH VANGUARD 3LC ENGINE This sheet is a guide for recommended service and maintenance for the 4200 power unit and Vanguard 3LC engines ...

Page 46: ...ce 46 MAINTENANCE CHART MAINTENANCE CHECKLIST VENTRAC 4200 POWER UNIT WITH VANGUARD 3LC ENGINE This sheet is a checklist for tracking service and maintenance for the 4200 power unit and Vanguard 3LC engines ...

Page 47: ...aulty injector pump Engine runs rough Plugged or partially plugged fuel filters Plugged or partially plugged air filters Fuel cap vent is plugged or dirty All diesel engines and Gasoline engines from Serial 2929 4285 Stale fuel dirty fuel insufficient fuel level Faulty fuel pump Dirty or faulty fuel injectors Faulty injector pump Engine is low in power Plugged or partially plugged fuel filters mos...

Page 48: ...ct engine oil Plugged air intake filter Worn rings or cylinder walls ENGINE CONT SYMPTOM POSSIBLE CAUSE Battery does not charge Loose or corroded connections Broken or loose wire in charge system Defective battery Loose alternator belt Defective alternator Defective voltage regulator Lights do not activate Blown fuse Blown light bulb Broken wire connection Faulty light switch Glow plugs do not act...

Page 49: ...raulic oil Faulty hydraulic cylinder Cold temperature Allow power unit to warm up Excessive noise in hydraulic system Low hydraulic oil Cold temperature Allow power unit to warm up SYMPTOM POSSIBLE CAUSE Power unit will not move with engine running Selector lever is in the park position Brake does not release Low hydraulic oil Pump control linkage is loose High low range shift lever is in neutral ...

Page 50: ... Wheel Drive Hydrostatic Transaxle 2 Peerless Fwd Speed High 10 mph 16 1 kph Fwd Speed Low 5 2 mph 8 4 kph Brakes Hydro Dynamic Hydraulic Oil Filtration 10 Micron 25 Micron CONTROLS INSTRUMENT PANEL Steering Power PTO Power Take Off Electric w brake Throttle Control Cable Directional Control Speed Direction Lift Auxiliary S D L A Control Orientation Hand Gauges Tachometer Volt Water Temperature Pa...

Page 51: ...varies based on engine size tire options and optional accessories Ventrac 4200 Fluid Capacities Engine Oil 4227 Gas 2 1 qt 2 0L 4231 Gas 3 5 qt 3 3L 4226 Diesel 3 5 qt 3 3L 4231 Turbo Diesel 3 5 qt 3 3L Hydraulic Oil Hydraulic System Standard Power Unit 11 4 qt 10 6L Equipped w 3pt Hitch 11 8 qt 11 2L Rear Transaxle 4 qt 3 8L Coolant Antifreeze 4227 Gas 2 9 qt 2 7L 4231 Gas 4 qt 3 8L 4226 Diesel 4...

Page 52: ...connection with the manufacture or sale of its products The engine warranty is covered by its respective engine manufacturer Please refer to the engine manufacturer s warranty statement that is included in the owner s manual The Ventrac turf equipment including any defective parts must be returned to an authorized Ventrac dealer within the warranty period The warranty shall extend to the cost to r...

Page 53: ...breach of warranty or viii attorney s fees The remedies of buyer set forth herein are exclusive and are in lieu of all other remedies The liability of V P I whether in contract tort under any warranty or otherwise shall not extend beyond its obligation as set forth herein V P I shall not be liable for cost of removal or installation nor shall V P I be responsible for any direct indirect special or...

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