Ventrac Operators Manual

Operator’s Manual 4520Z

Serial Number 4520Z-AR01001 --

VENTRAC.COM

Revised 03/06/23 09.10181 Rev. 03

Original Operator’s Manual

View all manuals

Visit ventrac.com/manuals for the latest version of this operator’s manual. A downloadable parts manual is also available.

500 Venture Drive Orrville, OH 44667 www.ventrac.com

To the Owner Contact Information and Product Identification

If you need to contact an authorized Ventrac dealer for information on servicing your product, al- ways provide the product model and serial numbers. Please fill in the following information for future reference. See the picture(s) below to find the loca - tion of the identification numbers. Record them in the spaces provided.

Date of Purchase: Dealer: Dealer Address:

Dealer Phone Number: Dealer Fax Number:

Model # (A):________________________________________ Serial # (B):_ ________________________________________ Engine Serial # (C) _________________________________

A B

Venture Products Inc. reserves the right to make chang- es in design or specifications without obligation to make like changes on previously manufactured products.

TABLE OF CONTENTS

INTRODUCTION PAGE 7 ProductDescription... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .7 WhyDoINeedanOperator’sManual?. . . . . . . . . . . . . . . . . . . . . . . . . . 7 Using Your Manual. 8 ManualGlossary... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 8 SAFETY PAGE 9 GeneralSafetyProcedures... .. .. .. .. .. .. .. .. .. .. .. .. .. .. 9 TrainingRequired... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 9 Requirements for Personal Protective Equipment (PPE) . 9 OperationSafety... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 9 Keep Riders Off . 11 Operating On Slopes. 11 Roadway Safety. 12 Truck Or Trailer Transport. 12 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Fuel Safety. 13 HydraulicSafety... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..14 Roll Over Protective Structure (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Operator Access System. 15 OperatorSafetyInterlockSystem. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SafetyDecals... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .18 OPERATIONAL CONTROLS PAGE 22 Standard Control Locations. 22 OptionalAccessoryControlLocations....................................... 23 Information Cluster Gauge (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Warning Alarm (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Ignition Switch (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Throttle Lever (D) . 25 High/Low Shift Lever (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Steering Wheel (F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Parking Brake (G) . 26 Front Hitch Latch Lever (H) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Neutral Assist Lever (J) . 26 Auxiliary Hydraulic Quick Couplers (K) . 26 PTO Belt Tensioner Rod (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 SDLA Control Lever (M & N) . 27 Power Take Off (PTO) Switch (O) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Headlight Switch (P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 USB Receptacle (Q) . 27 Seat Slide Lever (R) . 27 Fuel Shut-off Valve (S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Circuit Breaker & Battery Disconnect (T) . 28 Seat Prop Plate (U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Seat Strap Latch (V) . 28 Weight Transfer Traction Control Select Lever (W) . . . . . . . . . . . . . . . . . . . . . . 28 Choke Lever (X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Work Light Switch (AA) . 29 Strobe Light Switch (BB) . 29

TABLE OF CONTENTS

OPERATIONAL CONTROLS (Continued)

Directional Signal Switch (CC) . 29 Hazard Flasher Switch (DD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Horn Switch (EE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 12 Volt Front Switches and 4-Pin Socket (FF, GG, and HH) . 29 Dual Front Hydraulic Auxiliary Switch (II) . . . . . . . . . . . . . . . . . . . . . . . . . 29 Dual Front Hydraulic Auxiliary Valve (JJ) . . . . . . . . . . . . . . . . . . . . . . . . . . 29 12 Volt Rear Switches and 4-Pin Socket (KK, LL, and MM) . . . . . . . . . . . . . . . . . . . 30 Slope Indicator Gauge (NN) . 30 Foot Pedal (OO) . 30 3 Point Hitch & Rear Auxiliary Control Handles (PP, QQ, and RR) . 31 Rear Auxiliary Control Handles (QQ and RR) . . . . . . . . . . . . . . . . . . . . . . . . 31 Rear Auxiliary Quick Couplers (SS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Back Up Alarm (TT) . 31 Seat Slide Lever (UU) . 32 Lumbar Support Knob (VV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Backrest Angle Lever (WW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Weight Adjustment Lever (XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Heat Switch (YY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Optional Armrest Angle Knob (ZZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Front Hitch Valve (BA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 GENERAL OPERATION PAGE 33 DailyInspection... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..33 Starting the Engine. 33 ForwardandReverse... .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..34 StoppingthePowerUnit... .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34 Shutting Off the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Attaching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Detaching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 OperatingAttachments... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .35 FrontHitch... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..35 PTODriveBeltandPulley... .. .. .. .. .. .. .. .. .. .. .. .. .. .. 35 Front Auxiliary Couplers. 36 Weight Transfer. 36 High/LowRange... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..36 TurningRadius... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 37 Roll-OverProtectionSystem... .. .. .. .. .. .. .. .. .. .. .. .. .. .37 3 Point Hitch (Optional Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 12 Volt 4-Pin Auxiliary Sockets (Optional Accessory) . 38 Directional/Hazard Flasher Operation (Optional Accessory) . . . . . . . . . . . . . . . . . . 38 Operating On Slopes. 39 SlopeGaugeSettingsandOperation. . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Audible and Visual Alerts (70.4140 Gauge) . . . . . . . . . . . . . . . . . . . . . . . . .42 70.4140 Slope Gauge Calibration. 42 OperationinWater,Mud,Snow,orIce. . . . . . . . . . . . . . . . . . . . . . . . . . 42 Towing or Pushing the Power Unit. 42

TABLE OF CONTENTS

SERVICE PAGE 43 ServiceandGeneralMaintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Cleaning and Appearance Care. 43 ServiceAccessPoints... .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..44 LubricationLocations... .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..44 CheckingtheHydraulicOilLevel. . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 CheckingtheRearTransaxleOil. . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 ChangingtheHydraulicOilFilters. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 ChangingtheHydraulicOil... .. .. .. .. .. .. .. .. .. .. .. .. .. ..47 Changing the Rear Transaxle Differential Oil . . . . . . . . . . . . . . . . . . . . . . . . 48 Servicing the Closed Loop Hydrostatic Drive Circuit. . . . . . . . . . . . . . . . . . . . . 48 ServicingtheHydraulicCooler... .. .. .. .. .. .. .. .. .. .. .. .. .. 48 Checking the Engine RPM. 48 CheckingtheEngineOilLevel... .. .. .. .. .. .. .. .. .. .. .. .. .. 49 Changing the Engine Oil and Filter. 49 Changing the Air Filter Elements. 50 FillingtheFuelTank... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 51 Changing the In-line Fuel Filter. 51 Priming the Fuel System. 51 Checking the Fan/Alternator Belt. 51 Adjusting the Fan/Alternator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . 52 Cleaning the Engine Compartment and Engine. . . . . . . . . . . . . . . . . . . . . . . 52 Servicing the Cooling System. 52 Checking the Cooling System. 53 CleaningtheRadiatorandScreen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 DrainingtheCoolingSystem... .. .. .. .. .. .. .. .. .. .. .. .. .. .53 FlushingtheCoolingSystem... .. .. .. .. .. .. .. .. .. .. .. .. .. .54 Servicing the Battery. 54 RemovingtheBattery... .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..55 InstallingtheBattery... .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..55 CleaningtheBatteryandTerminals. . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Charging the Battery. 55 Jump Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 TCS (Tractor Control System) Explanation . 57 Replacing Fuses (Power Relay Module) . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Replacing Fuses (Front Fuse Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Replacing Fuses (Rear Fuse Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 ReplacingtheEngineFuseorFuseLink...................................... 58 Switching the Speedometer (mph or km/h) . 59 ReplacingtheHeadLights... .. .. .. .. .. .. .. .. .. .. .. .. .. ..59 Replacing the Tail Lights. 59 ReplacingtheWorkLights... .. .. .. .. .. .. .. .. .. .. .. .. .. ..59 ReplacingtheTurnSignalLights. . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Replacing the Strobe Light(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Changing the ROPS Strobe Light Flasher Mode . . . . . . . . . . . . . . . . . . . . . . . 59 PTOBeltInspection... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 60 PTO Belt Tension Adjustment. 60 PTO Belt Replacement. 60 Clutch Air Gap Inspection and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 61 WheelRemovalandInstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

TABLE OF CONTENTS

SERVICE (Continued)

Outer Dual Wheel Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 62 TirePressure... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .63 ROPSandSeatBeltInspection... .. .. .. .. .. .. .. .. .. .. .. .. .. 63 Parking Brake Inspection and Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 64 NeutralAdjustment... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 64 NeutralSwitchAdjustment... .. .. .. .. .. .. .. .. .. .. .. .. .. ..65 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 MaintenanceSchedule... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .67 Maintenance Checklist. 68 Maintenance Log. 69 TROUBLESHOOTING PAGE 71 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Electrical . 72 Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 PowerUnit... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..74 SPECIFICATIONS PAGE 75 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Electrical . 75 PowerTrain... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..75 Controls and Instrument Panel. 75 OtherFeatures... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 75 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Fluid Capacities and Specifications . 76

INTRODUCTION

Venture Products Inc. is pleased to provide you with your new Ventrac power unit! We hope that Ventrac equipment will provide you with a ONE Tractor Solution. Please visit our website, or contact your authorized Ventrac deal- er for a complete list of items available for your new power unit.

Product Description The Ventrac 4520 tractor combines all wheel drive and an articulating chassis with a low center of gravity to provide superior traction, braking, stability, and security on tough terrain and slopes without disturbing turf when turning. The attachment is placed out in front in a natural view, offering greater precision, as well as maximum protection for the operator. Ventrac’s SDLA control, located next to the operator, allows for easy control of Speed, Direction, Lift, and Auxil- iary functions with one hand. Standard features include: • a fold down roll bar. • a wiring harness that is pre-wired for optional accessories. • an electronic information gauge that includes a tachometer, speedometer, fuel gauge, hour meter, and temperature gauge. The information gauge also includes warning lights and alarms for the engine cool- ant temperature, hydraulic oil temperature, low voltage, and low engine oil pressure, along with a parking brake indicator. • a complete electrical system circuit breaker and battery disconnect. • an automotive pull style parking brake. • a hydraulic oil cooler with a thermostatically controlled fan. Why Do I Need an Operator’s Manual? This manual has been created to help you gain the important knowledge of what is needed to safely operate and maintain your machine, and to avoid injury and product damage. It is divided into chapters for convenient refer- ence of the appropriate information. 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. If this manual becomes damaged or unreadable, it should be replaced immediately. Contact your local Ventrac dealer for a replacement. When using a Ventrac attachment, be sure to read and follow the safety and operating instructions of both the power unit and the attachment being used to ensure the safest operation possible. The information in this manual provides the operator with the safest procedures to operate the machine while getting the maximum use out of the unit. Failure to follow the safety precautions listed in this manual may result in personal injury and/or damage to the equipment.

Introduction - 7

INTRODUCTION

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury and/or property damage. It may also be used to alert against unsafe practices. This manual also uses two words to highlight informa- tion. ATTENTION calls attention to special mechanical information to prevent equipment damage and/or best practices for equipment service and care. NOTE emphasizes general information that is worthy of special attention. Note: Right-Hand and Left-Hand orientations may be referred to at different places throughout this manual. Right-Hand and Left-Hand is determined as if facing forward from the operator station.

Using Your Manual This manual identifies potential hazards and safety concerns to help you, as well as others, avoid person- al injury and/or damage to the equipment. Safety should always be the first priority when work - ing on or operating equipment. Accidents are more likely to occur when proper operating procedures are not followed or inexperienced operators are involved. SYMBOL DEFINITIONS This symbol identifies potential health and safety hazards. It marks safety precau- tions. Your safety and the safety of others is involved. There are three signal words that describe the level of safety concern: Danger, Warning, and Caution. SIGNAL WORD DEFINITIONS DANGER 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. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Manual Glossary Power Unit

A Ventrac tractor or other Ventrac engine powered device that may be operated by itself or with an attachment or accessory.

Attachment A piece of Ventrac equipment that requires a Power Unit for operation. Accessory A device that attaches to a Power Unit or Attachment to extend its capabilities. Machine

Describes any “Attachment” or “Accessory” that is used in conjunction with a power unit.

Introduction - 8

SAFETY General Safety Procedures for Ventrac Power Units, Attachments, & Accessories

Training Required • The owner of this machine is solely responsible for properly training the operators. • The owner/operator is solely responsible for the operation of this machine and for the prevention of ac- cidents or injuries occurring to him/herself, other people, or property. • Do not allow operation or service by children or untrained personnel. Local regulations may restrict the age of the operator. • Before operating this machine, read the operator’s manual and understand its contents. • If the operator of the machine cannot understand this manual, then it is the responsibility of this machine’s owner to fully explain the material within this manual to the operator. • Learn and understand the use of all the controls. • Know how to stop the power unit and the attachments quickly in the event of an emergency. Requirements for Personal Protective Equipment (PPE) • The owner is responsible for ensuring that all the operators use the proper PPE while operating the ma- chine. Whenever you use the machine, use the following PPE: • Certified eye protection and hearing protection. • Closed toe, slip resistant footwear. • Long pants or trousers. • A dust mask for dusty conditions. • Additional PPE may be required. Refer to the product safety procedures for any additional requirements. Operation Safety • Secure long hair and loose clothing. Do not wear jewelry. • Inspect the machine before operation. Repair or replace any damaged, worn, or missing parts. Be sure the guards and shields are in proper working condition and are secured in place. Make any necessary adjust- ments before operating the machine. • Some pictures in this manual may show shields or covers opened or removed in order to clearly illustrate the instructions. Under no circumstance should the machine be operated without these devices in place. • Alterations or modifications to this machine can reduce safety and could cause damage to the machine. Do not alter the safety devices or operate with the shields or covers removed. • Before each use, verify that all the controls function properly and inspect all the safety devices. Do not op- erate if the controls or safety devices are not in proper working condition. • Check the parking brake function before operating. Repair or adjust the parking brake if necessary. • Observe and follow all of the safety decals. • All the controls are to be operated from the operator’s station only. • Always wear a seat belt if the machine has a roll cage/bar installed and in the upright position.

Safety - 9

SAFETY

General Safety Procedures for Ventrac Power Units, Attachments, & Accessories

• Ensure the attachment or accessory is locked or fastened securely to the power unit before operating. • Ensure that all bystanders are clear of the power unit and the attachment before operating. Stop the ma- chine if someone enters your work area. • Always be alert to what is happening around you, but do not lose focus on the task you are performing. Always look in the direction the machine is moving. • Look behind and down before backing up to be sure of a clear path. • If you hit an object, stop and inspect the machine. Make any necessary repairs before operating the ma- chine again. • Stop operation immediately at any sign of equipment failure. An unusual noise can be a warning of equipment failure or a sign that maintenance is required. Make any necessary repairs before operating the machine again. • If equipped with a high/low range feature, never shift between high and low range while on a slope. Always move the machine to level ground and engage the parking brake before shifting range. • Do not leave the machine unattended while it is running. • Always park the machine on level ground. • Always shut off the engine when connecting the attachment drive belt to the power unit. • Never leave the operator’s station without lowering the attachment to the ground, engaging the parking brake, shutting off the engine, and removing the ignition key. Make sure all moving parts have come to a complete stop before dismounting. • Never leave the machine unattended without lowering the attachment to the ground, engaging the park- ing brake, shutting off the engine, and removing the ignition key. • Only operate in well-lit conditions. • Do not operate when there is a risk of lightning. • Never direct the discharge of any attachment in the direction of people, buildings, animals, vehicles, or other objects of value. • Never discharge material against a wall or obstruction. The material may ricochet back toward the operator. • Use extra caution when approaching blind corners, shrubs, trees, or other objects that may obscure your vi- sion. • Do not 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 en - gine. These areas may be hot enough to cause a burn. • Do not change the engine governor settings or over-speed the engine. Operating the engine at excessive speeds may increase the hazard of personal injury. • To reduce the hazard of fire, keep the battery compartment, engine, and muffler areas free of grass, leaves, excessive grease, and other flammable materials. • Clear the working area of objects that might be hit or thrown from the machine.

Safety - 10

SAFETY

General Safety Procedures for Ventrac Power Units, Attachments, & Accessories

• Keep people and pets out of the working area. • Know the work area well before operation. Do not operate where traction or stability is questionable. • Reduce speed when you are operating over rough ground. • Equipment can cause serious injury and/or death when improperly used. Before operating, know and un- derstand the operation and safety of the power unit and the attachment being used. • Do not operate the machine if you are not in good physical and mental health, if you will be distracted by personal devices, or if you are under the influence of any substance which might impair your decisions, dexterity, or judgment. • Children are attracted to machine activity. Be aware of children and do not allow them in the work area. Turn off the machine if a child enters the work area. Keep Riders Off • Only allow the operator on the power unit. Keep riders off. • Never allow riders on any attachment or accessory. Operating On Slopes • Slopes can cause loss-of-control and tip-over accidents, which can result in severe injury or death. Be familiar with the emergency parking brake, along with the power unit controls and their functions. • If the power unit is equipped with a fold down roll bar, it must be locked in the upright position when operating on any slope. • Use low range (if equipped) when operating on slopes greater than 15 degrees. • Do not stop or start suddenly when operating on slopes. • Never shift between high and low range while on a slope. Always move the power unit to level ground and engage the parking brake before shifting range or placing the power unit in neutral. • Variables such as wet surfaces and loose ground will reduce the degree of safety. Do not drive where the machine could lose traction or tip over. • Keep alert for hidden hazards in the terrain. • Stay away from drop-offs, ditches, and embankments. • Sharp turns should be avoided when operating on slopes. • Pulling loads on hills decreases safety. It is the responsibility of the owner/operator to determine loads that can safely be controlled on slopes. • Transport the machine with the attachment lowered or close to the ground to improve stability. • While operating on slopes, drive in an up and down direction whenever possible. If turning is necessary while driving across slopes, reduce your speed and turn slowly in the downhill direction. • Ensure a sufficient supply of fuel for continuous operation. A minimum of one-half tank of fuel is recommended.

Safety - 11

SAFETY

General Safety Procedures for Ventrac Power Units, Attachments, & Accessories

Roadway Safety • Operate with safety lights when operating on or near roadways. • Obey all state and local laws concerning operation on roadways. • Slow down and be careful of traffic when operating near or crossing roadways. Stop before crossing roads or sidewalks. Use care when approaching areas or objects that may obscure vision. • If there is any doubt of safety conditions, discontinue the machine operation until a time when the opera- tion can be performed safely. • When operating near or on roadways, have a Slow Moving Vehicle Emblem clearly displayed. Truck Or Trailer Transport • The parking brake is not sufficient to lock the machine during transport. Always secure the power unit and/ or attachment to the transporting vehicle securely using straps, chains, cables, or ropes. Both the front and rear straps should be directed down and outward from the machine. • Shut off the fuel supply to the power unit during transport on a truck or trailer. • If equipped, turn the battery disconnect switch to the Off position to shut off electrical power. Maintenance • Keep the safety decals legible. Remove all grease, dirt, and debris from the 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 the current safety decals are affixed to the replacement components. • If any component requires replacement, use only original Ventrac replacement parts. • Use care when loading or unloading the machine into a truck or trailer. • Use full width ramps for loading the machine into a truck or trailer. • Always turn the battery disconnect to the Off position or disconnect the battery before performing any re - pairs. Disconnect the negative terminal first and the positive terminal last. Reconnect the positive terminal first and the negative terminal last. • Keep all bolts, nuts, screws, and other fasteners properly tightened. • Always lower the attachment to the ground, engage the parking brake, shut off the engine, and remove the ignition key. Make sure all moving parts have come to a complete stop before cleaning, inspecting, adjust- ing, or repairing. • If the power unit, attachment, or accessory requires repairs or adjustments not instructed in the operator’s manual, the power unit, attachment, or accessory must be taken to an authorized Ventrac dealer for service. • Never perform maintenance on the power unit and/or attachment if someone is in the operator’s station. • Always use protective glasses when handling the battery.

Safety - 12

SAFETY

General Safety Procedures for Ventrac Power Units, Attachments, & Accessories • Check the fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed. • To reduce the hazard of fire, keep the battery compartment, engine, and muffler areas free of grass, leaves, and excess grease. • Do not touch the engine, the muffler, or other exhaust components while the engine is running or immedi - ately after stopping the engine. These areas may be hot enough to cause a burn. • Allow the engine to cool before storing and do not store near an open flame. • Do not change the engine governor settings or over-speed the engine. Operating engine at excessive speeds 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 en- ergy. When the obstruction or blockage is removed, the drive system or moving/rotating parts may move suddenly. Do not attempt to remove an obstruction or blockage with your hands. Keep your hands, feet, and clothing away from all power-driven parts. Fuel Safety • To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive. • Do not refuel the machine while smoking or at a location near flames or sparks. • Always refuel the machine outdoors. • Do not store the machine or fuel container indoors where the fumes or fuel can reach an open flame, spark, or pilot light. • Only store fuel in an approved container. Keep out of the reach of children. • Never fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place the containers on the ground away from your vehicle before filling. • Remove the machine from the truck or trailer and refuel it on the ground. If this is not possible, refuel the machine using a portable container, rather than from a fuel dispenser nozzle. • Never remove the fuel cap or add fuel with the engine running. Allow the engine to cool before refueling. • Never remove the fuel cap while on a slope. Only remove the fuel cap when parked on a level surface. • Replace the fuel tank cap and the container cap securely. • Do not overfill the fuel tank. Only fill to the bottom of the fuel neck, do not fill the fuel neck full. Overfilling of the fuel tank could result in engine flooding, fuel leakage from the tank, and/or damage to the emissions control system. • If fuel is spilled, do not attempt to start the engine. Move the power unit away from the fuel spill and avoid creating any source of ignition until the fuel vapors have dissipated.

Safety - 13

SAFETY

General Safety Procedures for Ventrac Power Units, Attachments, & Accessories

• If the fuel tank must be drained, it should be drained outdoors into an approved container. • Check the fuel lines for tightness and wear on a regular basis. Tighten or repair them as needed. • The fuel system is equipped with a shut-off valve. Shut off the fuel when transporting the machine to and from the job, when parking the machine indoors, or when servicing the fuel system. Hydraulic Safety • Make sure the hydraulic connections are tight and all hydraulic hoses and tubes are in good condition. Re- pair any leaks and replace any damaged or deteriorated hoses or tubes before starting the machine. • Hydraulic leaks can occur under high pressure. Hydraulic leaks require special care and attention. • Use a piece of cardboard and a magnifying glass to locate suspected hydraulic leaks. • Keep your body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid. Hy - draulic fluid escaping under high pressure can penetrate the skin causing serious injury, leading to severe complications and/or secondary infections if left untreated. If hydraulic fluid is injected into the skin, seek immediate medical attention no matter how minor the injury appears. • The hydraulic system may contain stored energy. Before performing maintenance or repairs on the hydrau- lic system, remove any attachments, engage the parking brake, disengage the weight transfer system (if equipped), shut off the engine, and remove the ignition key. To relieve pressure on the auxiliary hydraulic system, shut off the power unit engine and move the hydraulic control lever left and right before disconnect - ing the auxiliary hydraulic quick couplers.

Safety - 14

SAFETY

4520 Safety Procedures

• The weight transfer spring may contain stored energy. Always disengage the weight transfer system (if equipped) before performing maintenance or repairs on the weight transfer system, the front hitch, or the lift hydraulics. Roll Over Protective Structure (ROPS) WARNING

WARNING Alterations or modifications to this machine and/ or the ROPS structure can reduce safety and could cause damage to the machine. Do not alter the ROPS. Do not alter any other safety devices.

Keep the ROPS locked in the upright position and the seat belt securely fastened during operation. Failure to do so could result in serious injury or loss of life.

Your power unit is equipped with a Roll Over Protective Structure (ROPS). This ROPS was tested and certified in accordance with the following standards. ROPS: SAE J1194 and OSHA 1928.51 = maximum GVW of 1,818 kg (4,000 pounds). ISO 21299 = maximum GVW of 1,329 kg (2,930 pounds). Seat Belt Anchorage: ISO 3776-2, ISO 3776-3, ISO 6683, & SAE J386 • The ROPS certification applies only when the roll bar is locked in the upright position. Be aware that there is no rollover protection when a folding ROPS is in the down position. • DO NOT remove the ROPS. Alterations to the ROPS structure are not permitted. • Lower the roll bar only when absolutely necessary and raise the roll bar to the upright position as soon as clearance allows. Never lower a folding ROPS in areas where there are slopes, drop offs, or water. • Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them. • Always wear the seat belt when the roll bar is locked in the upright position. Be certain the seat belt can be released quickly in the event of an emergency. • Do not wear a seat belt when the roll bar has been lowered to the down position. • If any part of this ROPS experiences structural damage, the entire ROPS must be replaced. • Inspect the seat belt for wear or damage before use. Failure to inspect or maintain the seat belt can cause injury or loss of life. Operator Access System • The operator access system is on the left side of the power unit. Mount and dismount the 4520 power unit only from the left side.

Safety - 15

SAFETY

Operator Safety Interlock System The 4520 power unit is equipped with a safety interlock system. This system: • Prevents the engine from starting unless the parking brake is engaged and the SDLA control is in neutral.

• Prevents the PTO from starting if the operator is not in the seat. • Prevents the power unit from driving if the parking brake is engaged.* • Shuts off the PTO if the operator leaves the seat.

• Shuts off the engine (and fuel pump) if the operator leaves the seat without engaging the parking brake. • Shuts off the engine if the forward / reverse controls (SDLA lever or foot pedal) are moved from neutral while the parking brake is engaged. * The parking brake must be completely disengaged before moving the SDLA lever forward or backward or the power unit engine will shut off. Testing the Safety Interlock System WARNING

WARNING The parking brake must be disengaged during por- tions of the safety interlock system test. Place wheel chocks in front and back of the wheels to prevent the power unit from moving. CAUTION The daily inspection should be performed prior to initial startup for the day.

Never operate the power unit if the safety interlock system is malfunctioning. Do not disengage or by- pass any switch. Failure to heed this warning could result in injury to yourself or others, or damage to property.

Perform the following safety interlock tests daily to test the electrical portion of the interlock system. Before testing, park the power unit on a level surface, place wheel chocks in front and back of the wheels, and place the high/low range shift lever in the neutral position. After testing is complete, place the high/low shift lever in either high or low range, engage the parking brake, and remove the wheel chocks. Tests 1-4 test the ‘Engine Start’ function. For each test, turn the ignition key to the RUN position (do not start the engine). As listed for each test, engage or disengage the parking brake*, place the SDLA in neutral or out of neutral^, and sit on the seat or raise your body weight from the seat. The engine starter should or should not engage as described for each test.

Test Number

Parking Brake* Engaged

Forward/Reverse Control (SDLA) in Neutral^

Operator Present in Seat

Engine Starts

1 2 3 4

No Yes Yes Yes

Yes No Yes Yes

Yes Yes No Yes

No No Yes

Engine Start

Yes *This tests the function of the parking brake switch. The parking brake handle should be engaged the minimum amount necessary to activate the parking brake indicator light on the information gauge. ^This tests the function of the neutral switch located on the hydraulic pump. Depending on settings and the age of the power unit, the range for neutral for the SDLA control may vary. For this test, the SDLA lever should move 2.5 cm (1 inch) or less forward or backward for neutral switch activation (measured at the top of the lever).

Safety - 16

SAFETY

Testing the Safety Interlock System (continued) Tests 5-9 test the ‘Engine Run’ function. For each test, start the power unit so that the engine is running. As listed for each test, engage or disengage the parking brake*, place the SDLA in neutral or out of neutral^, and sit on the seat or raise your body weight from the seat. The engine should continue running or stop running as described for each test.

Test Number

Parking Brake* Engaged

Forward/Reverse Control (SDLA) in Neutral^

Operator Present in Seat

Engine Runs

5 6 7 8 9

Yes Yes Yes Yes No

Yes Yes No No Yes

Yes No No Yes No

Yes Yes No No No

Engine Run

Tests 10-13 test the ‘PTO’ function. For each test, turn the ignition key to the RUN position (do not start the engine). As listed for each test, place the PTO switch in the On or OFF position and sit on the seat or raise your body weight from the seat. The electric PTO clutch will make an audible noise when it engages or disengages.

Test Number

PTO Switch

Operator Present in Seat

PTO Clutch

10 11 12 13

Off

Yes No Yes

Off No Yes

Pull to ‘On’ Position Pull to ‘On’ Position

PTO

On PTO Disengages (1/2 second delay) If the power unit fails any one of the safety interlock tests, the issue must be corrected before operating the power unit. *This tests the function of the parking brake switch. The parking brake handle should be engaged the minimum amount necessary to activate the parking brake indicator light on the information gauge. Neutral assist must be off. Raise Operator Body Weight from Seat ^This tests the function of the neutral switch located on the hydraulic pump. Depending on settings and the age of the power unit, the range for neutral for the SDLA control may vary. For this test, the SDLA lever should move 2.5 cm (1 inch) or less forward or backward for neutral switch activation (measured at the top of the lever).

Safety - 17

SAFETY

Safety Decals The following safety decals must be maintained on your power unit. 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 compo - nents.

E D

Directional/Hazard Light Kit

Safety - 18

SAFETY

1. Cutting/entanglement hazard - Stay away from moving parts.

1. Warning - Explosion/fire hazard. 2. Keep away from fire, sparks, and pilot lights when refueling or storing machine and fuel. 3. Smoking is prohibited. 4. Use unleaded gasoline only with an ethanol con- tent of 10 percent or less.

1. Warning - Read operator’s manual. 2. Rollover hazard - Roll bar must be in the raised and locked position when operating on slopes. 3. Always wear a seat belt when operating with the roll bar in the upright position. Do not wear a seat belt when operating with the roll bar in the lowered posi- tion.

1. Read the operator’s manual. 2. Operators must receive training prior to operating the machine. 3. Wear personal protective gear, such as safety glasses, closed toe shoes or boots, and ear protection. 4. Stay away from moving parts. 5. Keep all guards and shields in place. 6. WARNING: Hydraulic fluid is under high pressure and can penetrate skin, causing injury. Keep hands, face, and body away from pinholes or nozzles that eject hydraulic fluid under high pressure. 7. Do not operate while under the influence of drugs or alcohol.

8. Do not carry passengers. Stop the machine if someone enters the area. 9. WARNING: Stay away from the edge of drop-offs, ditches, and embank - ments. The machine could roll over if a wheel drops over the edge or if the edge caves in. 10. WARNING: Read slope operation instructions. Use low range when operat- ing on slopes. Keep the roll bar in the raised and locked position and the seat belt securely fastened. 11. When towing or pushing the power unit, the transaxles must be disen- gaged by moving the high/low range shift handle to the neutral position or damage to the hydraulic system will result.

Safety - 19

SAFETY

1. Pinching or crushing hazard - foot. Stay away from moving parts.

1. Caustic liquid/chemical burns hazard. 2. Explosion hazard - batteries produce flammable and explo - sive gases. 3. Do not expose the battery to arcs, sparks, or open flame. Do not smoke near batteries. 4. Keep bystanders away from the battery. 5. Wear eye protection, such as goggles or a face shield, when checking or servicing batteries. 6. Wear protective gear, such as rubber gloves and an apron, when checking or servicing batteries.

1. Warning - 20 degree maximum slope rating when equipped with single wheels. 2. Warning - 25 degree maximum slope rating when equipped with 7.6 cm (3 inch) wheel extensions. 3. Warning - 30 degree maximum slope rating when equipped with dual wheels. 4. Slope rating may be reduced when adding a cab and other accesso- ries or attachments. Read the operator’s manual for the cab, acces- sory, or attachment being used. 5. Reduce speed on slopes, especially when turning. Avoid sharp turns when operating on slopes. 6. Use low range when operating on slopes. Do not shift between high and low range on a slope. 7. Torque the wheel lug nuts to 75 Nm (55 ft-lbs). 8. Torque the dual wheel hub draw bolts to 163 Nm (120 ft-lbs). 9. Inflate All Terrain tires to the pressure range indicated for single wheels and the inner and outer dual wheels. 10. Inflate Bar tires to the pressure range indicated for single wheels and the inner and outer dual wheels. 11. Inflate Turf tires to the pressure range indicated for single wheels and the inner and outer dual wheels.

1. Place this side of the rim against the axle hub. Do not install the wheel lug nuts on this side of the rim. Refer to the operator's manual.

Safety - 20

SAFETY

1. Severing of fingers or hand - engine fan. Stay away from moving parts.

1. Cutting or pinching hazard. Stay away from mov- ing parts.

Decal

Description

Part Number

Quantity

A B C D

ROPS 4500/4520 Gasoline Safety

00.0644 00.0457 00.0339 00.0694 00.0639 00.0629 00.0645 00.0642 00.0638 00.0364

1 1 1 1 2 1 4 1 1 2

Moving Parts 4520 Safety

E F

Pinching Hazard Foot

Battery Hazard

G H

Hub Side

Slope Warning

Fan Blade Hazard

Pinch Point Hazard (optional kit)

Safety - 21

OPERATIONAL CONTROLS

Standard Control Locations Become familiar with all the controls before you start the engine and operate the machine.

M. Primary SDLA Control Lever N. Secondary SDLA Control Lever O. PTO Switch

P. Headlight Switch Q. USB Receptacle R. Seat Slide Lever S. Fuel Shut-off Valve T. Circuit Breaker and Battery Disconnect

A. Information Cluster Gauge B. Warning Alarm (Continuous)

C. Ignition Switch D. Throttle Lever E. High/Low Shift Lever

U. Seat Prop Plate V. Seat Latch Strap W. Weight Transfer Select Lever X. Choke Handle

F. Steering Wheel G. Parking Brake H. Front Hitch Latch Lever I. Front Hitch Latch Lever Lock J. Neutral Assist Lever K. Auxiliary Hydraulic Quick Couplers L. PTO Belt Tensioner Rod

Operation - 22

OPERATIONAL CONTROLS

Optional Accessory Control Locations Become familiar with all the controls before you start the engine and operate the machine. AA. Work Light Switch BB. Strobe Light Switch CC. Directional Signal Switch DD. Hazard Flasher Switch EE. Horn Switch FF. Front 12V Switch (On/Off) GG. Front 12V Switch (Momentary On/Off/On) HH. Front 12V 4-Pin Socket II. Dual Front Hydraulic Auxiliary Switch JJ. Dual Front Hydraulic Auxiliary Valve KK. Rear 12V Switch (On/Off) LL. Rear 12V Switch (Momentary On/Off/On) MM. Rear 12V 4-Pin Socket

NN. Slope Indicator Gauge OO. Foot Pedal PP. 3 Point Hitch Control Lever

QQ. Left Rear Auxiliary Hydraulics Handle RR. Right Rear Auxiliary Hydraulics Handle SS. Rear Auxiliary Hydraulic Quick Couplers

TT. Back-Up Alarm UU. Seat Slide Lever

VV. Lumbar Support Knob WW. Backrest Angle Lever XX. Weight Adjustment Lever YY. Heat Switch ZZ. Optional Armrest Angle Knob BA. Front Hitch Valve

QQ RR

V V

Operation - 23

OPERATIONAL CONTROLS

Information Cluster Gauge (A)

The low engine oil pressure light activates and an alarm sounds when the engine oil pressure is below safe levels. The light comes on when the ignition key is switched to the On position and stays illuminated until the engine is started and safe oil pressure de- velops. If this light comes on during operation, shut off the engine immediately. Do not restart the engine until the problem has been located and corrected. The high water temperature light activates and an alarm sounds when the temperature of the engine cooling system reaches unsafe levels. If this light comes on during operation, park the power unit, turn off the PTO, move the throttle lever to the low idle po - sition, and allow the engine to cool. Check the radiator screen and clean if needed. If the engine temperature continues to rise, shut off the engine. If the engine continually overheats, refer to the troubleshooting chapter for possible problems. The high hydraulic oil temperature light activates and an alarm sounds when the hydraulic oil tem- perature reaches unsafe levels. If this light comes on during operation, park the power unit and move the throttle lever to the slow idle position. Check the hydraulic cooling fan to ensure it is operating properly and refer to the troubleshooting chapter for possible problems. The low voltage light activates and an alarm sounds when the voltage drops below acceptable levels. If this light comes on, shut off any unnecessary lights and accessories to reduce the current draw. If the voltage continues to drop, park the power unit, shut off the engine, and turn the ignition key to the Off position. Refer to the troubleshooting chapter for pos- sible problems. The low fuel light activates to alert the operator when the fuel level is low. When this light comes on, the fuel tank should be refilled.

8 9 10111213

2 4

3 5

1. Tachometer 2. Speedometer 3. Parking Brake Indicator 4. Hour Meter 5. Volt Meter 6. Water Temperature Gauge 7. Fuel Gauge

8. Glow Plug Indicator 9. Low Engine Oil Pressure 10. High Water Temperature 11. High Hydraulic Oil Temperature 12. Low Voltage 13. Low Fuel

The information cluster gauge contains a tachometer, speedometer, hour meter, volt meter, water tempera- ture gauge, fuel gauge, and a parking brake indicator. It also contains an indicator light for the glow plugs and warning lights for low engine oil pressure, high water temperature, high hydraulic oil temperature, low voltage, and low fuel. The tachometer displays the engine speed in RPM. The speedometer displays the speed of the power unit when the power unit is in motion. The speedom- eter can be set to display speed in either miles per hour (mph) or kilometers per hour (km/h). When the power unit is stopped, this window displays the park- ing brake indicator. The parking brake indicator shows whether the parking brake is engaged or disengaged. This indica- tor is only displayed when the power unit is stopped. When the power unit is in motion, this window dis- plays the power unit’s speed. The hour meter records the accumulated time the ignition key has been switched to the On position. The hour meter is displayed when the power unit engine is not running and the key is switched to the On position. The volt meter displays the voltage level of the charg- ing system. The voltage is displayed when the power unit engine is running. The water temperature gauge displays the tempera- ture of the engine cooling system. The fuel gauge displays the level of fuel in the tank. The glow plug indicator is only used with diesel en- gines. It is not applicable to this engine.

Operation - 24

OPERATIONAL CONTROLS

Warning Alarm (B) The warning alarm works with the information clus- ter gauge to alert the operator to problems. When a condition activates a warning light on the gauge, the warning alarm also activates and sounds a continu- ous signal alarm to alert the operator. If the warning alarm sounds, check the lights on the information gauge to determine the cause of the warning alarm and then take appropriate action.

High/Low Shift Lever (E)

ATTENTION The high/low range shift lever shifts both the front and rear transaxles simultaneously. Occasionally, the engagement of the transaxle gears is prevented by misalignment. Moving the steering wheel slightly to the right or left will move the gears enough to complete the engagement. CAUTION Never shift while under load, while moving, or while on a slope. Always ensure the shift lever is secured in the lock position at the end of each shift stroke. Always install the ball pin to prevent the shift lever from accidentally moving to the neutral position. With the power unit parked on level ground,

Ignition Switch (C) 1. Off or Stop Position - all 12 volt power going through the ignition switch is off. 2. On or Run Position - en- gine run position, 12 volt power is sent to acces- sories. 3. Start Position - when the key is turned to the start position, the starter will engage.

remove the ball pin (A) and push the shift lever forward to select low range (1). Move the shift lever to the middle of the shift stroke to place the transaxle gears in neutral (0). Pull the shift lever back toward the opera- tor to select high range (2).

Throttle Lever (D) Moving the throttle lever forward toward the fast position (1) increases the engine Revolutions Per Minute (RPM). Moving the throttle lever backward toward the slow position (2) decreases the engine RPM.

Ensure the shift lever is secured in the lock position at the end of the shift stroke. Reinstall the

ball pin (A) into the shift select bracket position at the same end as the shift lever, in order to prevent the shift lever from being accidentally disengaged.

Operation - 25

Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34 Page 35 Page 36 Page 37 Page 38 Page 39 Page 40 Page 41 Page 42 Page 43 Page 44 Page 45 Page 46 Page 47 Page 48 Page 49 Page 50 Page 51 Page 52 Page 53 Page 54 Page 55 Page 56 Page 57 Page 58 Page 59 Page 60 Page 61 Page 62 Page 63 Page 64 Page 65 Page 66 Page 67 Page 68 Page 69 Page 70 Page 71 Page 72 Page 73 Page 74 Page 75 Page 76

Made with FlippingBook - Online Brochure Maker