Exmark Navigator, Navigator 850 User Manual

Download

NA VIGATOR®

ForSerialNos. 850,000&Higher

PartNo.4500-628Rev.B

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct containschemicalsknowntotheStateof Californiatocausecancer,birthdefects,or otherreproductiveharm.

Important:Theengineinthisproductisnot equippedwithasparkarrestermufer.Itisa violationofCaliforniaPublicResourceCode (CPRC)Section4442touseoroperatethis engineonanyforest-covered,brush-covered,or grass-coveredlandasdenedinCPRC4126. Otherstatesorfederalareasmayhavesimilar laws.

ThissparkignitionsystemcomplieswithCanadian ICES-002Cesystèmed’allumageparètincellede vèhiculeestconformeàlanormeNMB-002du Canada

TheenclosedEngineOwner’sManualis suppliedforinformationregardingTheU.S. EnvironmentalProtectionAgency(EPA)and theCaliforniaEmissionControlRegulationof emissionsystems,maintenanceandwarranty.

KeepthisengineOwner’sManualwithyourunit. ShouldthisengineOwner’sManualbecome damagedorillegible,replaceimmediately. Replacementsmaybeorderedthroughthe enginemanufacturer.

Exmarkreservestherighttomakechangesor addimprovementstoitsproductsatanytime withoutincurringanyobligationtomakesuch changestoproductsmanufacturedpreviously. Exmark,oritsdistributorsanddealers,accept noresponsibilityforvariationswhichmaybe evidentintheactualspecicationsofitsproducts andthestatementsanddescriptionscontained inthispublication.

Contactusatwww.Exmark.com.

PrintedintheUSA

AllRightsReserved

Introduction

CONGRATULATIONSonthepurchaseofyour ExmarkMower.Thisproducthasbeencarefully designedandmanufacturedtogiveyouamaximum amountofdependabilityandyearsoftrouble-free operation.

Thismanualcontainsoperating,maintenance, adjustment,andsafetyinstructionsforyourExmark mower.

BEFOREOPERATINGYOURMOWER, CAREFULLYREADTHISMANUALINITS ENTIRETY.

Byfollowingtheoperating,maintenance,andsafety instructions,youwillprolongthelifeofyourmower, maintainitsmaximumefciency ,andpromotesafe operation.

Ifadditionalinformationisneeded,orshouldyou requiretrainedmechanicservice,contactyour authorizedExmarkequipmentdealerordistributor. Exmarkpartsmanualsareavailableonlineat http://www.exmark.com/manuals.htm.

AllExmarkequipmentdealersanddistributorsare keptinformedofthelatestmethodsofservicing andareequippedtoprovidepromptandefcient serviceintheeldorattheirservicestations.They carryamplestockofservicepartsorcansecurethem promptlyforyoufromthefactory.

AllExmarkpartsarethoroughlytestedandinspected beforeleavingthefactory,however,attentionis requiredonyourpartifyouaretoobtainthefullest measureofsatisfactionandperformance.

Wheneveryouneedservice,genuineExmarkparts, oradditionalinformation,contactanAuthorized ServiceDealerorExmarkCustomerServiceandhave themodelandserialnumbersofyourproductready.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

Contents

Introduction...........................................................3

Safety.....................................................................5

SafetyAlertSymbol.........................................5

SafeOperatingPractices..................................5

SafetyandInstructionalDecals.....................11

Specications.......................................................14

ModelNumbers............................................14

Systems.........................................................14

Dimensions...................................................15

TorqueRequirements....................................16

ProductOverview................................................16

Operation.............................................................17

Controls........................................................17

Pre-Start........................................................18

OperatingInstructions..................................18

Transporting.................................................20

Maintenance.........................................................22

RecommendedMaintenanceSchedule(s)...........22

PeriodicMaintenance.......................................23

CheckEngineOilLevel.................................23

CheckBatteryCharge....................................23

CheckSafetyInterlockSystem.......................24

CheckforLooseHardware............................25

ServiceAirCleaner........................................25

ChangeEngineOil........................................25

CheckHydraulicOilLevel.............................26

CheckTirePressures.....................................26

CheckConditionOfBelts..............................26

LubricateGreaseFittings...............................26

LubricateRearCasterWheelHubs.................27

LubricateBrakeHandlePivot........................28

LubricateBrakeRodBushings.......................28

LubricateSteeringLinkageRodEnds.............28

LubricateHopperActuator............................28

CheckSparkPlugs.........................................28

ChangeHydraulicSystemFilter.....................29

CheckWheelHubLocknuts..........................29

CheckWheelLugNuts..................................29

ThreadLockingAdhesives.............................29

DielectricGrease...........................................30

Adjustments.....................................................30

PTODriveBeltTension................................30

PumpDriveBeltTension...............................30

PTOBeltReplacement..................................30

PumpDriveBeltReplacement......................31

BeltGuideAdjustment..................................31

AdjustSafetySwitch......................................32

BrakeAdjustment..........................................32

AdjustSpeedControlLeverTension..............32

SpeedControlLinkageAdjustment................33

SteeringControlLeverResponse

Adjustment...............................................34

TrackingAdjustment.....................................35

PTODrivePulleyAlignment.........................35

PumpDrivePulleyAlignment........................35

RearCasterPivotBearingsPre-Load

Adjustment...............................................36

HopperDoorAdjustment.............................36

PTOBrakeSpringAdjustment......................36

Cleaning...........................................................37

CleanEngineandExhaustSystem

Area..........................................................37

RemoveEngineShroudsandCleanCooling

Fins...........................................................37

CleanDebrisFromMachine..........................37

WasteDisposal..............................................37

Troubleshooting...................................................38

Schematics...........................................................40

Safety

SafetyAlertSymbol

ThisSafetyAlertSymbol(Figure2)isusedbothin thismanualandonthemachinetoidentifyimportant safetymessageswhichmustbefollowedtoavoid accidents

Thissymbolmeans:ATTENTION!BECOME

ALERT!YOURSAFETYISINVOLVED!

Figure2

1.Safetyalertsymbol

Thesafetyalertsymbolappearsaboveinformation whichalertsyoutounsafeactionsorsituations andwillbefollowedbythewordDANGER,

WARNING,orCAUTION.

DANGER:Whitelettering/Redbackground.

Indicatesanimminentlyhazardoussituationwhich,if notavoided,Willresultindeathorseriousinjury.

WARNING:Blacklettering/Orangebackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Couldresultindeathorseriousinjury.

CAUTION:Blacklettering/Yellowbackground. Indicatesapotentiallyhazardoussituationwhich,if notavoided,Mayresultinminorormoderateinjury.

Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizes generalinformationworthyofspecialattention.

•Neverletchildrenoruntrainedpeopleoperate orservicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Onlyadultsandmatureteenagersshouldoperate amower,andevenmatureteenagersshouldhave adultsupervision.Besureateenager:

1.hasreadandunderstandstheOperator’s

Manualandrecognizestherisksinvolved;

2.issufcientlymaturetousecaution;and

3.isofsufcientsizeandweighttooperate

thecontrolscomfortablyandtomanagethe mowerwithouttakingrisks.

•Theowner/usercanpreventandisresponsible foraccidentsorinjuriesoccurringtohimselfor herself,otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbyExmark.

•Wearappropriateclothingincludingsafetyglasses, substantialfootwear,longtrousers,andhearing protection.DoNotoperatewhenbarefootor whenwearingopensandals.Longhair,loose clothingorjewelrymaygettangledinmoving parts.

CAUTION

Thismachineproducessoundlevelsin excessof85dBAattheoperator’searand cancausehearinglossthroughextended periodsofexposure.

SafeOperatingPractices

Training

•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)can notreadEnglishitistheowner’sresponsibilityto explainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained. Theownerisresponsiblefortrainingtheusers.

Wearhearingprotectionwhenoperatingthis machine.

•Inspecttheareawheretheequipmentistobe usedandremoveallrocks,toys,sticks,wires, bones,andotherforeignobjectswhichcanbe thrownbythemachineandmaycausepersonal injurytotheoperatororbystanders.

Safety

DANGER

Incertainconditionsgasolineisextremely ammableandvaporsareexplosive.

Areorexplosionfromgasolinecanburn you,others,andcausepropertydamage.

•Fillthefueltankoutdoorsonlevel ground,inanopenarea,whentheengine iscold.Wipeupanygasolinethatspills.

•Neverrellthefueltankordrainthe machineindoorsorinsideanenclosed trailer.

•DoNotllthefueltankcompletelyfull. Fillthefueltanktothebottomoftheller neck.Theemptyspaceinthetankallows gasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengine oremissionsystem(ifequipped).

•Neversmokewhenhandlinggasoline, andstayawayfromanopenameor wheregasolinefumesmaybeignitedby spark.

•Storegasolineinanapprovedcontainer andkeepitoutofthereachofchildren.

•Addfuelbeforestartingtheengine. Neverremovethecapofthefueltankor addfuelwhenengineisrunningorwhen theengineishot.

•Iffuelisspilled,DoNotattempttostart theengine.Moveawayfromtheareaof thespillandavoidcreatinganysourceof ignitionuntilfuelvaporshavedissipated.

•DoNotoperatewithoutentireexhaust systeminplaceandinproperworking condition.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitegasolinevapors.Areor explosionfromgasolinecanburnyouand othersandcausepropertydamage.

•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebefore lling.

•DoNotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowthe lossofanystaticcharge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelson theground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.

•Ifagasolinedispensernozzlemustbe used,keepthenozzleincontactwiththe rimofthefueltankorcontaineropening atalltimesuntilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporshascaused cancerinlaboratoryanimals.Failuretouse cautionmaycauseseriousinjuryorillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgas tank/containeropening.

•Keepawayfromeyesandskin.

•Neversiphonbymouth.

Safety

•Checkthattheoperator’spresencecontrols, safetyswitches,andshieldsareattachedand functioningproperly.DoNotoperateunlessthey arefunctioningproperly.

Operation

WARNING

Operatingengineparts,especiallythe mufer,becomeextremelyhot.Severeburns canoccuroncontactanddebris,suchas leaves,grass,brush,etc.cancatchre.

•Allowengineparts,especiallythemufer, tocoolbeforetouching.

•Removeaccumulateddebrisfrommufer andenginearea.

•Installandmaintaininworkingordera sparkarresterbeforeusingequipment onforest-covered,grass-covered,or brush-coveredunimprovedland.

WARNING

OperatingaNavigatortractorwithoutan approvedExmarkfrontmountattachment increasesthepossibilityofoperator entanglementindrivewheelsorforwardtip over.Entanglementortip-overcouldcause seriousinjuryordeath.

WhenoperatingaNavigatortractor withoutanapprovedExmarkfrontmount attachment,observethefollowing:

•Keepfeetandclothingawayfromtires.

•Limitoperationtominimumrequiredto installadifferentfrontmountattachment.

•Minimizespeedanduseextremecaution.

•Onlyoperateonaatlevelsurface.

•Donotoperateupordownatrailerramp.

•Avoidsuddenaccelerationordeceleration.

•Operateonlyindaylightorgoodarticiallight, keepingawayfromholesandhiddenhazards.

WARNING

Engineexhaustcontainscarbonmonoxide, whichisanodorlessdeadlypoisonthatcan killyou.

DoNotrunengineindoorsorinasmall connedareawheredangerouscarbon monoxidefumescancollect.

•Besurealldrivesareinneutralandparkingbrake isengagedbeforestartingengine.

•Neverraisedeckwithbladesrunning.

•Neveroperatethemowerwithdamagedguards, shields,orcovers.Alwayshavesafetyshields, guards,switchesandotherdevicesinplaceandin properworkingcondition.

•Nevermowunlessthereisagrasscollection systemormulchkitinplaceandworkingproperly .

•DoNotchangetheenginegovernorsettingor overspeedtheengine.

•Stopengine,waitforallmovingpartstostop, removekeyandengageparkingbrake:

–Beforechecking,cleaningorworkingonthe

mower.

–Afterstrikingaforeignobjectorabnormal

vibrationoccurs(inspectthemowerfor damageandmakerepairsbeforerestarting andoperatingthemower).

–Beforeclearingblockages.

–Wheneveryouleavethemower.

Safety

•Stopengine,waitforallmovingpartstostop,and engageparkingbrake:

–Beforerefueling.

–Beforedumpingthegrasscatcher.

WARNING

Hands,feet,hair,clothing,oraccessoriescan becomeentangledinrotatingparts.Contact withtherotatingpartscancausetraumatic amputationorseverelacerations.

•DoNotoperatethemachinewithout guards,shields,andsafetydevicesin placeandworkingproperly.

•Keephands,feet,hair,jewelry,orclothing awayfromrotatingparts.

•NEVERcarrypassengers.DONOToperate themowerwhenpeople,especiallychildren,or petsareinthearea.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebefore changingdirections.

DANGER

Operatingonwetgrassorsteepslopescan causeslidingandlossofcontrol.Wheels droppingoveredges,ditches,steepbanks,or watercancauserollovers,whichmayresult inseriousinjury,deathordrowning.

•DoNotmowslopeswhengrassiswet.

•DoNotmowneardrop-offsornearwater.

•DoNotmowslopesgreaterthan15 degrees.

•Reducespeedanduseextremecaution onslopes.

•Avoidsuddenturnsorrapidspeed changes.

•Seeinsidethebackcovertodeterminethe approximateslopeangleoftheareatobemowed.

•Useawalkbehindmowerand/orahandtrimmer neardrop-offs,ditches,steepbanksorwater. (Figure3).

•Stoptheblades,slowdown,andusecautionwhen crossingsurfacesotherthangrassandwhen transportingthemowertoandfromtheareato bemowed.

•Beawareofthemowerdischargepathanddirect dischargeawayfromothers.

•DoNotoperatethemowerundertheinuence ofalcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

UseExtremecautionwhenmowingand/orturning onslopesaslossoftractionand/ortip-overcould occur.Theoperatorisresponsibleforsafeoperation onslopes.

Figure3

1.SafeZone-Usethemowerhereonslopeslessthan15 degrees

2.DangerZone-Useawalkbehindmowerand/orhand trimmeronslopesgreaterthan15degrees,near drop-offsandwater.

3.Water

•Removeormarkobstaclessuchasrocks,tree limbs,etc.fromthemowingarea.Tallgrasscan hideobstacles.

•Watchforditches,holes,rocks,dipsandrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.

Safety

•Avoidsuddenstartswhenmowingdownhill. Mowermaytipforwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopesordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagetheblades andproceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprove stability.

•Useextremecarewithattachments.Thesecan changethestabilityofthemachineandcauseloss ofcontrol.

Note:A2–postfoldableROPS(RolloverProtection System)isavailablefortheNavigatorasanaccessory. AROPSisrecommendedifyouwillbemowing nexttodrop-offs,nearwater,oronsteepbanks whichcouldresultinarollover.Themodelnumber fortheROPSattachmentisFRPSNAV .Contactan AuthorizedExmarkServiceDealerformoredetails.

•Disconnectbatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthe negativeterminalrstandthepositivelast. Reconnectpositiverstandnegativelast.

•Usecarewhencheckingblades.Wraptheblade(s) orweargloves,andusecautionwhenservicing them.Onlyreplacedamagedblades.Never straightenorweldthem.

•Keephandsandfeetawayfrommovingparts. Ifpossible,donotmakeadjustmentswiththe enginerunning.

•Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugcharger beforeconnectingordisconnectingfrombattery. Wearprotectiveclothinganduseinsulatedtools.

DANGER

Chargingorjumpstartingthebatterymay produceexplosivegases.Batterygasescan explodecausingseriousinjury.

•Keepsparks,ames,orcigarettesaway frombattery.

MaintenanceandStorage

•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.

•Keepengine,enginearea,andpumpdrivebelt compartmentfreefromaccumulationofgrass, leaves,excessivegreaseoroil,andotherdebris whichcanaccumulateintheseareas.These materialscanbecomecombustibleandmayresult inare.

•Letenginecoolbeforestoringanddonotstore nearameoranyenclosedareawhereopenpilot lightsorheatappliancesarepresent.

•Shutofffuelwhilestoringortransporting.Do Notstorefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallow untrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Ventilatewhenchargingorusingbattery inanenclosedspace.

•Makesureventingpathofbatteryis alwaysopenoncebatteryislledwith acid.

•Alwaysshieldeyesandfacefrombattery.

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately .

•Carefullyreleasepressurefromcomponentswith storedenergy.

Safety

CAUTION

Iftheignitionisinthe“ON”positionthere ispotentialforsparksandengagement ofcomponents.Sparkscouldcausean explosionormovingpartscouldaccidentally engagecausingpersonalinjury

Besureignitionswitchisinthe“OFF” positionbeforechargingthebattery.

•Keepallguards,shieldsandallsafetydevicesin placeandinsafeworkingcondition.

•Checkallboltsfrequentlytomaintainproper tightness.

•Frequentlycheckforwornordeteriorating componentsthatcouldcreateahazard.

WARNING

Removingstandardoriginalequipment parts,orusingnon-Exmarkreplacement partsandaccessoriesmayalterthewarranty, traction,andsafetyofthemachine.Failure touseoriginalExmarkpartscouldcause seriousinjuryordeath.

WARNING

Hydraulicuidescapingunderpressure canpenetrateskinandcauseinjury.Fluid accidentallyinjectedintotheskinmustbe surgicallyremovedwithinafewhoursbya doctorfamiliarwiththisformofinjuryor gangrenemayresult.

•Makesureallhydraulicuidhoses andlinesareingoodconditionand allhydraulicconnectionsandttings aretightbeforeapplyingpressureto hydraulicsystem.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

•Usecardboardorpaper,notyourhands, tondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic systembyplacingthemotioncontrol leversinneutralandshuttingoffthe enginebeforeperforminganyworkon thehydraulicsystem.

Replaceallpartsincluding,butnotlimited to,tires,belts,andbladeswithoriginal Exmarkparts.

SafetyandInstructionalDecals

Safety

•Keepallsafetysignslegible.Removeallgrease, dirtanddebrisfromsafetysignsandinstructional labels.

•Replaceallworn,damaged,ormissingsafety signs.

•Whenreplacementcomponentsareinstalled,be surethatcurrentsafetysignsareafxedtothe replacedcomponents.

•Ifanattachmentoraccessoryhasbeeninstalled, makesurecurrentsafetysignsarevisible.

1-513747

•Newsafetysignsmaybeobtainedfrom yourauthorizedExmarkequipmentdealeror distributororfromExmarkMfg.Co.Inc.

•Safetysignsmaybeafxedbypeelingoffthe backingtoexposetheadhesivesurface.Apply onlytoaclean,drysurface.Smoothtoremove anyairbubbles.

•Familiarizeyourselfwiththefollowingsafetysigns andinstructionlabels.Theyarecriticaltothesafe operationofyourExmarkcommercialmower.

103-8444

65-2690

98-4361

103-8451

98-5954

103-8495

103-8611

103-8425

Safety

103-9034

109-4638

103-9724

109-7318

109-4273

116-0404

Safety

116-1175

117–2718

MoldedinLHConsole

MoldedintoFrontofHopper

Specications

ModelNumbers

SerialNos:850,000andHigher

NAV20KC;NAV27KC

Systems

Engine

•EngineSpecications:SeeyourEngineOwner’s Manual

•RPM:FullSpeed:3600±50RPM(NoLoad) Idle:1500RPM

FuelSystem

•Capacity:7.5gal.(28L)

•TypeofFuel:Regularunleadedgasoline,87 octaneorhigher;containingnomorethan10% methanolorethanol.

•FuelFilter:In-line30MicronKohlerP/N

2405010.

•FuelShut-OffValve:1/4turnincrementsin-line valvebyfuellter.

ElectricalSystem

•ChargingSystem:FlywheelAlternator

•ChargingCapacity:15amps

•BatteryType:BCIGroupU1

•BatteryVoltage:12Volt

•Polarity:NegativeGround

•Fuses:Two20ampandone30ampbladetype

•SafetyInterlockSystem:

–PTOmustbedisengaged,brakeengaged,and

speedcontrolleverinneutralpositiontostart engine.(Itisnotnecessaryfortheoperatorto beintheseattostarttheengine.)

–OperatormustbeinseatwhenPTOis

engaged,brakeisdisengaged,orspeedcontrol leverismovedoutofneutralorenginewill stop.

–Enginewillstopinthefollowingconditions:

◊Ifthespeedcontrolleverismovedfrom

neutralpositionwhilebrakeisengaged.

◊IfthePTOisengagedwhilethehopper

istiltedup.

OperatorControls

•SteeringandMotionControl:

–SpeedControllever,locatedonRHconsole,

setsmaximumforwardspeed.

–Steeringlevers,centeredinfrontoftheseat,

controlthespeedanddirectionoftravelof therespectivedrivewheels.

–Movingspeedcontrolleverrearwardtothe

neutralpositionplacesthedrivesystemin neutral.

Note:Theunitmaybemovedinreverse whilethespeedcontrolisintheneutral positionbypullingbackonthesteeringlevers.

•PTOEngagementLever:EngagesdrivetoPTO (mowerdeck)andblower.

•ParkingBrakeLever:Pullbacktoengageparking brake.

Seat

•Type:Standardseatwithhighback,foampadded (internalsuspension).

•Mounting:Seatishingedtotiltupforaccessto hydraulicpumpsandothercomponents.Theseat isheldinthetiltedpositionwithalink.

•Armrests:None.

•SeatSafetySwitch:Internaltothebottomseat cushion,nonserviceable.Timedelaymodule incorporatedintotheSafetyInterlockSystem eliminatesroughgroundcut-outs.

HydrostaticGroundDriveSystem

•HydrostaticPumps:TwoHydroGearvariable displacementpistonpumps.

•WheelMotors:HydroGearplanetaryreduction motors.

Specications

•HydraulicOilType:UseExmarkPremiumHydro oil.

•HydraulicOilCapacity:4.0qt.(3.8L)

•HydraulicFilter:Replaceablecartridgetype.

–Summeruseabove32°F(0°C):

P/N109-0071:25microns,10psibypass

–Winterusebelow32°F(0°C):

P/N1-523541:40microns,18psibypass

•Speeds:

–0-7.0mph(11.3km/hr)forward.

–0-5.5mph(8.6km/hr)reverse.

•Drivewheelreleasevalvesallowmachinetobe movedwhenengineisnotrunning.

Tires&Wheels

Drive

Pneumatic (Air-Filled)

Quantity

221

Front Caster

SemiPneumatic

RearCaster

SemiPneumatic

–Clutchingbeltonhorizontalengineshaft.

Dual“ A ”sectionhexagonbeltwithspring tensionedidlertojackshaftandblower.

–Heavy-dutycastiron,spiralbevelgearboxis

naldrivetoblades.

•Deck:

Fulloatingdeckisattachedtoout-frontsupport frame.Deckdesignallowsforbaggingor mulching.

•DeckDepth:

–42inchDeck:45/8inches(11.7cm)

–48inchDeck:45/8inches(11.7cm)

Dimensions

OverallWidth:

WithoutDeck42inchDeck48inchDeck

42.6inches (108.2cm)

43.2inches (109.7cm)

49.2inches (125.0cm)

Tread

Size

PlyRating

Pressure

“Multi-Trac C/S”

18x

10.50-10

15psi(103 kPa)

SmoothSmooth

8x3.00-413x8.00-6

CuttingDeck

(Soldseparately)

•ModelNumbers:

–CD42CD

–CD48CD

•CuttingWidth:

–42inchDeck:42inch(106.7cm)

–48inchDeck:48inch(121.9cm)

•Discharge:Center

•BladeSize:(2ea.)

–w/42inchDeck:22.00inches(55.9cm)

–w/48inchDeck:25.00inches(63.5cm)

•DeckDrive:

OverallLength:

WithoutDeck42inchDeck48inchDeck

67.3inches (170.9cm)

91.8inches (233.2cm)

94.5inches (240.0cm)

OverallHeight:

WithoutDeck42inchDeck48inchDeck

51.2inches (130.0cm)

TreadWidth:(CentertoCenterof Tires,Widthwise)

42inchDeck48inchDeck

DriveWheels32.7inches

(83.1cm)

32.7inches (83.1cm)

WheelBase:(CenterofDriveWheel toCenterofRearCasterWheel)

42inchDeck48inchDeck

44.2inches(112.3cm)44.2inches(112.3cm)

ProductOverview

CurbWeight:

42inchDeck48inchDeck

850lb(386kg)1145lb(519kg)

TorqueRequirements

BoltLocation

BladeMountingBolt85-110ft-lb(115-149N-m)

EngineMountingBolts

WheelLugNuts

WheelMotorMounting Bolts

WheelHubLocknut210-250ft-lb

Torque

30-35ft-lb(41-47N-m)

90-95ft-lb(122-129N-m)

72-77ft-lb(98-104N-m)

(285-339N-m)

ProductOverview

Figure4

1.SpeedControlLever4.SteeringLevers

2.Controls5.PTOEngagementLever

3.FuelCap

6.ParkingBrakeLever

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

Controls

SteeringLevers

Locatedinthecenterinfrontoftheseat.

Pullingbackonthesteeringlevers,progressively slows,thenreversesthedirectionoftravelofthe respectivedrivewheels.

Bymovingbothsteeringleversanequalamountback, themachinecanbesloweddownortravelbackward inastraightline.

Steeringiscontrolledbyvaryingthepositionofthe steeringleversrelativetoeachother.

SpeedControlLever

Locatedonrighthandconsole.

Thespeedcontrolleversetsmaximumforwardspeed.

Movingspeedcontrolleverrearwardtotheneutral positionplacesthedrivesysteminneutral.

BrakeLever

Locatedonleftsideofunit,betweentheseatand console.

Thebrakeleverengagesaparkingbrakeonthedrive wheels.

Pulltheleverupandrearwardtoengagethebrake.

Pushtheleverforwardanddowntodisengagethe brake.

Theunitmustbetieddownandbrakeengagedwhen transporting.

IgnitionSwitch

Locatedontherighthandconsole.

Theignitionswitchisusedtostartandstopthe engine.Theswitchhasthreepositions“OFF”,“ON” and“START”.Insertkeyintoswitchandrotate clockwisetothe“ON”position.Rotateclockwiseto thenextpositiontoengagethestarter(keymustbe heldagainstspringpressureinthisposition).

Note:Brakemustbeengaged,speedcontrollever rearward(neutralposition)andPTOdisengagedto startengine.(Itisnotnecessaryfortheoperatorto beintheseattostarttheengine.)

HourMeter

ChokeControl

Locatedonrighthandconsole.

Thechokeisusedtoaidinstartingacoldengine. Movingthechokeleverforwardwillputthechokein the“ON”positionandmovingthechokelevertothe rearwillputthechokeinthe“OFF”position.DO NOTrunawarmenginewithchokeinthe“ON” position.

ThrottleControl

Locatedonrighthandconsole.

Thethrottleisusedtocontrolenginespeed.Moving throttleleverforwardwillincreaseenginespeedand movingthrottlelevertotherearwilldecreaseengine speed.

Locatedontherighthandconsole.

Thehourmeterisconnectedtoapressureswitch installedintheengineblockanditrecordsthe numberofhoursthattheenginehasrun.Ifthe ignitionswitchisleftonwithoutenginerunning, hourmeterwillnotrun.

Note:Thisswitchisnotalowoilsensorandwillnot alerttheoperatoriftheengineoilislow .

FuelShut-OffValve

Locatedinfuellinebyfueltankandfuellter (accessiblebyraisingthehopper).

Thefuelshut-offvalveisusedtoshutoffthefuel whenthemachinewillnotbeusedforafewdays, duringtransporttoandfromthejobsite,andwhen parkedinsideabuilding.

Rotatethevalve1/4turnclockwisetoshutoffthe fuel.rotatethevalve1/4turncounterclockwiseto turnonthefuel.

Operation

DriveWheelReleaseValves

Locatedonthetopleftfrontcornerofhydrostatic pumps.

Drivewheelreleasevalvesareusedtoreleasethe hydrostaticdrivesystemtoallowthemachinetobe pushedwithouttheenginerunning.Tiltseatupto gainaccesstopumps.

Witha7/16wrench,turnbothvalvesoneturn counterclockwisetoreleasedrivesystem.Turn clockwisetoresetsystem.DoNotovertighten.Do

Nottowmachine.

TrackingAdjustmentKnob

Locatedundertheseatontheleftpumpcontrollink.

Rotatingthisknoballowsnetuningadjustmentsso thatthemachinetracksstraightwiththedrivelevers inthefullforwardposition.

Rununitat3/4speedforatleast5minutesto bringhydraulicoiluptooperatingtemperature. Stopmachineandwaitforallmovingpartstostop. Engageparkbrake.Tiltseatforwardtogainaccess tothetrackingknob.Rotatetheknobtowardsthe righttosteerrightandrotatetowardstheleftto steerleft.Adjustin1/8turnincrementsuntilthe machinetracksstraight.Checkthatthemachine doesnotcreepwheninneutralwiththeparkbrakes disengaged.

Important:DoNotrotatetheknobtoofar,as thismaycausethemachinetocreepinneutral. RefertotheMotionControlLinkageAdjustment sectioninMaintenance.

PTOEngagementLever

Locatedimmediatelyleftoftheleftconsole.

Levermustbemoveduptothe“ROTATE”position toengagethePTOandblowerdrives.Leverismoved downtothe“STOP”positiontostopthedrives.

EngineOilTemperatureLightand Buzzer

Locatedontherightconsole.

Theengineoiltemperaturelightmonitorsthe temperatureoftheengineoil.Anilluminatedengine oiltemperaturelightandintermittentbuzzingsound signalstheengineisoverheating.

Pre-Start

Fillfueltanks.Forbestresultsuseonlyclean,fresh regulargradeunleadedgasolinewithanoctanerating of87orhigher.

Important:Neverusemethanol,gasoline containingmethanol,gasoholcontainingmore than10%ethanol,premiumgasoline,orwhite gasbecausethefuelsystemcouldbedamaged.

DoNotaddoiltogasoline.

DoNotoverllfueltank.Fillthefueltanktothe

bottomofthellerneck.Theemptyspaceinthe tankallowsgasolinetoexpand.Overllingmayresult infuelleakageordamagetotheengineoremission system(ifequipped).

Makesureyouunderstandthecontrols,their locations,theirfunctions,andtheirsafety requirements.

RefertotheMaintenancesectionandperformallthe necessaryinspectionandmaintenancesteps.

OperatingInstructions

OpentheFuelShut-OffValve

Thefuelshut-offvalveislocatedontherightsideof unitinfuellinenexttothefuellter.Raisethehopper toaccess.Rotatethevalve1/4counterclockwiseto turnonfuel.

StartingtheEngine

1.Movethespeedcontrollevertotheneutral position.

2.Pullupandbackontheparkingbrakeleverto engagetheparkingbrake.

3.PushthePTOengagementleverdowntothe “STOP”position.

Note:Itisnotnecessaryfortheoperatortobe intheseattostarttheengine.

4.Placethethrottlemidwaybetweenthe“SLOW” and“FAST”positions.

5.Onacoldengine,pushthechokeleverforward intothe“ON”position.

Onawarmengine,leavethechokeinthe“OFF” position.

Operation

6.Turnignitionswitchtothe“START”position. Releasetheswitchassoonastheenginestarts.

Important:DoNotcranktheengine continuouslyformorethantensecondsata time.Iftheenginedoesnotstart,allowa60 secondcool-downperiodbetweenstarting attempts.Failuretofollowtheseguidelines canburnoutthestartermotor.

7.Ifthechokeisinthe“ON”position,gradually returnchoketothe“OFF”positionastheengine warmsup.

EngagingthePTO

DANGER

Therotatingbladesunderthemowerdeck aredangerous.Bladecontactcancause seriousinjuryorkillyou.

DoNotputhandsorfeetunderthemower ormowerdeckwhenthebladesareengaged.

DisengagingthePTO

1.Setthethrottletothe“MIDWAY”position.

2.PushPTOleverdowntothe“STOP”position stoppingthePTOandblower.

StoppingtheEngine

1.Bringtheunittoafullstop.

2.DisengagethePTO.

3.Movespeedcontrollevertotheneutralposition.

4.Engagetheparkingbrake.

5.Placethethrottlemidwaybetweenthe“SLOW” and“FAST”positions.

6.Allowtheenginetorunforaminimumof15 seconds,thenturntheignitionswitchtothe “OFF”positiontostoptheengine.

7.Removethekeytopreventchildrenorother unauthorizedpersonsfromstartingengine.

8.Closethefuelshut-offvalvewhenthemachine willnotbeinuseforafewdays,when transporting,orwhentheunitisparkedinside abuilding.

DANGER

Anuncovereddischargeopeningwillallow objectstobethrowninanoperator’sor bystander’sdirection.Also,contactwiththe blowerbladescouldoccur.Thrownobjects orbladecontactcancauseseriousinjuryor death.

Neveroperatethemowerwiththehopper orhopperdoorraised,removed,oraltered unlessthereisamulchkitinplaceand workingproperly.

ThePTOleverengagesthePTOandblower.Besure thatthehopperisdown,thehopperdoorissecurely closed,andallpersonsareclearofthemowerdeck anddischargeareabeforeengagingPTO.

Important:Operatormustbeinseatbeforethe PTOcanbeengaged.

1.Setthethrottletothe“MIDWAY”position.

2.PullthePTOleverupwarduntillockedover center.

DrivingtheMachine

CAUTION

Machinecanspinveryrapidlybypositioning onelevertoomuchaheadoftheother. Operatormaylosecontrolofthemachine, whichmaycausedamagetothemachine orinjury.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking sharpturns.

Important:Tobeginmovement(forwardor backward)theoperatormustbeintheseat,the brakelevermustbedisengaged(pusheddown) beforethespeedcontrollevercanbemoved forwardortheenginewillstop.

DrivingForward

1.Starttheengine.

2.Releasetheparkingbrake.

3.Placethethrottleinthe“FAST”positiontobegin mowing.

3.Tomoveforwardinastraightlinemovethespeed controlleverforward.

Operation

Toturnleftorright,pulloneofthesteeringlevers backtowardneutralinthedirectiondesired.

Themachinewillmovefasterthefartherthe speedcontrolleverismovedawayfromneutral.

4.Tostop,pullthespeedcontrolleverbacktothe neutralposition.

DrivinginReverse

1.Tomoverearwardinastraightlineapplyingequal pressurepullbothsteeringleversrearward.

Toturnleftorright,releasepressureonthe steeringlevertowardthedirectiondesired.

2.Tostop,releasethesteeringleverstotheneutral position.

EmptyingHopper

1.Afullhopperisindicatedbyabuzzerlocated behindtheoperatorinthehopper.Emptyhopper whenbuzzersoundstopreventcloggingofthe blowerordeck.

2.DisengagePTO,movespeedcontroltoneutral, setparkbrakeanddismountunittodumphopper.

3.Makesureunitisonadrylevelsurface.

4.Liftthereardoorupandallowittorestontop ofhopper.

5.Dumphopperbyrmlygraspingoneofthe hopperhandlesoneithersideoftheunitand liftingthehopper.

ClearingHopperScreen

Screenmayberemovedbyrmlyliftingscreen handles(seeFigure5).

Pullscreentowardsthebacktoremove.Gentlytap debrisfromthescreenasneeded.

Excessivebuild-uponthescreencancausethe blowertoplug.

Figure5

1.Frontremovablescreen canberotatedand storedforwetcondtions

2.Frontremovablescreen4.Handles.

3.Primaryscreen

Transporting

TransportingaUnit

Useaheavy-dutytrailerortrucktotransportthe machine.Lockbrakeandblockwheels.Securely fastenthemachinetothetrailerortruckwithstraps, chains,cable,orropes.Besurethatthetrailerortruck hasallnecessarylightingandmarkingasrequiredby law .Secureatrailerwithasafetychain.

CAUTION

Thisunitdoesnothaveproperturn signals,lights,reectivemarkings,ora slowmovingvehicleemblem.Drivingona streetorroadwaywithoutsuchequipment isdangerousandcanleadtoaccidents causingpersonalinjury.Drivingonastreet orroadwaywithoutsuchequipmentmayalso beaviolationofStatelawsandtheoperator maybesubjecttotrafcticketsand/ornes.

DoNotdriveaunitonapublicstreetor roadway.

Note:Inconditionswherethescreenclogsquickly, thefrontremovablescreenpanelcanbeturnedand reinstalledundertheprimaryscreentoallowfreeair owfromthehopper.

WARNING

Loadingaunitonatrailerortruckincreases thepossibilityoftip-over.Tip-overcould causeseriousinjuryordeath.

•Useextremecautionwhenoperatinga unitonaramp.

•Useonlyasingle,fullwidthramp;Do Notuseindividualrampsforeachside oftheunit.

•Ifindividualrampsmustbeused,use enoughrampstocreateanunbroken rampsurfacewiderthantheunit.

•DoNotexceeda15°anglebetweenramp andgroundorbetweenrampandtrailer ortruck.

•Avoidsuddenaccelerationwhiledriving unitonaramp.

Operation

LoadingaUnit

Useextremecautionwhenloadingunitsontrailers ortrucks.Onefullwidthrampisrequired.Ifitis notpossibletouseonefullwidthramp,useenough individualrampstosimulateafullwidthcontinuous ramp.

Rampshouldbelongenoughsothattheangles betweentherampandthegroundandtherampand thetrailerortruckdonotexceed15°.Asteeperangle maycausemowerdeckcomponentstogetcaughtas theunitmovesfromramptotrailerortruck.Steeper anglesmayalsocausetheunittotip.Ifloadingonor nearaslope,positionthetrailerortrucksoitison thedownsideoftheslopeandtherampextendsup theslope.Thiswillminimizetherampangle.The trailerortruckshouldbeaslevelaspossible.

Important:DoNotattempttoturntheunit whileontheramp,youmaylosecontroland driveofftheside.

Avoidsuddenaccelerationwhendrivingonaramp.

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

WARNING

Whilemaintenanceoradjustmentsarebeing made,someonecouldstarttheengine. Accidentalstartingoftheenginecould seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionswitch, engageparkingbrake,andpullthewire(s) offthesparkplug(s)beforeyoudoany maintenance.Alsopushthewire(s)aside soitdoesnotaccidentallycontactthespark plug(s).

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhublocknutstorquespecication.

•Checkthewheellugnuttorquespecication.

WARNING

Theenginecanbecomeveryhot.T ouching ahotenginecancausesevereburns.

Allowtheenginetocoolcompletelybefore serviceormakingrepairsaroundtheengine area.

Aftertherst250hours

Beforeeachuseordaily

Every40hours

Every50hours

Every80hours

Every100hours

Every160hours

Every500hours

•Changethehydrauliclter.

•Checktheengineoillevel.

•Checkthesafetyinterlocksystem.

•Checkforloosehardware.

•Removeaccumulateddebrisfromengine(seeCleaningsection.)

•Cleanthegrassanddebrisbuild-upfromthemachine.

•Checkthehydraulicoillevel.

•Checkthetirepressures.

•Checktheconditionofthebelts.

•Servicetheaircleaner.(Mayneedmoreoftenundersevereconditions.SeetheEngine Owner’sManualforadditionalinformation.)

•Removeengineshroudsandcleancoolingns(seeCleaningsection.)

•Changetheengineoil.(Mayneedmoreoftenundersevereconditions.)

•Lubricatethebrakehandlepivot.

•Lubricatethebrakerodbushings.

•Lubricatethesteeringlinkagerodends.

•Lubricatehopperactuator

•Checkthesparkplugs.

•Changethehydrauliclter(Every250hours/yearlyifusingMobil115W50)

•Checkthewheelhublocknutstorquespecication.

•Checkthewheellugnuttorquespecication.

Maintenance

MaintenanceService

Interval

Monthly

Yearly

MaintenanceProcedure

•Checkthebatterycharge.

•Lubricategreasettings.

•Lubricatethecasterwheelhubs.

PeriodicMaintenance

CheckEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Stopengineandwaitforallmovingpartstostop. Makesureunitisonalevelsurface.

2.Checkwithenginecold.

3.Raisehopper.

4.Cleanareaarounddipstick.Removedipstickand wipeoiloff.Reinsertthedipstickandpushitall thewaydownintothetube.Removethedipstick andreadtheoillevel.

5.Iftheoillevelislow ,wipeofftheareaaroundthe oilllcap,removecapandlltothe“FULL” markonthedipstick.Useoilasspeciedin EngineOwner’ sManual.DoNotoverll.

Important:DoNotoperatetheenginewiththe oillevelbelowthe“LOW”(or“ADD”)markon thedipstick,oroverthe“FULL”mark.

CheckBatteryCharge

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknowntotheStateof

Californiatocausecancerandreproductive

harm.Washhandsafterhandling.

Allowingbatteriestostandforanextendedperiodof timewithoutrechargingthemwillresultinreduced performanceandservicelife.T opreserveoptimum batteryperformanceandlife,rechargebatteriesin storagewhentheopencircuitvoltagedropsto12.4 volts.

Note:Topreventdamageduetofreezing,battery shouldbefullychargedbeforeputtingawayfor winterstorage.

Checkthevoltageofthebatterywithadigital voltmeter.Locatethevoltagereadingofthebatteryin thetableandchargethebatteryfortherecommended timeintervaltobringthechargeuptoafullcharge of12.6voltsorgreater.

Important:Makesurethenegativebattery cablesaredisconnectedandthebatterycharger usedforchargingthebatteryhasanoutputof 16voltsand7ampsorlesstoavoiddamaging thebattery(seechartforrecommendedcharger settings).

Voltage Reading

12.6or greater

12.4–12.675–100%

12.2–12.450–75%

12.0–12.225–50%

11.7–12.00–25%

11.7orless

Percent Charge

100%

Maximum Charger Settings

16volts/7 amps

14.4volts/4 amps

14.4volts/2 amps

Charging Interval

No Charging Required

30Minutes

1Hour

2Hours

3Hours

6Hoursor More

RecommendedJump StartingProcedure

ServiceInterval:Asrequired

1.Checktheweakbatteryforterminalcorrosion (white,green,orblue“snow”),itmustbecleaned offpriortojumpstarting.Cleanandtighten connectionsasnecessary.

Maintenance

CAUTION

Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejumpstartingprocedure.

DoNotattempttojumpstartwithlooseor corrodedbatteryterminalsordamagetothe enginemayoccur.

DANGER

Jumpstartingaweakbatterythatiscracked, frozen,haslowelectrolytelevel,oran open/shortedbatterycell,cancausean explosionresultinginseriouspersonalinjury.

DoNotjumpstartaweakbatteryifthese conditionsexist.

2.Makesuretheboosterisagoodandfullycharged leadacidbatteryat12.6voltsorgreater.Use properlysizedjumpercables(4to6AWG)with shortlengthstoreducevoltagedropbetween systems.Makesurethecablesarecolorcodedor labeledforthecorrectpolarity .

CAUTION

Note:Besuretheventcapsaretightandlevel.

Placeadampcloth,ifavailable,overanyvent capsonbothbatteries.Besurethevehiclesdo nottouchandthatbothelectricalsystemsare offandatthesameratedsystemvoltage.These instructionsarefornegativegroundsystemsonly.

3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredto thestarterorsolenoidasshowninFigure6.

Figure6

1.Positive(+)cableondischargedbattery

2.Positive(+)cableonboosterbattery

3.Negative(–)cableontheboosterbattery

4.Negative(–)cableontheengineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamage theelectricalsystem.

Becertainofbatteryterminalpolarityand jumpercablepolaritywhenhookingup batteries.

Note:Thefollowinginstructionsareadapted fromtheSAEJ1494Rev.Dec.2001–Battery BoosterCables–SurfaceVehicleRecommended Practice(SAE–SocietyofAutomotive Engineers).

WARNING

Batteriescontainacidandproduceexplosive gases.

•Shieldtheeyesandfacefromthebatteries atalltimes.

•DoNotleanoverthebatteries.

4.Connecttheotherendofthepositivecabletothe positiveterminaloftheboosterbattery.

5.Connecttheblacknegative(–)cabletotheother terminal(negative)oftheboosterbattery.

6.MAKETHEFINALCONNECTIONON THEENGINEBLOCKOFTHESTALLED VEHICLE(NOTTOTHENEGATIVEPOST) AWAYFROMTHEBATTERY .STANDBACK.

7.Startthevehicleandremovethecablesinthe reverseorderofconnection(theengineblock (black)connectionisthersttodisconnect).

CheckSafetyInterlock System

ServiceInterval:Beforeeachuseordaily

Note:Topreventenginecut-outsonroughterrain

theseatkillswitchhasa1/2seconddelay.

1.Checkstartingcircuit.Startershouldcrankwith, parkingbrakeengaged,PTOdisengagedand

Maintenance

speedcontrolleverintheneutralposition.The operatordoesnotneedtobeintheseattostart theengine.

Trytostartwithoperatorinseat,parking brakedisengaged,PTOdisengagedandspeed controlleverintheneutralposition-starter mustnotcrank.

Trytostartwithoperatorinseat,parkingbrake engaged,PTOengagedandspeedcontrollever intheneutralposition-startermustnotcrank.

Trytostartwithoperatorinseat,parkingbrake

engaged,PTOdisengaged,andthespeed controlleverforward(outofneutral),starter mustnotcrank.

2.Checkthekillcircuits.Runengineatone-third throttle,disengageparkingbrakeandraiseoff ofseat(butdonotgetoffofmachine)engine mustinitiateshutdownafterapproximately1/2 secondhaselapsed(seathastimedelaykillswitch topreventcut-outsonroughterrain).

Runengineatone-thirdthrottle,engagePTO andraiseoffofseat(butdonotgetoffof machine)enginemustinitiateshutdownafter 1/2secondhaselapsed.

Manualforadditional information.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Tilthopperuptogainaccesstotheaircleaner.

3.Loosenretainingclipsandremoveaircleaner compartmentcover.

4.Removepaperelement.Checkthecondition ofthepaperelement.Replaceifdirty,bentor damaged.

5.Checktheconditionoftheinnerelement.Replace wheneveritappearsdirty,typicallyeveryother timethepaperelementisreplaced.Cleanthebase aroundtheinnerelementbeforeremoving,so dirtdoesnotgetintotheengine.

6.DoNotwashorusepressurizedairtoclean paperelementorinnerelement.

7.Reinstallelements.Positionthecoversothatthe rubberdustejectorispointingdownwardand securewithretainingclips.

ChangeEngineOil

Note:Ifmachinedoesnotpassanyofthesetests,

donotoperate.ContactyourauthorizedEXMARK SERVICEDEALER.

Important:Itisessentialthatoperatorsafety mechanismsbeconnectedandinproper operatingconditionpriortouseformowing.

CheckforLooseHardware

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Visuallyinspectmachineforanyloosehardware oranyotherpossibleproblem.Tightenhardware orcorrecttheproblembeforeoperating.

ServiceAirCleaner

ServiceInterval:Every50hours—Service

theaircleaner.(May needmoreoftenunder severeconditions.See theEngineOwner’s

ServiceInterval:Aftertherst5hours

Every100hours(May needmoreoftenunder severeconditions.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Drainoilwhileengineiswarmfromoperation.

3.Tilthopperuptogainaccesstotheenginearea.

4.Theoildrainvalveislocatedonrighthandside ofengineatthebackoftheunit.Removetwo nutsnearrighthanddrivetireandswingoutthe fueltank.Installoildrainhose,suppliedinthe literaturepack,ontooildrainvalve.Placepan undermachinetocatchoil.Openvalvetoallow oiltodrainandthenclosevalve

5.Replacetheoilltereveryotheroilchange.Clean aroundoillterandunscrewltertoremove. Beforereinstallingnewlter,applyathincoating ofoilonthesurfaceoftherubberseal.Turn lterclockwiseuntilrubbersealcontactsthelter adapterthentightenlteranadditional1/2to 3/4turn.

Maintenance

6.Cleanaroundoilllcapandremovecap.Fillto speciedcapacityandreplacecap.

7.Removedrainhose,closefueltank,andlower hopper.

8.Useoilrecommendedinengineowner’smanual. DoNotoverll.Starttheengineandcheckfor leaks.

9.Wipeupanyspilledoilfromenginedeck mountingsurfaces.

CheckHydraulicOilLevel

ServiceInterval:Every40hours

WARNING

Oilspilledorventedfromanoverlled hydraulicreservoirontothePTObrakeband willcausealongerstoppingtimeforthedeck andblowerrotatingcomponents.Thedeck andblowerrotatingcomponentscancause seriousinjury.

•Waitforallmovingpartstocometoa completestopbeforeservicing.

halfwaybetweenthe“HOT”and“COLD”levels. Iftheoilisatroomtemperature(about75°F (24°C)),llonlytothe“COLD”level.DoNot overll.

CheckTirePressures

ServiceInterval:Every40hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Checktirepressureindrivetires.

3.Inatedrivetiresto15psi(103kPa).

4.Therearcastertireissemi-pneumaticanddoes notneedtobeinated.

Note:DoNotaddanytypeoftirelinerorfoam llmaterialtothetires.Excessiveloadscreatedby

foamlledtiresmaycausefailurestothehydrodrive system,frame,andothercomponents.Foamlling tireswillvoidthewarranty.

CheckConditionOfBelts

ServiceInterval:Every40hours

•DoNotoverllthehydraulicreservoir. Carefullyllonlytotherecommended level.

•Replacethebrakebandifitbecomes contaminatedwithoil.

1.Stopengineandwaitforallmovingpartstostop. Engageparkingbrake.

2.Tilthopperup.

3.Cleanareaaroundhydraulicreservoircapand removecap.Oillevelshouldbetothetopofthe bafeinsidethetank.Ifnot,addoil.Useonly ExmarkPremiumHydrooil.Replacehydraulic reservoircapandtightenuntilsnug.DoNot overtighten.DoNotoverll.

Note:Thebafeislabeled“HOT”and “COLD”.Theoillevelvarieswiththe temperatureoftheoil.The“HOT”levelshows thelevelofoilwhenitisat225°F(107°C).The “COLD”levelshowstheleveloftheoilwhen itisat75°F(24°C).Filltotheappropriatelevel dependinguponthetemperatureoftheoil.For example:Iftheoilisabout150°F(65°C),llto

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.TilthopperupandcheckpumpandPTOdrive beltsforwear,cracking,orcontamination.

3.Beltsarespringtensionedandnoadjustmentis necessaryunlessbeltsarereplaced.SeePTO

BeltReplacementandPumpDriveBelt Replacementsectionsforbeltreplacement.

LubricateGreaseFittings

Note:Seechartforserviceintervals.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatettingswithonetotwopumpsof NGLIgrade#2multi-purposegungrease.

RefertotheLubricationChartforttinglocations andlubricationschedule.

Maintenance

LubricationChart

Fitting

Locations

1.Caster Pivot

2.PTO Idler

3.Pump Idler

4.Rear CasterHub

Initial

Pumps

*03

Numberof

Places

*Seestep3forspeciallubricationinstructionson thefrontandrearcasterpivotsandtheLubricate RearCasterWheelHubssectionforspecial lubricationinstructionsontherearcasterwheel hubs.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

Service

Interval

*Yearly

Yearly

*Yearly

Figure7

1.Sealguard2.Spacernutwithwrench ats

2.Removecasterwheelfromcasterforks.

3.Removesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxle assemblyinthecasterwheel.Notethatthread lockingadhesivehasbeenappliedtolockthe spacernutstotheaxle.Removetheaxle(with theotherspacernutstillassembledtoit)from thewheelassembly .

Deckshownforreferenceonly.Seeattachment

manualforlubricationschedule.

3.Lubricatecasterpivotsonceayear.Removehex plugandcap.Threadgreasezerkinholeand pumpwithgreaseuntilitoozesoutaroundtop bearing.Removegreasezerkandthreadplugback in.Placecapbackon.

LubricateRearCasterWheel Hubs

ServiceInterval:Yearly

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.PackthebearingswithaNGLIgrade#1 multi-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Seals(ExmarkPN103-0063)mustbe replaced.

8.Iftheaxleassemblyhashadbothspacernuts removed(orbrokenloose),applyathreadlocking adhesivetoonespacernutandthreadontothe axlewiththewrenchatsfacingoutward.Do Notthreadspacernutallofthewayontotheend oftheaxle.Leaveapproximately1/8inch(3mm) fromtheoutersurfaceofthespacernuttothe endoftheaxleinsidethenut.

9.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.

10.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof NGLIgrade#1multi-purposegrease.

Maintenance

11.Insertthesecondbearingandnewsealintothe wheel.

12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.

13.T orquethenutto75-80in-lb(8-9N-m),loosen, thenre-torqueto20-25in-lb(2-3N-m).Make sureaxledoesnotextendbeyondeithernut.

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully .

Important:Topreventsealandbearingdamage, checkthebearingadjustmentoften.Spinthe castertire.Thetireshouldnotspinfreely (morethan1or2revolutions)orhaveanyside play.Ifthewheelspinsfreely,adjusttorqueon spacernutuntilthereisaslightamountofdrag. Reapplythreadlockingadhesive.

LubricateBrakeHandlePivot

ServiceInterval:Every160hours

LubricateBrakeRod Bushings

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricatebronzebushingsoneachendofbrake rodshaftwithaspraytypelubricantoralightoil (bushingsarelocatedtotheinsideoftheange bearings).

LubricateSteeringLinkage RodEnds

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Unhookseatlatchandtiltseatup.

3.Lubricateeachendofbothsteeringlinkagerods withaspraylubricantoralightoil.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Lubricatebronzebushingsonbrakehandle pivotwithaspraytypelubricantorlightoil(see Figure8).

Figure8

LeftSideofUnitShown

1.BrakeHandlePivot

2.PTOHandlePivot

3.SpringArmPivot

4.TogglePivot

LubricateHopperActuator

ServiceInterval:Every160hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Raisehopperandlocateactuatoronrighthand sideofmainframe.

3.Lubricateswitchactuatorrodwithaspray lubricantoralightoil.

CheckSparkPlugs

ServiceInterval:Every160hours

Removesparkplugs,checkconditionandresetgaps, orreplacewithnewplugs.SeeEngineOwner’s Manual.

ChangeFuelFilter

ServiceInterval:Asrequired

Afuellterisinstalledbetweenthefueltankandthe engine.Replacewhennecessary.

ReplacementFilters

Kohler

KohlerP/N2405010

Maintenance

ChangeHydraulicSystem Filter

ServiceInterval:Aftertherst250hours

Every500hours/Yearly (whichevercomes rst)thereafter (Every250hours/Yearlyif usingMobil115W50)

Note:UseonlyExmarkPartNo.109-0071for

Summeruseabove32°F(0°C)orP/N1-523541 forWinterusebelow32°F(0°C).(Refertothe HydrostaticGroundDriveSystemsectionin Specicationsforlterspecications.)

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Carefullycleanareaaroundlter.Itisimportant thatnodirtorcontaminationenterhydraulic system.

3.Unscrewltertoremoveandallowoiltodrain fromreservoir.

Note:DoNotchangehydraulicsystemoil(except forwhatcanbedrainedwhenchanginglter),unless itisfelttheoilhasbeencontaminatedorbeen extremelyhot.

Changingoilunnecessarilycoulddamagehydraulic systembyintroducingcontaminatesintothesystem.

CheckWheelHubLocknuts

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Torqueto210–250ft-lb(285–339N-m).

CheckWheelLugNuts

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Torqueto90–95ft-lb(122–129N-m)crosspattern.

FuelTank—Mounting

Important:Beforereinstallingnewlter,ll

itwithExmarkPremiumHydrooilandapply athincoatofoilonthesurfaceoftherubber seal.

Turnlterclockwiseuntilrubbersealcontactsthe lteradapter,thentightenthelteranadditional 2/3to3/4turn.

4.FillreservoirasstatedinCheckHydraulicOil Levelsection.

ExmarkPremiumHydroOilisrecommended. Refertothechartforanacceptablealternative:

HydroOil

ExmarkPremiumHydro Oil(Preferred)

Mobil115W50

5.Raisetherearofmachineupandsupportwith jackstands(orequivalentsupport)justhigh enoughtoallowdrivewheelstoturnfreely.

6.Startengineandmovethrottlecontrolaheadto fullthrottleposition.Movethespeedcontrol leverstothefullspeedandrunforseveral minutes.Shutdownmachineandrecheckoil level.

ChangeInterval

500Hours

250Hours

HardwareSpecications

ServiceInterval:Asrequired

Wheninstallingthenutsonthefueltankstuds,fully tightenthenylocnutandbackoff1/2turn.This allowsfornormalfueltankexpansionandcontraction withchangesintemperatureandfuellevels.

ThreadLockingAdhesives

Threadlockingadhesivessuchas“Loctite242” or“Fel-Pro,Pro-LockNutType”areusedonthe followingfasteners:

•Pumpdrivesheavesetscrews.

•SquareheadsetscrewsonHydropumpcontrol arms.

•Sheaveretainingboltintheendofengine crankshaft,blowershaftandjackshaft.

•Casterwheelspacernuts.

•Fueltankbulkheadttingnuts.

Adhesivessuchas“LoctiteRC/609orRC/680”or “Fel-ProPro-LockRetainingIorRetainingII”are usedonthefollowing:

Maintenance

Fueltankstuds,wherestudsareinsertedintotank.

DielectricGrease

Dielectricgreaseisusedonallbladetypeelectrical connectionstopreventcorrosionandlossofcontact.

Adjustments

Note:DisengagePTO ,shutoffengine,waitfor allmovingpartstostop,engageparkingbrake,and removekeybeforeservicing,cleaning,ormakingany adjustmentstotheunit.

PTODriveBeltTension

Self-tensioning-Noadjustmentnecessary.

PumpDriveBeltTension

Self-tensioning-Noadjustmentnecessary.

PTOBeltReplacement

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Withengine“off”,engagePTOlever,then removethehairpinandclevispinatthebottom ofthePTObrakeband.

3.Rotatethebrakebandupwardsoutofthewayof thebeltskeepingclearofthebeltdrive.

4.DisengagePTOlever.

5.Loosenbeltguides“ A ”and“B”(SeeFigure9).

6.Removecurrentbelts

7.Routenewbeltsontosheavesasshowninthe decallocatedonthebackoftheleftdriveshield (seeFigure9).

Figure9

1.Idler5.Engine

2.BeltGuide“B”6.BeltGuide“A”

3.PTOBelt

4.Jackshaft

7.Blower

8.EngagethePTOlever

9.Rotatebrakebandbackdownintooriginal position

10.Re-installclevispinandhairpintosecurebrake band.

11.EngagethePTOlever.

12.Loosenthejamnutsandadjustlinkageuntilthe topoftheidlerarmisalignedwiththebottomof notchontensionarmasshowninFigure10.

Maintenance

Figure11

1.PumpDriveBelt4.Pump

2.Pump5.Idler

3.Idler6.Engine

Figure10

1.TensionArm

2.Loosenjamnuts

3.WhenPTOisengaged,aligntopofidlerarmwithbottom ofnotchontensionarm,asshown.

4.IdlerArm

13.TightenjamnutsanddisengagePTOlever. Re-engagePTOleverandcheckalignment.

14.CheckandadjustbeltguidesasstatedinBelt GuideAdjustmentsection.

PumpDriveBelt Replacement

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.RemovePTOBelts.SeePTOBeltReplacement sectionforremovalinstructions.

3.Pullspringidlerorremovespringtorelievepump drivebelttension.Removeoldbelt.

5.ReinstallPTOBeltsasstatedinthePTOBelt Replacementsection

BeltGuideAdjustment

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.EngagePTOlever.

3.AdjustbeltguidesasshowninFigure12.

Figure12

1.1/8inch(3mm)4.Rotatewireformguideto

2.7/16inch(11mm)5.1/4inch(6mm)

3.1/8inch(3mm) Clearance

centerbeltsinguide.

6.5/16inch(8mm)

4.Routenewbeltontosheavesasshowninthe decallocatedonthebackoftheleftdriveshield (seeFigure11).

Maintenance

AdjustSafetySwitch

Adjustallsafetyswitchessoplungerextends3/16 inchto1/4inch(4.8mm-6.4mm)fromswitchbody whenplungeriscompressed(seeFigure13).

Figure13

1.3/16inchto1/4inch(4.8mm-6.4mm)

BrakeAdjustment

Checktomakesureeachbrakeisadjustedproperly.

1.Pullthebrakeleverupandbacktotheengaged position.

2.Agapmustexistbetweenthebottomofthebrake boltheadandthetopsurfaceofthebrakeswivel asshowninFigure14.Ifagapdoesnotexist, adjustthelinkagetoamaximumgapof1/2inch ±1/8inch(1.3cm±0.33cm)asshown.

3.Thebrakesonbothsidescanbesimultaneously adjustedbylengtheningorshorteningthelinkage showninFigure15.

Figure15

BrakeAdjustmentforBothSides

(Atthesametime)

1.BrakeLeverinengaged position

2.Removeclevispin4.Loosennuthere

3.Rotateyoke

4.Ifindividualadjustmentisnecessary,loosenthe jamnutonthebrakeboltthatisagainsttheclevis connectedtothebrakearmonthewheelmotor. Turnthebrakebolttoachieveproperadjustment.

BrakeAdjustmentforEachSide(Separately)

1.BrakeLeverinengaged position

2.Loosennuthere

3.1/2inch±1/8inch(1.3 cm±0.33cm)

Figure14

4.BrakeBolt

5.BrakeSwivel

5.Tightenthejamnutagainsttheclevis.

6.Repeatforothersideofunit.

7.Engageanddisengagethebrakestocheckfor properengagementanddisengagement.Readjust ifnecessary.Whenthebrakesaredisengaged, thereshouldbefreeplayinthebrakelinkagewith nodragginginthebrakes.

AdjustSpeedControlLever Tension

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Tensioninspeedcontrollevercanbeadjusted byadjustingthetightnessoftheleverpivotbolt, whichislocatedundertheseatnearthespeed controllever(seeFigure16).

3.Setthetensionhighenoughthatthespeedcontrol leverpositionismaintainedduringoperationand

Maintenance

looseenoughtobemovedcomfortablybythe operator.

Figure16

1.SpeedControlLever3.Springdiscwashers

2.FrictionPlate4.Hexlocknut

CAUTION

Raisingthemowerdeckforserviceor maintenancerelyingsolelyonmechanical orhydraulicjackscouldbedangerous.The mechanicalorhydraulicjacksmaynotbe enoughsupportormaymalfunctionallowing theunittofall,whichcouldcauseinjury.

DoNotrelysolelyonmechanicalorhydraulic jacksforsupport.Useadequatejackstands orequivalentsupport.

•Adjuststeeringlevers

1.Stopengineandwaitforallmovingpartsto stop.

2.Pullthespeedcontrollevercompletelybackto theneutralposition.Thetwosteeringlevers shouldbestraightupanddown(vertical).If necessary,adjuststeeringleversbychanging thelengthofthelinkbetweenthespeed controlleverandthecontrolarmontheend ofthesteeringcontrolshaft(seeFigure17).

SpeedControlLinkage Adjustment

WARNING

Enginemustberunninganddrive wheelsmustbeturningsomotioncontrol adjustmentcanbeperformed.Contactwith movingpartsorhotsurfacesmaycause personalinjury.

Keepngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.

Figure17

1.Loosenjamnutshereto adjustlinkage

•Setneutral:

1.Removetheelectricalconnectionfromthe seatsafetyswitch,locateddirectlyinfrontof theseatswitchassembly.

2.Theneutraladjustmentmustbemadewith thedrivewheelsturning.Raisetheframeand placeonjackstandssothatdrivewheelscan rotatefreely.Temporarilyinstallajumperwire

2.Steeringleversshould bevertical

Maintenance

acrosstheterminalsintheconnectorofthe wiringharness.

3.Starttheengine.

4.Runtheunitatleast5minuteswiththe speedcontrolleveratfullforwardspeedto bringhydraulicsystemoiluptooperating temperature.Returnspeedcontrolleverto neutral(fullrear)position.

5.Toobtaintheneutralposition,adjustthe leftandrightpumpcontrolrodlinkagesthat connectthesteeringcontroltothepump controlarmsuntilthewheelsstop,orcreep slightlyinreverse.

6.Adjusttheleftpumplinkagebyrotatingthe trackingadjustmentknob.

7.Adjusttherightpumplinkagebyusing awrenchtoturnthedoublenutsonthe assembly(seeFigure18)

Setforwardstopbolt:

1.Removeseatdeck(withseatattached)toobtain aclearviewofthesteeringcontrolshaftto completethisadjustment.

2.Pushthespeedcontrolleverforwardtofull forwardspeedposition.

3.Ifeithersteeringcontrolleversurfacedoesnot contactthestopbaratthefullforwardspeed position,adjustthestopboltuntilcontactoccurs (seeFigure19).Oncecontactoccurs,turnthe stopboltonemorefullturntopreventbottoming ofthehydraulicpumpinternalstops.

Figure18

1.Rotatetrackingknobon leftside

2.Rotatedoublenutson rightside

8.Movethesteeringleverstothereverse position.Whileapplyingslightpressureto thelevers,allowthesteeringleverstoreturn toneutral.Thewheelsmuststopturning(or slightlycreepinreverse).

9.Stopengineandwaitforallmovingpartsto stop.Removejumperwirefromwireharness connectorandplugconnectorintoseatswitch.

Figure19

1.SpeedcontrolLever forwardstopbolt

2.Contactmustbe maintainedbetween thesecomponentsatfull forwardspeedcondition

SteeringControlLever ResponseAdjustment

1.Stopengine,waitforallmovingpartstostopand removekey.Engageparkingbrake.

2.Movethespeedcontrollevertothefullforward position.

3.Lifttheseatandlocatethepumpcontrolsprings. Toincreaseresponsiveness,increasespring tensionbyhookingtherearspringanchordirectly totheanchorbolt.Todecreaseresponsiveness, hooktherearspringanchortotheanchortab.

Note:Besurebothspringsmaintainthesame adjustment.

10.Lowerfromjackstands.

Figure20

1.Toincreasesteeringresponsivenesshook pumpcontrolsprintsdirectlyonanchorbolt. Todecreasesteeringresponsivenesshookpump controlspringsonanchortabsasshown.

Maintenance

inchto1/16inch(0.8-1.6mm).Useastraight edgetoalignallthreesurfaces(seeFigure21).

Figure21

1.Alignthreepumpdrive pulleysurfacesshown withthispatternwithin 1/32inchto1/16inch (0.8-1.6mm).

2.AlignthreePTOdrive pulleysurfacesshown withthispatternwithin 1/32inchto1/16inch (0.8-1.6mm).

TrackingAdjustment

SeeMotionControlLinkageAdjustmentsection

PTODrivePulleyAlignment

PTOdrivepulleyalignmentisnecessaryforanyof thefollowingconditions:

•Theblowerhasbeenremovedorreplaced.

•Theenginemountingboltshavebeenloosened ortheenginehasbeenmovedorreplaced.

•Thejackshaftmountingboltshavebeenloosened orthejackshafthasbeenmovedorreplaced.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Movethespeedcontrollevertotheneutral position.

3.DisengagethePTOlever.

4.Removefueltankmountingnutsandswingout fueltank.

5.Verifythattheblowerisinstalledandsecured tightly.

6.Loosenthe4enginemountingbolts.

7.Unhookthepumpbelttensionspring.

8.Loosenthe4jackshaftmountingbolts.

9.Measuringfromtheblowerpulleyasabaseline, movetheengineandjackshaftuntiltherear surfaceofall3pulleysarealignedwithin1/32

10.Tightenthefourenginemountingboltsandfour jackshaftmountingbolts.Checkalignmentafter tightening.

11.Re-installpumpbelttensionspring.

12.Swingfueltankinandre-installtankmounting nuts.

13.CompletethePumpDrivePulleyAlignment section.

PumpDrivePulleyAlignment

Pumpdrivepulleyalignmentisnecessaryforanyof thefollowingconditions:

•Theenginemountingboltshavebeenloosened ortheenginehasbeenmovedorreplaced.

•Thepumppulleyshavebeenloosened,moved, orreplaced.

•ThePTOpulleyalignmenthasbeenperformed (seePTODrivePulleyAlignmentsection).

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Loosensetscrewsonbothpumppulleys.

3.Usingastraightedge,aligneachpumppulleywith theenginepulleybyslidingalongthepumpshaft (seeFigure21).

4.Re-tightenpulleysetscrewsandrecheck alignment.

Maintenance

RearCasterPivotBearings Pre-LoadAdjustment

Removedustcapfromcasterandtightennyloc nutuntilwashersareat.Backoff1/4ofaturn toproperlysetthepre-loadonthebearings.If disassembled,makesurethespringdiscwashersare reinstalledasshowninFigure22.

1.Loosendoorhinge nuts-threeperside

PTOBrakeSpring

Figure23

2.Placeapieceof3/8inch (9.5mm)rubberonthis surface

Figure22

1.Springdiscwashers

HopperDoorAdjustment

DoorClosing:

Loosensixdoorhingenuts(seeFigure23).

Opendoorandplacea3/8inchrubberstripor3/8 inchdiameterhosebetweenthehopperandhopper door(seeFigure23).

Closedoorandpushtightagainsthopper.

Tightenhingehardware.Openhopperdoorand removerubberstrip.

Adjustment

PTObrakespringadjustmentisonlynecessaryifthe blowerhasbeenremovedorreplacedorifthePTO driveidlerarmhasbeendisassembled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Locatethebrakespringandthreadthetwojam nutsouttotheendofthebrakespringrod(see Figure24).

3.Tightenjamnutstogetheratendofbrakespring rod.

1.Tightenjamnutshere

2.PTOBrakespringassembly

Figure24

Maintenance

Cleaning

CleanEngineandExhaust SystemArea

ServiceInterval:Beforeeachuseordaily

(Mayberequiredmore oftenindryordirty conditions.)

CAUTION

Excessivedebrisaroundtheenginecooling airintakeandinsideofthepumpdrive beltcompartmentanddamagedormissing rubberbafescancausetheengineand hydraulicsystemtooverheatwhichcan createarehazard.

Cleanalldebrisfrominsideofpumpdrive beltcompartmentdaily.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanalldebrisfromrotatingengineairintake screenandfromaroundengineshroudingand exhaustsystemarea.

3.Cleanalldebrisfromaroundengine,drivebelts, andexhaustsystemarea.

RemoveEngineShroudsand CleanCoolingFins

ServiceInterval:Every80hours

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removecoolingshroudclean-outcoversfrom engineandcleancoolingns.Alsocleandust, dirt,andoilfromexternalsurfacesofengine, whichcancauseimpropercooling.

3.Makesurecoolingshroudclean-outcoversare reinstalled.Operatingtheenginewithoutcooling shroudclean-outcoverswillcauseenginedamage duetooverheating.

4.For27HPKohlerunits:Swingoutthefueltank andremovedebrisfromaroundtheoilcooler positionedatrightfrontcornerofengine.

Important:DoNotusewatertocleanengine. Uselowpressurecompressedair.SeeEngine Owner’sManual.

CleanDebrisFromMachine

ServiceInterval:Beforeeachuseordaily

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Cleanoffanyoil,debris,orgrassbuild-uponthe machine,especiallyaroundthefueltank,around engineandexhaustarea.

WasteDisposal

MotorOilDisposal

Engineoilandhydraulicoilarebothpollutantsto theenvironment.Disposeofusedoilatacertied recyclingcenteroraccordingtoyourstateandlocal regulations.

BatteryDisposal

DANGER

Batteryelectrolytecontainssulfuricacid, whichispoisonousandcancausesevere burns.Swallowingelectrolytecanbefatalor ifittouchesskincancausesevereburns.

•Wearsafetyglassestoshieldeyes,and rubberglovestoprotectskinandclothing whenhandlingelectrolyte.

•DoNotswallowelectrolyte.

•Intheeventofanaccident,ushwith waterandcalladoctorimmediately .

Federallawstatesthatbatteriesshouldnotbeplaced inthegarbage.Managementanddisposalpractices mustbewithinrelevantfederal,state,orlocallaws.

Ifabatteryisbeingreplacedoriftheunitcontaining thebatteryisnolongeroperatingandisbeing scrapped,takethebatterytoalocalcertiedrecycling center.Ifnolocalrecyclingisavailablereturnthe batterytoanycertiedbatteryreseller.

Troubleshooting

Important:Itisessentialthatalloperatorsafetymechanismsbeconnectedandinproperoperating

conditionpriortomoweruse.

Whenaproblemoccurs,donotoverlookthesimplecauses.Forexample:startingproblemscouldbecaused byanemptyfueltank.

Thefollowingtablelistssomeofthecommoncausesoftrouble.DoNotattempttoserviceorreplacemajor itemsoranyitemsthatcallforspecialtimingoradjustmentsprocedures(suchasvalves,governor,etc.).Have thisworkdonebyyourEngineServiceDealer.

Note:WhendisconnectingelectricalconnectorsDoNotpullonthewirestoseparatetheconnectors.

ProblemPossibleCauseCorrectiveAction

Starterdoesnotcrank.

Enginewillnotstart,startshard,orfailsto keeprunning.

1.PTOisengaged.

2.Parkingbrakeisnotset.2.Settheparkingbrake.

3.Speedcontrolleverisnotinneutral position.

4.Batterydoesnothaveafullcharge.

5.Electricalconnectionsarecorroded,loose orfaulty.

6.Fuseisblown.6.Replacetheblownfuse.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.1.Fillthefueltank.

2.Fuelshutoffvalveisclosed.

3.Oillevelinthecrankcaseislow .

4.Thethrottleandchokearenotinthe correctposition.

5.Dirtinfuellter.5.Replacethefuellter.

6.Dirt,water,orstalefuelisinthefuel system.

7.Aircleanerisdirty.

8.Electricalconnectionsarecorroded,loose orfaulty.

9.Relayorswitchisdefective.9.ContactanAuthorizedServiceDealer.

10.Faultysparkplug.

11.Sparkplugwireisnotconnected.

1.DisengagethePTO .

3.Ensurethespeedcontrolleverisinthe neutralposition.

Chargethebattery.SeeCheck

BatteryChargeandRecommended JumpStartingProceduresectionsin

Maintenance.

5.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

2.Openthefuelshutoffvalve.

3.Addoiltothecrankcase.

4.Besurethethrottlecontrolismidway betweenthe“SLOW”and“FAST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleanerelement.

8.Checktheelectricalconnectionsfor goodcontact.Cleanconnectorterminals thoroughlywithelectricalcontactcleaner, applydielectricgreaseandreconnect.

10.Clean,adjustorreplacesparkplug.

11.Checkthesparkplugwireconnection.

Enginelosespower.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow .

4.Coolingnsandairpassagesforthe engineareplugged.

5.Ventholeinthefuelcapisplugged.

6.Dirtinfuellter.6.Replacethefuellter.

7.Dirt,water,orstalefuelisinthefuel system.

2.Cleanorreplacetheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionsfromthecooling nsandairpassages.

5.Cleanorreplacethefuelcap.

7.ContactanAuthorizedServiceDealer.

Troubleshooting

ProblemPossibleCauseCorrectiveAction

Engineoverheats.

Mowerpullsleftorright(withleversfully forward).

Machinedoesnotdrive.

Abnormalvibration.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow .

3.Coolingnsandairpassagesforthe engineareplugged.

1.Trackingneedsadjustment.1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

3.Reverseindicatorandspeedcontrol linkageneedadjustment.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor broken.

3.Driveorpumpbeltisoffapulley .3.Changethebelt.

4.Brokenormissingidlerspring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

1.Enginemountingboltsareloose.1.Tightentheenginemountingbolts.

2.Looseenginepulley,idlerpulley ,orblade pulley.

3.Enginepulleyisdamaged.3.ContactanAuthorizedServiceDealer.

4.Beltisdamaged.4.Installnewbelt.

2.Addoiltothecrankcase.

3.Removetheobstructionsfromthecooling nsandairpassages.

3.Adjustthereverseindicatorandthespeed controllinkage.

2.Changethebelt.

4.Replacethespring.

cooldown.

2.Tightentheappropriatepulley .

Schematics

ENGINE

OVERHEAT

BUZZER

ENGINE

VERHEAT

LED

ACCESSORY PLUG

CLOSED WITH

HOPPER DOWN

SWITCH IS CLOSED

WITH OPERATOR IN SEAT

TEMP

SWITCH

SEAT DELAY

MODULE CONTROL

SEAT

SWITCH

BATTERY

GROUND

SEAT DELAY

MODULE INPUT

HOPPER

SWITCH

BLACK ORANGE

ORANGE

PINK

ORANGE

PINK

ORANGE

PINK

TAN

BLACK

DK GRN

TAN

BROWN

LT. BLUE

BLACK

ORANGE

WHITE

VIOLET

FUSE

20 AMP

BATTERY (+)

STARTER

SOLENOID

VIOLET

RED

ORANGE/BLACK STRIPE

DK. BLUE

FUSE

20 AMP

FUSE

30 AMP

ENGINE

CONNECTOR

ORANGE

DK. GREEN

BLACK

DK GREEN

DK.GREEN

WHITE

DK. GREEN

KILL

REL

DK. GREEN

OPEN WITH BRAKE

ENGAGED

CLOSED WITH BRAKE

ENGAGED

LT. BLUE

ORANGE/BLACK STRIPE

DK. GREEN

YELLOW

GRAY

DK. GREEN

BRAKE

START

RELAY

LT. BLUE

ORANGE

BLACK

PTO

RELAY

BLACK

GRAY

BROWN

DK. GREEN

SPEED

NOTE:

CONNECTORS VIEWED FROM WIRE END

LT. BLUE

DK. GREEN

SPEED CONTROL SWITCH

IS CLOSED WITH CONTROL LEVER

IN NEUTRAL POSITION

PTO

SWITCH

BATTERY

GROUND

IGNITION

SWITCH

HOUR

METER

BLACK

TAN

BLACK

DK. GREEN

BROWN

ORANGE

BLACK

LT. BLUE

BLACK

VIOLET

RED

YELLOWORANGE

ORANGE

. BLUE

HOPPER HARNESS

CONNECTED

HERE

LT. BLUE

BLACK

WIPER

MOTOR

PURPLE

LT. BLUE

HOPPER

SWITCH

LT. BLUE

BLACK

HOPPER

FILL

BUZZER

PURPLE

BLACK

3. START

POSITION

1. OFF

2. RUN

B + I + S

CIRCUIT "MAKE"

X + Y

NONE

B I A

IGNITION SWITCH

TERMINAL CONNECTIONS

TERMINAL A VOLTAGE REGULATOR

TERMINAL B BATTERY

TERMINAL I HOUR METER, ENGINE, PTO SWITCH

TERMINAL S START RELAY

TERMINAL X SEAT DELAY

TERMINAL Y HOUR METER, ENGINE, PTO SWITCH

TERMINAL S

TERMINAL B

TERMINAL A

TERMINAL Y

TERMINAL X

TERMINAL I

G006851

Schematics

ElectricalDiagram

BLACK

ACCESSORY PLUG

ORANGE

BLACK

RED

LT. BLUE

BLACK

VIOLET

WIPER

MOTOR

HOPPER

FILL

SWITCH

BUZZER

BLACK

LT. BLUE

BLACK

LT. BLUE

BROWN

SEAT

SWITCH

BATTERY

(+) 12V

RED

BROWN

ORANGE

PINK

ORANGE

DK. BLUE

TEMP

SWITCH

BUZZER

ORANGE

PINK

ENGINE

OVERHEAT

LED

BROWN

DK. GREEN

ORANGE

BLACK

HOPPER

SWITCH

DK. GREEN

GRAY

PTO

RELAY

ORANGE

LT. BLUE

BLACK

DK. GREEN

LT. BLUE

DK. GREEN

BLACK

BATTERY

GROUND

YELLOW

TAN

ORANGE

20 AMP

FUSE

DK. GREEN

FUEL SOLENOID

REGULATOR

ENGINE KILL

OIL PRESSURE

STARTER

SOLENOID

DK. GREEN

TAN

BLACK

WHITE

DK. GREEN

ORANGE/BLACK STRIPE

YELLOW

GRAY

DK. GREEN

LT. BLUE

BLACK

TAN

BLACK

LT. BLUE

VIOLET

RED

ORANGE

VIOLET

RED

ORANGE/BLACK STRIPE

DK. BLUE

WHITE

VIOLET

SEAT DELAY

MODULE

BATTERY

GROUND

20 AMP

FUSE

30 AMP

FUSE

SPEED

CONTROL

BRAKE

START

RELAY

IGNITION

SWITCH

HOUR

METER

PTO

SWITCH

KILL

REL

3. START

POSITION

1. OFF

2. RUN

B + I + S

CIRCUIT "MAKE"

X + Y

NONE

B I A

WIRES CROSSING

(NOT CONNECTED)

WIRES CONNECTED

YXSIB

STARTRUNOFF

DK. GREEN

FILL SWITCH OPEN

WHEN SENSOR IN

NEUTRAL POSITION

CLOSED WITH

HOPPER DOWN

SHOWN WITH SPEED CONTROL

LEVER IN NEUTRAL POSITION

SHOWN WITH

BRAKE ENGAGED

SHOWN WITH OPERATOR

IN SEAT

TERMINAL X

TERMINAL Y

TERMINAL A

TERMINAL B

TERMINAL S

TERMINAL I

G006949

ElectricalLogicSchematic

Schematics

G006950

CASE DRAIN

CHARGE PUMP

HIGH PRESSURE

BYPASS VALVE

HIGH PRESSURE FORWARD

HIGH PRESSURE

FORWARD

HIGH PRESSURE REVERSE

HydraulicDiagram

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 two years.

This warranty applies to Exmark commercial turf 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 2 years*

* 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.

• 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.

• Any repairs necessary due to use of parts, accessories or   supplies, including gasoline, oil or lubricants, incompatible   with the turf 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 www.exmark.com. U.S. or Canada customers may also call 402-223-6375.

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 68310  402-223-6375 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 turf 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.

Exmark Commercial Turf Equipment

2 Year Limited Warranty

G4500-589_B

Notes:

ServiceRecord

Date:

DescriptionofWorkDone:ServiceDoneBy:

G011841

Figure25

Thispagemaybecopiedforpersonaluse.

1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopeindicatortodeterminethe degreeofslopeofhillsbeforeoperating.DoNotoperatethismachineonaslopegreaterthan15degrees.Fold alongtheappropriatelinetomatchtherecommendedslope.

2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.

3.Exampleofhowtocompareslopewithfoldededge.

MI D-MOUNT RIDING ACCE SSORIES AND OPTIONS

SEE EXMARK’S COMPLETE LINE OF ACCESSORIES AND OPTIONS

WALK-BEHIND ACCESSORIES AND OPTIONS

GRASS CATCHER

MICRO-MULCH SYSTEM

TURF STRIPER

STANDON

CUSTOM RIDE SEAT SUSPENSION SYSTEM

FULL SUSPENSION SEAT

DECK LIFT ASSIST KIT

HITCH KIT

LIGHT KIT

V POWER PORT

MICRO-MULCH SYSTEM

OPERATOR CONTROLLED DISCHARGE

ROLL OVER PROTECTION SYSTEM (ROPS)

SUN SHADE

TRASH CONTAINER

TURF STRIPER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

OU T-FRONT RIDING ACCESSORIES AND OP TIONS

CUSTOM RIDE SEAT SUSPENSION SYSTEM

DUAL-TAIL WHEEL

FLOOR PAN EXTENDER

HITCH KIT

LIGHT KIT

MICRO-MULCH SYSTEM

ROLL OVER PROTECTION SYSTEM (ROPS)

SNOW BLADE

SNOWBLOWER

SUN SHADE

TRASH CONTAINER

ULTRA VAC COLLECTION SYSTEM

ULTRA VAC QUICK DISPOSAL SYSTEM

WEATHER CAB

PlaceModelNo.andSerialNo.

LabelHere(IncludedintheLiterature

Pack)orFillinBelow

ModelNo.EngineSerialNo.(E/No)

SerialNo.

DatePurchased

EngineModelNo.andSpec.No.

PartNo.4500-628Rev.B (402)223-6300 Fax(402)223-5489 PrintedintheUSA

www.exmark.com

Exmark Navigator, Navigator 850 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual