Exmark VH3615KA manual Assembly Instructions, Torque Requirements, Upper Handle Mounting

2.11 TORQUE REQUIREMENTS

BOLT LOCATION	TORQUE
Blade/Cutter Housing Spindle Bolt	75-80 ft-lbs.
Caster Bracket Mounts	30-35 ft-lbs.
Cutter Deck/Engine Deck Mount	30-35 ft-lbs.
Engine Mounting Bolts (Kohler & Kawasaki)	25-30 ft-lbs.

3.ASSEMBLY INSTRUCTIONS

3.1Uncrate unit, leaving it on the pallet, place upper handle assembly, fuel tank, and drive linkages at the rear of the machine. Place casters at the front of unit.

3.2Place a length of 4" x 4" block between the front of the cutter deck and the pallet.

3.3Remove the bolt bag from the top of the fuel tank support.

3.4Loosen the 5/16" hardware at the two (2) discharge deflector hinge points so that the deflector is snug, but can be moved up and down freely.

3.5Refer to Parts Manual to help you identify and locate parts and their proper position.

3.6Install casters to front of deck using appropriate hardware from the bolt bag (eight 3/8 x 3/4" bolts and eight 3/8" whizlock nuts); tightening the lower four bolts first, then the top four.

3.7Apply retaining adhesive “Fel-Pro Prolock Retaining I or Retaining II” or “Loctite RC 609 or 680” on the two threaded studs from the bolt bag and install into the two left holes underneath fuel tank. Install the fuel tank on top of the fuel tank support with the studs going through the slots in the support. Install two 5/16 x 3/4 screws with a 5/16 SAE flatwasher and 5/16 lockwasher into the threaded holes in the right side of the fuel tank. Do not over-tighten. Place a 5/16” SAE flatwasher, then a spring, over each of the studs and fasten with a 5/16 nyloc nut. Tighten the 5/16 nylock nut fully than back off a 1/2 turn. This is to allow for normal fuel expansion and contraction with changes in temperature and fuel levels. Do not over-tighten.

3.8Attach the fuel tank hose to the tank fitting and secure with the clamp provided. Make sure that fuel hose is not between engine and throttle plate on engine.

3.9Position the lower end of the handle assembly on the outsideof the upper rear section of the fuel tank & handle support.

Install four 3/8-16 x 1" bolts (with four spring disk washers against the head of each bolt) from the outside in. Secure using four 3/8" whizlock nuts on the inside of each handle support and tighten until the spring disk washers are flat (See Figure 1).

FIG. 1

UPPER HANDLE MOUNTING

3.10Route the throttle cable along the right side of the upper handle, under the fuel tank support, and position the cable on the left side of the engine.

Attach throttle cable to engine:

a)Position the throttle control lever (on console) in the full throttle (but not choke) position. You will feel a detent when the throttle lever is approximately 3/4”from the upper end of the slot (this is full throttle position).

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