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Exmark 0 Lawn Mower User Manual

1. 6 Pack the bearings with a NGLI grade 1 multi purpose grease 7 Insert one bearing one new seal into the wheel Note Seals Exmark PN 103 0063 must be replaced 4 8 Ifthe axle assembly has had both spacer nuts Deck shown for reference only See attachment removed or broken loose apply a thread locking manual for schedule adhesive to one spacer nut and thread onto the axle with the wrench flats facing outward Do 3 Lubricate caster pivots once a year Remove hex Not thread spacer nut all of the way onto the end plug and cap Thread grease zerk in hole and of the axle Leave approximately 1 8 inch 3 mm pump with grease until it oozes out around top from the outer surface of the spacer nut to the beating Remove grease zerk and thread plug back end of the axle inside the nut in Place cap back on 5 Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and Lubricate Rear Caster Wheel bearing Hubs 10 With the open end of the wheel facing up fill the area inside the wheel around the axle full of Service Interval Yearly NGLI grade 1 multi purpose grease 27 Maintenance 11 Insert the second bearing and new seal into the wheel 12 Apply a thread locking adhesive to the 2nd spacer nut and thread onto the axle with the wrench flats facing outward Torque the nut to 75 80 in lb 8 9 N
2. 15 Product Overview Curb Weight Product Overview Torque Requirements Blade Mounting Bolt 85 110 ft lb 115 149 N m Engine Mounting Bolts 30 35 ft lb 41 47 N m Wheel Lug Nuts 90 95 ft lb 122 129 N m Wheel Motor Mounting 72 77 ft lb 98 104 N m Bolts Wheel Hub Locknut 210 250 ft lb 285 339 N m Figure 4 1 Speed Control Lever 4 Steering Levers 2 Controls 5 PTO Engagement Lever 3 Fuel Cap 6 Parking Brake Lever 16 Operation Operation Note Determine the left and right sides of the machine from the normal operating position Controls Steering Levers Located in the center in front of the seat Pulling back on the steering levers progressively slows then reverses the direction of travel of the respective drive wheels By moving both steering levers an equal amount back the machine can be slowed down travel backward in a straight line Steering is controlled by varying the position of the steering levers relative to each other Speed Control Lever Located on right hand console The speed control lever sets maximum forward speed Moving speed control lever rearward to the neutral 5 position places the drive system in neutral Choke Control Located on right hand console The choke is used to aid in starting a cold engine Moving the choke lever forward will put the choke in the ON position and moving the choke lever to the rear will put th
3. 33 Steering Control Lever Response Adjustments m i co o ora ad oa fus 34 Tracking Adjustment costretti des 35 PTO Drive Pulley Alignment ieitiiete 35 Pump Drive Pulley Alignment sace 35 Rear Caster Pivot Bearings Pre Load Foral vr insita ROS 36 Hopper Door Adjustment sess 36 Brake Spring Adjustment 36 Si 37 Clean Engine and Exhaust System PEA iste ditat essi ga Sahat dain ate 37 Remove Engine Shrouds and Clean Cooling 27 Clean Debris From 37 37 Tro bleshootng ga Ped 38 Schemat s noe eim disti dos 40 Safety Safety Safety Alert Symbol This Safety Alert Symbol Figure 2 is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents This symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Figure 2 1 Safety alert symbol The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER WARNING or CAUTION DANGER White lettering Red background Indicates an imminently hazardous situation which if not avoided Will result in death or serious injury WARNING Black lettering Orange background Indicates a potentially hazardous situation which if not avoided Could
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6. Unscrew filter to remove and allow oil to drain from reservoir Important Before reinstalling new filter fill it with Exmark Premium Hydro oil and apply a thin coat of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten the filter an additional 2 3 to 3 4 turn Fill reservoir as stated in Check Hydraulic Oil Level section Exmark Premium Hydro Oil is recommended Refer to the chart for an acceptable alternative Hydro Oil Change Interval Exmark Premium Hydro 500 Hours Oil Preferred Mobil 1 15W50 250 Hours Raise the rear of machine up and support with jack stands or equivalent support just high enough to allow drive wheels to turn freely Start engine and move throttle control ahead to full throttle position Move the speed control levers to the full speed and run for several minutes Shut down machine and recheck oil level Note Do Not change hydraulic system oil except for what can be drained when changing filter unless it is felt the oil has been contaminated or been extremely hot Changing oil unnecessarily could damage hydraulic system by introducing contaminates into the system Check Wheel Hub Locknuts Service Interval After the first 100 hours Every 500 hours thereafter Torque to 210 250 ft Ib 285 339 N m Check Wheel Lug Nuts Service Interval After the first 100 hours Every 500 hours thereafter Torque t
7. 13 Specifications Specifications Model Numbers Serial Nos 850 000 and Higher NAV20KC NAV27KC Systems Engine Engine Specifications See your Engine Owner s Manual RPM Full Speed 3600 50 RPM No Load Idle 1500 RPM Fuel System Capacity 7 5 gal 28 L Type of Fuel Regular unleaded gasoline 87 octane or higher containing no more than 10 methanol or ethanol Fuel Filter In line 30 Micron Kohler P N 2405010 Fuel Shut Off Valve 1 4 turn increments in line valve by fuel filter Electrical System Charging System Flywheel Alternator Charging Capacity 15 amps Battery Type BCI Group U1 Battery Voltage 12 Volt Polarity Negative Ground Fuses Two 20 amp and one 30 amp blade type Safety Interlock System PTO must be disengaged brake engaged and speed control lever in neutral position to start engine It is not necessary for the operator to be in the seat to start the engine Operator must be in seat when PTO is engaged brake is disengaged or speed control lever is moved out of neutral or engine will stop Engine will stop in the following conditions If the speed control lever is moved from neutral position while brake is engaged Ifthe PTO is engaged while the hopper is tilted up Operator Controls Steering and Motion Control Speed Control lever located on RH console sets maximum forward speed Steering levers centered in front of the sea
8. control lever in the neutral position starter must not crank Try to start with operator in seat parking brake engaged PTO disengaged and the speed control lever forward out of neutral starter must not crank Check the kill circuits Run engine at one third throttle disengage parking brake and raise off of seat but do not get off of machine engine must initiate shutdown after approximately 1 2 second has elapsed seat has time delay kill switch to prevent cut outs on rough terrain Run engine at one third throttle engage PTO and raise offof seat but do not get off of machine engine must initiate shutdown after 1 2 second has elapsed Note If machine does not pass any of these tests do not operate Contact your authorized EXMARK SERVICE DEALER Important It is essential that operator safety mechanisms be connected and in proper operating condition prior to use for mowing Check for Loose Hardware Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Visually inspect machine for any loose hardware ot any other possible problem Tighten hardware ot correct the problem before operating Service Air Cleaner Service Interval Every 50 hours Service the air cleaner May need more often under severe conditions See the Engine Owner s Manual for additional information 1 Stop engine wait for all moving parts to stop and
9. cracked frozen has low electrolyte level or an open shorted battery cell can cause an explosion resulting in serious personal injury Do Not jump start a weak battery if these conditions exist 2 Make sure the booster is a good and fully charged lead acid battery at 12 6 volts or greater Use properly sized jumper cables 4 to 6 AWG with short lengths to reduce voltage drop between systems Make sure the cables are color coded or labeled for the correct polarity A CAUTION Connecting the jumper cables incorrectly wrong polarity can immediately damage the electrical system Be certain of battery terminal polarity and jumper cable polarity when hooking up batteries Note The following instructions are adapted from the SAE J1494 Rev Dec 2001 Battery Booster Cables Surface Vehicle Recommended Practice SAE Society of Automotive Engineers WARNING Batteries contain acid and produce explosive gases Shield the eyes and face from the batteries at all times Do Notlean over the batteries Note Be sure the vent caps are tight and level Place a damp cloth if available over any vent caps on both batteries Be sure the vehicles do not touch and that both electrical systems are off and at the same rated system voltage These instructions are for negative ground systems only 3 Connect the positive cable to the positive terminal of the discharged battery that is wired t
10. filter apply a thin coating of oil on the surface of the rubber seal Turn filter clockwise until rubber seal contacts the filter adapter then tighten filter an additional 1 2 to 3 4 turn 25 Maintenance 6 Clean around oil fill cap and remove cap Fill to specified capacity and replace cap 7 Remove drain hose close fuel tank and lower hopper 8 Use oil recommended in engine owner s manual Do Not overfill Start the engine and check for leaks 9 Wipe up any spilled oil from engine deck mounting surfaces Check Hydraulic Oil Level Service Interval Every 40 hours A WARNING Oil spilled vented from an overfilled hydraulic reservoir onto the PTO brake band will cause a longer stopping time for the deck and blower rotating components The deck and blower rotating components can cause serious injury Wait for all moving parts to come to a complete stop before servicing Do Not overfill the hydraulic reservoir Carefully fill only to the recommended level Replace the brake band if it becomes contaminated with oil 1 Stop engine and wait for all moving parts to stop Engage parking brake 2 Tilt hopper up Clean area around hydraulic reservoir cap and remove cap Oil level should be to the top of the baffle inside the tank If not add oil Use only Exmark Premium Hydro oil Replace hydraulic reservoir cap and tighten until snug Do Not overtighten Do Not overfill Note The baffle
11. for a minimum of 15 seconds then turn the ignition switch to the OFF position to stop the engine Remove the key to prevent children or other unauthorized persons from starting engine Close the fuel shut off valve when the machine will not be in use for a few days when transporting or when the unit is parked inside a building Driving the Machine A CAUTION Machine can spin very rapidly by positioning one lever too much ahead of the other Operator may lose control of the machine which may cause damage to the machine or injury e Use caution when making turns Slow the machine down before making sharp turns Important To begin movement forward or backward the operator must be in the seat the brake lever must be disengaged pushed down before the speed control lever can be moved forward or the engine will stop Driving Forward 1 Start the engine 2 3 Release the parking brake To move forward in a straight line move the speed control lever forward 19 Operation To turn left or right pull one of the steering levers back toward neutral in the direction desired The machine will move faster the farther the speed control lever is moved away from neutral To stop pull the speed control lever back to the neutral position Driving in Reverse 1 To move rearward in a straight line applying equal pressure pull both steering levers rearward To turn left or right release p
12. m loosen then re torque to 20 25 in lb 2 3 N m Make sure axle does not extend beyond either nut 13 14 Reinstall the seal guards over the wheel hub and insert wheel into caster fork Reinstall caster bolt and tighten nut fully Important To prevent seal and bearing damage check the bearing adjustment often Spin the caster tire The tire should not spin freely more than 1 or 2 revolutions or have any side play If the wheel spins freely adjust torque on spacer nut until there is a slight amount of drag Reapply thread locking adhesive Lubricate Brake Handle Pivot Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Lubricate bronze bushings on brake handle pivot with a spray type lubricant or light oil see Figure 8 9006835 Figure 8 Left Side of Unit Shown 1 Brake Handle Pivot 2 PTO Handle Pivot 3 Spring Arm Pivot 4 Toggle Pivot Lubricate Brake Rod Bushings Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Unhook seat latch and tilt seat up Lubricate bronze bushings on each end of brake rod shaft with a spray type lubricant or a light oil bushings are located to the inside of the flange bearings Lubricate Steering Linkage Rod Ends Service Interval Every 160 hours 1 Stop engine wait for all moving parts to stop
13. or truck do not exceed 15 A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck Steeper angles may also cause the unit to tip If loading on near a slope position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope This will minimize the ramp angle The trailer or truck should be as level as possible Important Do Not attempt to turn the unit while on the ramp you may lose control and drive off the side Avoid sudden acceleration when driving on a ramp 21 Maintenance Maintenance Note Determine the left and right sides of the machine from the normal operating position A WARNING A WARNING While maintenance or adjustments are being The engine can become very hot Touching made someone could start the Accidental starting of the engin seriously injure you ot other bystanders engine a hot engine can cause severe burns e could Allow the engine to cool completely before service or making repairs around the engine Remove the key from the ignition switch area engage parking brake and pull the wire s off the spark plug s before you do any maintenance Also push the wire s aside so it does not accidentally contact the spark plug s Recommended Maintenance Schedule s Maintenance Service Maintenance Procedure Interval After the first 5 hours Change the engine oil Aft
14. remove key Engage parking brake Tilt hopper up to gain access to the air cleaner Loosen retaining clips and remove air cleaner compartment cover Remove paper element Check the condition of the paper element Replace if dirty bent or damaged Check the condition of the inner element Replace whenever it appears dirty typically every other time the paper element is replaced Clean the base around the inner element before removing so dirt does not get into the engine Do Not wash or use pressurized air to clean paper element or inner element Reinstall elements Position the cover so that the rubber dust ejector is pointing downward and secure with retaining clips Change Engine Oil Service Interval After the first 5 hours Every 100 hours May need more often under severe conditions 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Drain oil while engine is warm from operation Tilt hopper up to gain access to the engine area The oil drain valve is located on right hand side of engine at the back of the unit Remove two nuts near right hand drive tire and swing out the fuel tank Install oil drain hose supplied in the literature pack onto oil drain valve Place pan under machine to catch oil Open valve to allow oil to drain and then close valve Replace the oil filter every other oil change Clean around oil filter and unscrew filter to remove Before reinstalling new
15. with the following safety signs and instruction labels They are critical to the safe operation of your Exmark commercial mower WARNING PINCH POINT Can cause serious injury Keep hands clear of door hinge bars and door frame with the door open 103 8444 103 8444 5 65 2690 AWARNING 98 4361 SPEED CONTROL e t IGNITION 103 8451 OFF 103 8451 A DANGER COVER IS MISSING DO NOT OPERATE 385354 THIS UNIT WHEN COVER IS NOT IN PLACE 98 5954 Only use handles to lift and lower hopper Keep hands out from under hopper 103 8495 103 8495 ROTATING DRIVELINE Can cause serious injury or death ET PAL Keep all driveline shields in place Securely attach both ends of the driveline 103 8425 103 8425 START RELAY RELAY RELAY 103 8611 103 8611 11 Safety WHEN ENGAGED IDLER ARM POSITION MUST BE IN AREA OR ADJUSTMENT IS REQUIRED READ OPERATOR S MANUAL FOR ADJUSTMENT PROCEDURE 103 9034 103 9034 PTO DRIVE BELT ROUTING BELT 103 6737 BELT 103 4244 103 9274 103 9724 DRIVE WHEEL RELEASE One turn counterclockwise to release Do not over tighten 109 4273 109 4273 109 4638 109 4638 DANGER ROTATING BLADES Can cause serious injury or death Disenga
16. 0000000001 Yearly Lubricate grease fittings Lubricate the caster wheel hubs Periodic Maintenance Check Engine Oil Level Service Interval Before each use or daily 1 Stop engine and wait for all moving parts to stop Make sure unit is on a level surface 2 Check with engine cold 3 Raise hopper Clean area around dipstick Remove dipstick and wipe oil off Reinsert the dipstick and push it all the way down into the tube Remove the dipstick and read the oil level 5 If the oil level is low wipe off the area around the oil fill cap remove cap and fill to the FULL mark on the dipstick Use oil as specified in Engine Owner s Manual Do Not overfill Important Do Not operate the engine with the oil level below the LOW or ADD mark on the dipstick or over the FULL mark Check Battery Charge Service Interval Monthly AWARNING CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling Allowing batteries to stand for an extended period of time without recharging them will result in reduced performance and service life To preserve optimum battery performance and life recharge batteries in storage when the open circuit voltage drops to 12 4 volts Note To prevent damage due to freezing battery s
17. 22 Recommended Maintenance Schedule s 22 Periodic Maintenance uoo ee eg e EET 23 Check Engine Oil Level uio ote 23 Check Battery do Pado eus 23 Check Safety Interlock System 24 Check for Loose Hardware 002204 141 25 Service Air Cleaner 25 Change Bo neh oes 25 Check Hydraulic Oil Level 26 Check Hire 26 Check Condition Of Belts san tao nadia gens 26 Lubricate Grease uet tcp 26 Lubricate Rear Caster Wheel Hubs 27 Lubricate Brake Handle Pivot 28 Lubricate Brake Rod Bushings 28 Lubricate Steering Linkage Rod Ends 28 Lubricate Hopper oun aen 28 Gheck Spark PIugs se 28 Change Hydraulic System Filter 29 Check Wheel Hub Locknuts 29 Cheek Wheel Lug Nuts ovas bep eios 29 Thread Locking Adhesives 29 ere rivis dedi sets 30 Xd USHERS au ek eae 30 PTO Drive Belt Tension ouo eterne 30 Pump Drive Belt Tensi n cete terne 30 PTO Belt Replacerehibo 30 Pump Drive Belt Replacement 31 Belt Guide Adjustimietit e iato ttes itas 31 Adjust Safety Switch i oon ie o ted ts 32 Brake 92 Adjust Speed Control Lever Tension 32 Speed Control Linkage Adjustment
18. Dealer Fill the fuel tank Open the fuel shutoff valve Add oil to the crankcase Be sure the throttle control is midway between the SLOW and FAST positions and the choke is in the ON position for a cold engine or the OFF position for a warm engine Replace the fuel filter Contact an Authorized Service Dealer Clean or replace the air cleaner element Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Contact an Authorized Service Dealer Clean adjust or replace spark plug Check the spark plug wire connection Reduce the ground speed Clean or replace the air cleaner element Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Clean or replace the fuel cap Replace the fuel filter Contact an Authorized Service Dealer Troubleshooting Engine overheats Mower pulls left or right with levers fully forward Machine does not drive Abnormal vibration Engine load is excessive Oil level in the crankcase is low Cooling fins and ait passages for the engine are plugged Tracking needs adjustment Tire pressure in drive tires not correct Reverse indicator and speed control linkage need adjustment Bypass valve is not closed tight Drive or pump belt is worn loose or broken Drive or pump belt is off a
19. ID MOUNT RIDING ACCESSORIES AND OPTIONS CUSTOM RIDE SEAT SUSPENSION SYSTEM OPERATOR CONTROLLED DISCHARGE FULL SUSPENSION SEAT ROLL OVER PROTECTION SYSTEM ROPS DECK LIFT ASSIST KIT SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT TURF STRIPER 12V POWER PORT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM CUSTOM RIDE SEAT SUSPENSION SYSTEM SNOW BLADE DUAL TAIL WHEEL SNOWBLOWER FLOOR PAN EXTENDER SUN SHADE HITCH KIT TRASH CONTAINER LIGHT KIT ULTRA VAC COLLECTION SYSTEM MICRO MULCH SYSTEM ULTRA VAC QUICK DISPOSAL SYSTEM ROLL OVER PROTECTION SYSTEM ROPS WEATHER CAB GRASS CATCHER TURF STRIPER MICRO MULCH SYSTEM STANDON Place Model No and Serial No Label Here Included in the Literature Pack or Fill in Below Date Purchased Engine Model No and Spec No Model No Engine Serial No E No Serial No 2010 Exmark Mfg Co Inc Part No 4500 628 Rev B Industrial Park Box 808 402 223 6300 Cle Beatrice NE 68310 Fax 402 223 5489 All Rights Reserved Printed in the USA www exmark com
20. NAVIGATOR E E 2 5 a o For Serial Nos 850 000 amp Higher Part No 4500 628 Rev B AWARNING CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancet birth defects or other reproductive harm Important The engine in this product is not equipped with a spark arrester muffler It is a violation of California Public Resource Code CPRC Section 4442 to use operate this engine on any forest covered brush covered or grass covered land as defined in CPRC 4126 Other states or federal areas may have similar laws This spark ignition system complies with Canadian ICES 002 Ce syst me d allumage par tincelle de v hicule est conforme la norme NMB 002 du Canada The enclosed Engine Owner s Manual is supplied for information regarding The U S Environmental Protection Agency EPA and the California Emission Control Regulation of emission systems maintenance and warranty Keep this engine Owner s Manual with your unit Should this engine Owner s Manual become damaged or illegible replace immediately Replacements may be ordered through the engine manufacturet Exmatk reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously Exmark or its distributors and dealers accept no respon
21. NO9 S38M mx O amo os 931915 391615 YOVIBIONYHO E 3900 Mae dM dq o ch eee 1 pes we 38 o 38 t MOTA esa HOLIMS 1 90 o i asna d divo T 13 N a 5 1 9 19913 1 div 02 ru is 1 be oly Atx 1 _ 13104 3X VIA LINDHID NOILISOd 3505 39Nv80 X WNIWHSL E E E E HOLIM 55 g i 8 pet 22338 E 3 RR 1 8 1 pur 84 337209 T S 1 HOLINS 775 sq 508 aNnouwd HOLIMS S 155 5 pe 3080 NNOG H34dOH anaon Av taa 35 an WS NI AV3Hd3A0 3014340 ANIONS Orid ANOSSIIOV 41 Schematics Hydraulic Diagram BYPASS VALVE BYPASS VALVE HIGH PRESSURE REVERSE HIGH PRESSURE FORWARD HIGH PRESSURE FORWARD HIGH PRESSURE REVERSE 6006950 HIGH PRESSURE CHARGE PUMP CASE DRAIN 42 Exmark Commercial Turf Equipment 2 Year Limited Warranty 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 wil
22. and remove key Engage parking brake Unhook seat latch and tilt seat up Lubricate each end of both steering linkage rods with a spray lubricant or a light oil Lubricate Hopper Actuator Service Interval Every 160 hours Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Raise hopper and locate actuator on right hand side of mainframe 3 Lubricate switch actuator rod with a spray lubricant a light oil Check Spark Plugs Service Interval Every 160 hours Remove spark plugs check condition and reset gaps replace with new plugs See Engine Owner s Manual Change Fuel Filter Service Interval As required fuel filter is installed between the fuel tank and the engine Replace when necessaty Replacement Filters Kohler Kohler P N 2405010 28 Maintenance Change Hydraulic System Filter Service Interval After the first 250 hours Every 500 hours Yearly whichever comes first thereafter Every 250 hours Yearly if using Mobil 1 15W50 Note Use only Exmark Part No 109 0071 for Summer use above 32 F 0 C or P N 1 523541 for Winter use below 32 F 0 C Refer to the Hydrostatic Ground Drive System section in Specifications for filter specifications 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Carefully clean area around filter It is important that no dirt or contamination enter hydraulic system
23. arter does not crank Engine will not start starts hard or fails to keep running Engine loses power PTO is engaged Parking brake is not set Speed control lever is not in neutral position Battery does not have a full charge Electrical connections are corroded loose faulty Fuse is blown Relay or switch is defective Fuel tank is empty Fuel shutoff valve is closed Oil level in the crankcase is low The throttle and choke ate not in the correct position Dirt in fuel filter Dirt watet or stale fuel is in the fuel system Air cleaner is dirty Electrical connections ate corroded loose faulty Relay or switch is defective Faulty spark plug Spark plug wire is not connected Engine load is excessive Air cleaner is dirty Oil level in the crankcase is low Cooling fins and ait passages for the engine are plugged Vent hole in the fuel cap is plugged Dirt in fuel filter Dirt water or stale fuel is in the fuel system 38 Disengage the PTO Set the parking brake Ensure the speed control lever is in the neutral position Charge the battery See Check Battery Charge and Recommended Jump Starting Procedure sections in Maintenance Check the electrical connections for good contact Clean connector terminals thoroughly with electrical contact cleaner apply dielectric grease and reconnect Replace the blown fuse Contact an Authorized Service
24. bypass da Winter use below 32 F 0 C Pull floating deck is attached to out front support frame Deck design allows for bagging or P N 1 523541 40 microns 18 psi bypass mulching Speeds Deck Depth 0 7 0 mph 11 3 km hr forward 42 inch Deck 4 5 8 inches 11 7 cm 0 5 5 mph 8 6 km hr reverse e Drive wheel release valves allow machine to be moved when engine is not running 48 inch Deck 4 5 8 inches 11 7 cm Dimensions Tires amp Wheels Drive Front Rear Caster Caster Pneumatic Semi Semi 42 6 inches 43 2 inches 49 2 inches Air Filled Pneumatic Pneumatic 108 2 cm 109 7 cm 125 0 cm Qmd e p F C S Size 182 8 x 3 00 4 13 x 8 00 6 Without Deck 42 inch Deck 48 inch Deck pes 10 50 10 67 3 inches 91 8 inches 94 5 inches Ply Rating qp o o _ 170 9 cm 233 2 cm 240 0 cm kPa Overall Height Sold separately 130 0 cm 130 0 cm 130 0 cm Model Numbers CD42CD Tread Width Center to Center of CD48CD Tires Widthwise 42 inch Deck 42 inch 106 7 cm 48 inch Deck 48 inch 121 9 cm PUN Coo Discharge Center Wheel Base Center of Drive Wheel w 42 inch Deck 22 00 inches 55 9 cm to Center of Rear Caster Wheel w 48 inch Deck 25 00 inches 63 5 cm Decks meh Deck c D ck Dave 44 2 inches 112 3 cm 44 2 inches 112 3 cm Overall Width Without Deck 42 inch Deck 48 inch Deck
25. c acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns e Wear safety glasses to shield eyes and rubber gloves to protect skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately Federal law states that batteries should not be placed in the garbage Management and disposal practices must be within relevant federal state or local laws If a battery is being replaced or if the unit containing the battery is no longer operating and is being scrapped take the battery to a local certified recycling center If no local recycling is available return the battery to any certified battery reseller 37 Troubleshooting Troubleshooting Important It is essential that all operator safety mechanisms be connected and in proper operating condition prior to mower use When a problem occurs do not overlook the simple causes For example starting problems could be caused by an empty fuel tank The following table lists some of the common causes of trouble Do Not attempt to service or replace major items or any items that call for special timing or adjustments procedures such as valves governor etc Have this work done by your Engine Service Dealer Note When disconnecting electrical connectors Do Not pull on the wires to separate the connectors St
26. ch 0 8 1 6 mm 10 11 12 13 Tighten the four engine mounting bolts and four jackshaft mounting bolts Check alignment after tightening Re install pump belt tension spring Swing fuel tank in and re install tank mounting nuts Complete the Pump Drive Pulley Alignment section Pump Drive Pulley Alignment Pump drive pulley alignment is necessary for any of the following conditions The engine mounting bolts have been loosened or the engine has been moved or replaced The pump pulleys have been loosened moved or replaced The PTO pulley alignment has been performed see PTO Drive Pulley Alignment section Stop engine wait for all moving parts to stop and remove key Engage parking brake Loosen set screws on both pump pulleys Using a straight edge align each pump pulley with the engine pulley by sliding along the pump shaft see Figure 21 Re tighten pulley set screws and recheck alignment Maintenance Rear Caster Pivot Bearings Pre Load Adjustment Remove dust cap from caster and tighten nyloc nut until washers are flat Back off 1 4 of a turn to properly set the pre load on the bearings If disassembled make sure the spring disc washers are reinstalled as shown in Figure 22 Figure 22 1 Spring disc washers Hopper Door Adjustment Door Closing Loosen six door hinge nuts see Figure 23 Open door and place a 3 8 inch rubber strip or 3 8 inch diame
27. drain the machine indoors inside an enclosed trailer Do Not fill the fuel tank completely full Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system if equipped Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by spark Store gasoline in an approved container and keep it out of the reach of children Add fuel before starting the engine Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot If fuel is spilled Do Not attempt to start the engine Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated Do Not operate without entire exhaust system in place and in proper working condition Always place gasoline containers on the ground away from your vehicle before filling Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gas
28. e Slopes drop offs or water CALIFORNIA SPARK ARRESTER WARNING Operation of this equipment may create sparks that can start fires around dry vegetation A spark arrester may be required The operator should contact local fire agencies for laws or regulations relating to fire prevention requirements 4172715 To avoid serious injury or death 117 2718 Avoid blades unless engine and blades are stopped A WARNING 09 avoid serious injury or death Read and understand the operator s manual before using this machine PARK Do NOT operate unless trained to PTO BRAKE safely use this machine Pick up objects that could be thrown by the blades Do NOT mow when people and pets are in the area Do NOT carry passengers NOT operate under the influence lt of alcohol or drugs Do NOT operate without shields guards and safety devices in place Molded in LH Console and working Look behind and to the side before changing directions Before leaving operator s position Disengage PTO Move speed control lever to neutral position Engage park brake Stop engine Check the function of the operator presence controls OPC safety system daily Do NOT defeat the OPC system Stop engine and remove key before adjusting servicing or cleaning machine and attachments Hearing protection is recommended Molded into Front of Hopper
29. e brake lever up and back to the engaged 1 Brake Leveripandaged position position 2 A gap must exist between the bottom of the brake 2 Remove clevis pin 4 Loosen nut here bolt head and the top surface of the brake swivel as shown in Figure 14 If a gap does not exist 4 If individual adjustment is necessary loosen the adjust the linkage to a maximum gap of 1 2 inch jam nut on the brake bolt that is against the clevis 1 8i h 1 8 inch 1 3 0 33 cm as shown connected to the brake arm on the wheel motot Turn the brake bolt to achieve proper adjustment 5 Tighten the jam nut against the clevis Repeat for other side of unit Engage and disengage the brakes to check for proper engagement and disengagement Readjust if necessary When the brakes are disengaged there should be free play in the brake linkage with no dragging in the brakes Adjust Speed Control Lever Tension p 1 Stop engine wait for all moving parts to stop and Figure 14 remove key Engage parking brake 2 Tension speed control lever can be adjusted 1 Brake Leverinengaged 4 Brake Bolt by adjusting the tightness of the lever pivot bolt E dene E pom which is located under the seat neat the speed Loosen nut here Brake Swive 3 1 2 inch amp 1 8 inch 1 3 control lever see Figure 16 cm 0 33 cm 3 Setthe tension high enough that the speed control lever position is maintained during
30. e choke in the OFF position DO NOT run a warm engine with choke in the ON position Throttle Control Located on right hand console The throttle is used to control engine speed Moving throttle lever forward will increase engine speed and moving throttle lever to the rear will decrease engine speed Brake Lever Located on left side of unit between the seat and console The brake lever engages a parking brake on the drive wheels Pull the lever up and rearward to engage the brake Push the lever forward and down to disengage the brake The unit must be tied down and brake engaged when transporting Ignition Switch Located on the right hand console The ignition switch is used to start and stop the engine The switch has three positions OFF ON and START Insert key into switch and rotate clockwise to the ON position Rotate clockwise to the next position to engage the starter key must be held against spring pressure in this position Note Brake must be engaged speed control lever rearward neutral position and PTO disengaged to start engine It is not necessary for the operator to be in the seat to start the engine Hour Meter Located on the right hand console The hour meter is connected to a pressure switch installed in the engine block and it records the number of hours that the engine has run If the ignition switch is left on without engine running hour meter w
31. elt Replacement sections for belt replacement Lubricate Grease Fittings Note See chart for service intervals 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Lubricate fittings with one to two pumps of NGLI grade 2 multi purpose gun grease Refer to the Lubrication Chart for fitting locations and lubrication schedule 26 Maintenance Lubrication Chart 1 Stop engine wait for all moving parts to stop and Fitting Initial Number of Service Locations Pumps Places Interval 1 Caster 0 3 Yearly Pivot remove key Engage parking brake 2 PTO 1 1 Yearly Idler 3 Pump 1 1 Yearly Idler 4 Rear 0 1 Yearly Caster Hub 6006115 Figure 7 See step 3 for special lubrication instructions on 1 Seal guard 2 Spacer nut with wrench the front and rear caster pivots and the Lubricate flats Rear Caster Wheel Hubs section for special lubrication instructions on the rear caster wheel 5 Remove castet whe l caster forks hubs 3 Remove seal guards from the wheel hub 4 Remove one of the spacer nuts from the axle assembly in the caster wheel Note that thread locking adhesive has been applied to lock the spacer nuts to the axle Remove the axle with the other spacer nut still assembled to it from Hr the wheel assembly L 5 Pry out seals and inspect bearings for wear or damage and replace if necessary
32. ent 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 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 43 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 T
33. er allow untrained personnel to service machine Use jack stands to support components when required e Carefully release pressure from components with stored energy Disconnect battery or remove spark plug wire before making any repairs Disconnect the negative terminal first and the positive last Reconnect positive first and negative last Use care when checking blades Wrap the blade s or wear gloves and use caution when servicing them Only replace damaged blades Never straighten or weld them Keep hands and feet away from moving parts If possible do not make adjustments with the engine running Charge batteries in an open well ventilated area away from spark and flames Unplug charger before connecting or disconnecting from battery Wear protective clothing and use insulated tools DANGER Charging or jump starting the battery may produce explosive gases Battery gases can explode causing serious injury Keep sparks flames or cigarettes away from battery Ventilate when charging or using battery in an enclosed space Make sure venting path of battery is always open once battery is filled with acid Always shield eyes and face from battery DANGER Battery electrolyte contains sulfuric acid which is poisonous and can cause severe burns Swallowing electrolyte can be fatal or if it touches skin can cause severe burns e Wear safety glasses to shield eyes and rubber gloves to protect
34. er the first 100 hours bo k the wheel hub locknuts torque specification k the wheel lug nut torque specification ec After the first 250 hours Change the hydraulic filter ec n 81 the engine oil level k the safety interlock system Before each use or daily hec k for loose hardware emove accumulated debris from engine see Cleaning section ean the grass and debris build up from the machine heck the hydraulic oil level Every 40 hours heck the tire pressures heck the condition of the belts Service the air cleaner May need more often under severe conditions See the Engine Every 50 hours d Md Owner s Manual for additional information Every 80 hours Remove engine shrouds and clean cooling fins see Cleaning section Every 100 hours Change the engine oil May need more often under severe conditions Lubricate the brake handle pivot Lubricate the brake rod bushings Every 160 hours Lubricate the steering linkage rod ends Lubricate hopper actuator Check the spark plugs Chan ge the hydraulic filter Every 250 hours yearly if using Mobil 1 15W50 Every 500 hours Check the wheel hub locknuts torque specification Check the wheel lug nut torque specification 22 Maintenance Maintenance Service Maintenance Procedure Interval Monthly o Check the battery charge 000000000001 the battery Check the battery charge 00
35. 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 G4500 589 B Notes 44 Service Record Date Description of Work Done Service Done By 45 NEW EXMARK PREMIUM HYDRO OIL BENEFITS Designed amp manufactured with superior anti wear protection Superior thermal stability Consistent hydro performance Superior shear resistance under heavy loads Field tested amp proven performance Twice the shear stability of SPECIALLY FORMULATED amp competing oils MANUFACTURED FOR SUPERIOR P CR CORMANCE IN ALL EXMARK Enhanced control performance DRAULIC DRIVE SYSTEMS Specially formulated for any 1 US Quart 946 ML 32 FL oz Exmark hydraulic system NOW AVAILABLE FOR PURCHASE Part No 109 9828 46 G011841 Figure 25 This page may be copied for personal use 1 The maximum slope you can safely operate the machine on is 15 degrees Use the slope indicator to determine the degree of slope of hills before operating Do Not operate this machine on a slope greater than 15 degrees Fold along the appropriate line to match the recommended slope 2 Align this edge with a vertical surface a tree building fence pole etc 3 Example of how to compare slope with folded edge 47 EXMARK S COMPLETE LINE OF ACCESSORIES AND OPTIONS M
36. g the PTO A DANGER The rotating blades under the mower deck ate dangerous Blade contact can cause serious injury or kill you Do Not put hands or feet under the mower or mower deck when the blades are engaged A DANGER An uncovered discharge opening will allow objects to be thrown in an operator s or bystander s direction Also contact with the blower blades could occur Thrown objects or blade contact can cause serious injury or death Never operate the mower with the hopper or hopper door raised removed or altered unless there is a mulch kit in place and working properly The PTO lever engages the PTO and blower Be sure that the hopper is down the hopper door is securely closed and all persons are clear of the mower deck and discharge area before engaging PTO Important Operator must be in seat before the PTO can be engaged 1 Set the throttle to the MIDWAY position 2 Pull the PTO lever upward until locked over center Place the throttle in the FAST position to begin mowing Disengaging the PTO 1 Set the throttle to the MIDWAY position 2 Push PTO lever down to the STOP position stopping the PTO and blower Stopping the Engine 1 Bring the unit to a full stop 2 Disengage the PTO 3 Move speed control lever to the neutral position 4 Engage the parking brake 5 Place the throttle midway between the SLOW and FAST positions Allow the engine to run
37. ge PTO stop engine engage parking brake remove key WAIT FOR ALL MOVING PARTS TO STOP before reaching into discharge chute opening Do not operate mower with 109 7318 hopper raised 109 7318 ONLY USE EXMARK HYDRO OIL FILL TO TOP OF BAFFLE CAUTION 77 116 0404 116 0404 Safety SERVICE AID 10 Every 8 hours 1 Check engine oil 2 Grease front caster wheel bearings Every 40 hours 3 Check hydraulic oil Only use recommended hydro oil 4 Check tire pressure 15 psi 5 Grease deck drive PTO 6 Check air cleaner Greater than 15 Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges can cause rollovers which may result in serious injury death or drowning To avoid loss of control and possibility of rollover Do NOT operate near drop offs or near water Do NOT operate on slopes greater than 15 Reduce speed and use extreme 116 1175 caution on slopes Avoid sudden turns or rapid speed changes Every 100 hours 7 Grease deck lock mechanism 8 Grease deck pivots 9 Check gearbox oil Use only Mobil 1 75W 90 gear oil Yearly 10 Grease front caster pivots 11 Grease rear caster pivot 12 Grease rear caster wheel bearings 13 Grease belt idlers See operator s manual for additional details 116 1175 e A rollbar is available and its use is recommended for areas where there ar
38. he 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
39. hould be fully charged before putting away for winter storage Check the voltage of the battery with a digital voltmeter Locate the voltage reading of the battery in the table and charge the battery for the recommended time interval to bring the charge up to a full charge of 12 6 volts or greater Important Make sure the negative battery cables are disconnected and the battery charger used for charging the battery has an output of 16 volts and 7 amps or less to avoid damaging the battery see chart for recommended charger settings Voltage Reading Maximum Charging Charger Settings 16 volts 7 amps 12 8 12 6 75 100 16 volts 7 30 Minutes amps 12 6 greater 100 12 2 12 4 50 75 16 volts 7 1 Hour amps 12 0 12 2 25 50 14 4 volts 4 2 Hours amps 11 7 12 0 0 25 14 4 volts 4 3 Hours amps 11 7 or less 0 14 4 volts 2 6 Hours or amps More Recommended Jump Starting Procedure Service Interval As required 1 Check the weak battery for terminal corrosion white green or blue snow it must be cleaned off prior to jump starting Clean and tighten connections as necessary Maintenance A CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at anytime during the jump starting procedure Do Not attempt to jump start with loose or corroded battery terminals or damage to the engine may occur A DANGER Jump starting a weak battery that is
40. ill not run Note This switch is not a low oil sensor and will not alert the operator if the engine oil is low Fuel Shut Off Valve Located in fuel line by fuel tank and fuel filter accessible by raising the hopper The fuel shut off valve is used to shut off the fuel when the machine will not be used for a few days during transport to and from the jobsite and when parked inside a building Rotate the valve 1 4 turn clockwise to shut off the fuel rotate the valve 1 4 turn counterclockwise to turn on the fuel 17 Operation Drive Wheel Release Valves Located on the top left front corner of hydrostatic pumps Drive wheel release valves are used to release the hydrostatic drive system to allow the machine to be pushed without the engine running Tilt seat up to gain access to pumps With a 7 16 wrench turn both valves one turn counterclockwise to release drive system Turn clockwise to reset system Do Not overtighten Do Not tow machine Tracking Adjustment Knob Located under the seat on the left pump control link Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position Run unit at 3 4 speed for at least 5 minutes to bring hydraulic oil up to operating temperature Stop machine and wait for all moving parts to stop Engage park brake Tilt seat forward to gain access to the tracking knob Rotate the knob towards the right t
41. is labeled HOT and COLD The oil level varies with the temperature of the oil The HOT level shows the level of oil when it is at 225 F 107 C The COLD level shows the level of the oil when it is at 75 F 24 Fill to the appropriate level depending upon the temperature of the oil For example If the oil is about 150 F 65 C fill to halfway between the HOT and COLD levels If the oil is at room temperature about 75 F 24 C only to the COLD level Do Not overfill Check Tire Pressures Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Check tire pressure in drive tires Inflate drive tires to 15 psi 103 kPa 4 The rear caster tite is semi pneumatic and does not need to be inflated Note Do Not add any type of tire liner or foam fill material to the tires Excessive loads created by foam filled tires may cause failures to the hydro drive system frame and other components Foam filling tires will void the warranty Check Condition Of Belts Service Interval Every 40 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Tilt hopper up and check pump and PTO drive belts for wear cracking or contamination 3 Belts are spring tensioned and no adjustment is necessary unless belts are replaced See PTO Belt Replacement and Pump Drive B
42. king and steering Always avoid sudden starting or stopping on a slope If tires lose traction disengage the blades and proceed slowly off the slope Follow the manufacturer s recommendations for wheel weights or counter weights to improve stability Use extreme cate with attachments These can change the stability of the machine and cause loss of control Note A 2 post foldable ROPS Rollover Protection System is available for the Navigator as an accessory ROPS is recommended if you will be mowing next to drop offs near water or on steep banks which could result in a rollover The model number for the ROPS attachment is FRPSNAV Contact an Authorized Exmark Service Dealer for more details Maintenance and Storage Disengage drives lower implement set parking brake stop engine and remove key or disconnect spark plug wire Wait for all movement to stop before adjusting cleaning or repairing Keep engine engine area and pump drive belt compartment free from accumulation of grass leaves excessive grease or oil and other debris which can accumulate in these areas These materials can become combustible and may result in a fire Let engine cool before storing and do not store near flame or any enclosed area where open pilot lights or heat appliances are present Shut off fuel while storing or transporting Do Not store fuel near flames or drain indoors e Park machine on level ground Nev
43. l 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 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 equipm
44. nging directions Stop the blades slow down and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to cw be mowed Beawate of the mower discharge path and direct discharge away from others 3 SO SN Do Not operate the mower under the influence SS of alcohol or drugs Use extreme care when loading or unloading the machine into a trailer or truck 6006832 Figure 3 Use care when approaching blind corners shrubs oa 1 Safe Zone Use the mower here on slopes less than 15 trees ot other objects that may obscure vision P degrees 2 Danger Zone Use a walk behind mower and or hand trimmer on slopes greater than 15 degrees near Slope Operation drop offs and water Use Extreme caution when mowing and or turning a ENNIS on slopes as loss of traction and or tip over could occur The operator is responsible for safe operation Remove or mark obstacles such as rocks tree on slopes limbs etc from the mowing area Tall grass can hide obstacles e Watch for ditches holes rocks dips and rises that change the operating angle as rough terrain could overturn the machine Safety Avoid sudden starts when mowing downhill Mower may tip forwards Beaware that operating on wet grass actoss steep slopes ot downhill may cause the mowet to lose traction Loss of traction to the drive wheels may result in sliding and a loss of bra
45. nkage be vertical Set neutral 1 Remove the electrical connection from the seat safety switch located directly in front of the seat switch assembly 2 The neutral adjustment must be made with the drive wheels turning Raise the frame and place on jack stands so that drive wheels can rotate freely Temporarily install a jumper wire Maintenance actoss the terminals in the connector of the wiring harness Start the engine 4 Run the unit at least 5 minutes with the speed control lever at full forward speed to bring hydraulic system oil up to operating temperature Return speed control lever to neutral full rear position 5 obtain the neutral position adjust the left and right pump control rod linkages that connect the steering control to the pump control arms until the wheels stop or creep slightly in reverse 6 Adjust the left pump linkage by rotating the tracking adjustment knob 7 Adjust the right pump linkage by using a wrench to turn the double nuts on the assembly see Figure 18 6006843 Figure 18 2 Rotate double nuts on right side 1 Rotate tracking knob on left side 8 Move the steering levers to the reverse position While applying slight pressure to the levers allow the steering levers to return to neutral The wheels must stop turning or slightly creep in reverse 9 Stop engine and wait for all m
46. o the startet or solenoid as shown in Figure 6 2 5 3 G012785 Figure 6 Positive cable on discharged battery Positive cable on booster battery Negative cable on the booster battery Negative cable on the engine block Booster battery Discharged battery Engine block 4 Connect the other end of the positive cable to the positive terminal of the booster battery 5 Connect the black negative cable to the other terminal negative of the booster battery 6 MAKE THE FINAL CONNECTION ON THE ENGINE BLOCK OF THE STALLED VEHICLE NOT TO THE NEGATIVE POST AWAY FROM THE BATTERY STAND BACK 7 Start the vehicle and remove the cables in the reverse order of connection the engine block black connection is the first to disconnect Check Safety Interlock System Service Interval Before each use or daily Note To prevent engine cut outs on rough terrain the seat kill switch has a 1 2 second delay 1 Check starting circuit Starter should crank with parking brake engaged PTO disengaged and 24 Maintenance speed control lever in the neutral position The operator does not need to be in the seat to start the engine Try to start with operator in seat parking brake disengaged PTO disengaged and speed control lever in the neutral position starter must not crank Try to start with operator in seat parking brake engaged PTO engaged and speed
47. o 90 95 ft lb 122 129 N m cross pattern Fuel Tank Mounting Hardware Specifications Service Interval As required When installing the nuts on the fuel tank studs fully tighten the nyloc nut and back off 1 2 turn This allows for normal fuel tank expansion and contraction with changes in temperature and fuel levels Thread Locking Adhesives Thread locking adhesives such as Loctite 242 ot Fel Pro Pro Lock Nut Type are used on the following fastenets Pump drive sheave set screws Square head setscrews on Hydro pump control arms Sheave retaining bolt in the end of engine crankshaft blower shaft and jackshaft e Caster wheel spacer nuts e Fuel tank bulkhead fitting nuts Adhesives such as Loctite RC 609 or RC 680 or Fel Pro Pro Lock Retaining I or Retaining IT are used on the following 29 Maintenance Fuel tank studs where studs are inserted into tank Dielectric Grease Dielectric grease is used on all blade type electrical connections to prevent corrosion and loss of contact Adjustments Note Disengage PTO shut off engine wait for all moving parts to stop engage parking brake and remove key before servicing cleaning or making any adjustments to the unit PTO Drive Belt Tension Self tensioning No adjustment necessary Pump Drive Belt Tension Self tensioning No adjustment necessary PTO Belt Replacement 1 Stop engine wait for all moving
48. o steer right and rotate towards the left to steer left Adjust in 1 8 turn increments until the machine tracks straight Check that the machine does not creep when in neutral with the park brakes disengaged Important Do Not rotate the knob too far as this may cause the machine to creep in neutral Refer to the Motion Control Linkage Adjustment section in Maintenance PTO Engagement Lever Located immediately left of the left console Lever must be moved up to the ROTATE position to engage the PTO and blower drives Lever is moved down to the STOP position to stop the drives Engine Oil Temperature Light and Buzzer Located on the right console The engine oil temperature light monitors the temperature of the engine oil An illuminated engine oil temperature light and intermittent buzzing sound signals the engine is overheating Pre Start Fill fuel tanks For best results use only clean fresh regular grade unleaded gasoline with an octane rating of 87 or higher Important Never use methanol gasoline containing methanol gasohol containing more than 10 ethanol premium gasoline or white gas because the fuel system could be damaged Do Not add oil to gasoline Do Not overfill fuel tank Fill the fuel tank to the bottom of the filler neck The empty space in the tank allows gasoline to expand Overfilling may result in fuel leakage or damage to the engine or emission system if equipped Make sure you
49. ods of servicing and ate equipped to provide prompt and efficient service in the field or at their service stations They carry ample stock of service parts or can secure them promptly for you from the factory All Exmark parts are thoroughly tested and inspected before leaving the factory however attention is required on your part if you are to obtain the fullest measure of satisfaction and performance Whenever you need service genuine Exmark parts ot additional information contact an Authorized Service Dealer or Exmark Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided 1 6006831 Figure 1 Model and serial number location Model No Serial No Contents eer erent rT 3 Mov dp 5 Safety Alert 5 Safe Operating 5 Safety and Instructional Decals 11 aats 14 ea tt 14 14 15 Torque Requirements edt ttes 16 Product Overview peur ro A 16 ehe a TN OP PEU E RASA 17 17 18 Operating Inste retlonis eere 18 20
50. oline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete WARNING Gasoline is harmful or fatal if swallowed Long term exposure to vapors has caused cancer in laboratory animals Failure to use caution may cause serious injury or illness Avoid prolonged breathing of vapors Keep face away from nozzle and gas tank container opening Keep away from eyes and skin Never siphon by mouth Safety Check that the operator s presence controls safety switches and shields are attached and functioning properly Do Not operate unless they are functioning properly Operation A WARNING Operating engine parts especially the muffler become extremely hot Severe burns can occur on contact and debris such as leaves grass brush etc can catch fire Allow engine parts especially the muffler to cool before touching Remove accumulated debris from muffler and engine area Install and maintain in working order a spark arrester before using equipment on forest covered grass covered or brush covered unimproved land A WARNING Engine exhaust contains carbon monoxide which is an odorless deadly poison that can kill you Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect WARNING Operating a Navigator trac
51. op and remove key Engage parking brake 2 Remove PTO Belts See PTO Belt Replacement section for removal instructions 3 Pull spring idler or remove spring to relieve pump drive belt tension Remove old belt 4 Route new belt onto sheaves as shown in the decal located on the back of the left drive shield see Figure 11 G006838 Figure 11 Pump Drive Belt 4 Pump 2 Pump 5 Idler Idler 6 Engine 5 Reinstall PTO Belts as stated in the PTO Belt Replacement section Belt Guide Adjustment 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Engage PTO lever Adjust belt guides as shown in Figure 12 4 a Figure 12 1 8 inch 3 mm 4 Rotate wireform guide to center belts in guide 7 16 inch 11 mm 5 1 4 inch 6 mm 1 8 inch 3 mm 6 5 16 inch 8 mm Clearance Maintenance Adj ust Safety Switch 3 brakes on both sides can be simultaneously adjusted by lengthening or shortening the linkage Adjust all safety switches so plunger extends 3 16 shown in Figure 15 inch to 1 4 inch 4 8 mm 6 4 mm from switch body when plunger is compressed see Figure 13 1 OQ G006849 Figure 13 1 3 16 inch to 1 4 inch 4 8 mm 6 4 mm bi 1 G006949 Brake Adjustment Figure 15 Brake Adjust t for Both Si Check to make sure each brake is adjusted properly e d AL Io cane fio 2n h 1 Pull th
52. operation and 32 Maintenance loose enough to be moved comfortably by the operator a 6006841 Figure 16 1 Speed Control Lever 2 Friction Plate 3 Spring disc washers 4 Hex locknut Speed Control Linkage Adjustment A WARNING Engine must be running and drive wheels must be turning so motion control adjustment can be performed Contact with moving parts or hot surfaces may cause personal injury Keep fingers hands and clothing clear of rotating components and hot surfaces 33 A CAUTION Raising the mower deck for service or maintenance relying solely on mechanical ot hydraulic jacks could be dangerous The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the unit to fall which could cause injury Do Not rely solely on mechanical or hydraulic jacks for support Use adequate jack stands or equivalent support Adjust steering levers 1 Stop engine and wait for all moving parts to stop 2 Pull the speed control lever completely back to the neutral position The two steering levers should be straight up and down vertical If necessary adjust steering levers by changing the length of the link between the speed control lever and the control arm on the end of the steering control shaft see Figure 17 2 6006842 Figure 17 1 Loosen jam nuts here to 2 Steering levers should adjust li
53. operty Preparation Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job Only use accessories and attachments approved by Exmark e Wear appropriate clothing including safety glasses substantial footwear long trousers and hearing protection Do Not operate when barefoot or when wearing open sandals Long hair loose clothing or jewelry may get tangled in moving parts A CAUTION This machine produces sound levels in excess of 85 dBA at the operator s ear and can cause hearing loss through extended periods of exposure Wear hearing protection when operating this machine e Inspect the area where the equipment is to be used and remove all rocks toys sticks wires bones and other foreign objects which can be thrown by the machine and may cause personal injury to the operator or bystanders Safety A DANGER In certain conditions gasoline is extremely flammable and vapors are explosive A DANGER In certain conditions during fueling static electricity can be released causing a spark which can ignite gasoline vapors A fire or explosion from gasoline can burn you and others and cause property damage A fire explosion from gasoline can burn you others and cause property damage Fill the fuel tank outdoors on level ground in an open area when the engine is cold Wipe up any gasoline that spills Never refill the fuel tank or
54. oving parts to stop Remove jumper wire from wire harness connector and plug connector into seat switch 10 Lower from jackstands 34 Set forward stop bolt 1 1 Remove seat deck with seat attached to obtain a clear view of the steering control shaft to complete this adjustment Push the speed control lever forward to full forward speed position If either steering control lever surface does not contact the stop bar at the full forward speed position adjust the stop bolt until contact occurs see Figure 19 Once contact occurs turn the stop bolt one more full turn to prevent bottoming of the hydraulic pump internal stops Figure 19 Contact must be maintained between these components at full forward speed condition Speed control Lever 2 forward stop bolt Steering Control Lever Response Adjustment Stop engine wait for all moving parts to stop and remove key Engage parking brake Move the speed control lever to the full forward position Lift the seat and locate the pump control springs To increase responsiveness increase spring tension by hooking the rear spring anchor directly to the anchor bolt To decrease responsiveness hook the rear spring anchor to the anchor tab Note Be sure both springs maintain the same adjustment Maintenance 0006845 Figure 20 1 increase steering responsi
55. parts to stop and remove key Engage parking brake 2 With engine off engage PTO lever then remove the hairpin and clevis pin at the bottom of the brake band 3 Rotate the brake band upwards out of the way of the belts keeping clear of the belt drive 4 Disengage PTO lever 5 Loosen belt guides and See Figure 9 6 Remove current belts 7 Route new belts onto sheaves as shown in the decal located on the back of the left drive shield see Figure 9 1 2 3 4 5 6 7 Figure 9 1 Idler 5 Engine 2 Belt Guide B 6 Belt Guide A 3 PTO Belt 7 Blower 4 Jackshaft 8 Engage the PTO lever 9 Rotate brake band back down into original position Maintenance 10 Re install clevis pin and hairpin to secure brake band 11 Engage the PTO lever 12 Loosen the jam nuts and adjust linkage until the top of the idler arm is aligned with the bottom of notch on tension arm as shown in Figure 10 DA RA 6006837 Figure 10 Tension Arm Loosen jam nuts 3 When PTO is engaged align top of idler arm with bottom of notch on tension arm as shown 4 Idler Arm 13 Tighten jam nuts and disengage PTO lever Re engage PTO lever and check alignment 14 Check and adjust belt guides as stated in Belt Guide Adjustment section Pump Drive Belt Replacement 1 Stop engine wait for all moving parts to st
56. pulley Broken or missing idler spring Hydraulic fluid level is low or too hot Engine mounting bolts are loose Loose engine pulley idler pulley or blade pulley Engine pulley is damaged Belt is damaged 39 Reduce the ground speed Add oil to the crankcase Remove the obstructions from the cooling fins and air passages Adjust the tracking Adjust tire pressure in the drive tires Adjust the reverse indicator and the speed control linkage Tighten the bypass valve Change the belt Change the belt Replace the spring Add hydraulic fluid to reservoir or let it cool down Tighten the engine mounting bolts Tighten the appropriate pulley Contact an Authorized Service Dealer Install new belt Schematics Schematics Electrical Diagram 0207918 awaa 508 NI YH N30 suu HA 43131 108109 HUM 35012 SI HOLIMS 1081402 03348 m 1815 Na SHIM OIM3IA SOLO3NNOO Avia
57. rating the mower Before clearing blockages Whenever you leave the mower Safety Stop engine wait for all moving parts to stop and engage patking brake DANGER Before refueling Operating on wet grass or steep slopes can cause sliding and loss of control Wheels dropping over edges ditches steep banks or water can cause rollovers which may result in serious injury death or drowning Before dumping the grass catcher A WARNING Hands feet hair clothing or accessories can become entangled in rotating parts Contact with the rotating parts can cause traumatic amputation or severe lacerations Do Not mow slopes when grass is wet Do Not mow near drop offs or near water Do Not mow slopes greater than 15 degrees Do Not operate the machine without guards shields and safety devices in place and working properly Reduce speed and use extreme caution on slopes Avoid sudden turns rapid speed Keep hands feet hair jewelry clothing away from rotating parts changes NEVER carry passengers DO NOT operate See inside the back cover to determine the the mower when people especially children or approximate slope angle of the area to be mowed pets are in the area e Usea walk behind mower and or a hand trimmer alert slow down and use caution when making neat drop offs ditches steep banks or water turns Look behind and to the side before Figure 5 cha
58. ressure on the steering lever toward the direction desired To stop release the steering levers to the neutral position Emptying Hopper 1 A full hopper is indicated by a buzzer located behind the operator in the hopper Empty hopper when buzzer sounds to prevent clogging of the blower or deck Disengage PTO move speed control to neutral set park brake and dismount unit to dump hopper 3 Make sure unit is on a dry level surface Lift the rear door up and allow it to rest on top of hopper Dump hopper by firmly grasping one of the hopper handles on either side of the unit and lifting the hopper Clearing Hopper Screen Screen may be removed by firmly lifting screen handles see Figure 5 Pull screen towards the back to remove Gently tap debris from the screen as needed Excessive build up on the screen can cause the blower to plug Note In conditions where the screen clogs quickly the front removable screen panel can be turned and reinstalled under the primary screen to allow free air flow from the hopper Figure 5 1 Front removable screen can be rotated and stored for wet condtions Front removable screen 3 Primary screen 4 Handles Transporting Transporting a Unit Use a heavy duty trailer or truck to transport the machine Lock brake and block wheels Securely fasten the machine to the trailer truck with straps chains cable or ropes Be sure that the trailer or truck ha
59. result in death or serious injury CAUTION Black lettering Yellow background Indicates a potentially hazardous situation which if not avoided May result in minor or moderate injury This manual uses two other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention Safe Operating Practices Training Read the Operator s Manual and other training material If the operator s or mechanic s can not read English it is the owner s responsibility to explain this material to them Become familiar with the safe operation of the equipment operator controls and safety signs e All operators and mechanics should be trained The owner is responsible for training the users Never let children or untrained people operate service the equipment Local regulations may restrict the age of the operator Only adults and mature teenagers should operate mower and even mature teenagers should have adult supervision Be sure a teenager 1 has read and understands the Operator s Manual and recognizes the risks involved 2 is sufficiently mature to use caution and 3 is of sufficient size and weight to operate the controls comfortably and to manage the mower without taking risks e The owner usert can prevent and is responsible for accidents or injuries occurring to himself or herself other people or pr
60. round engine shrouding and exhaust system area 3 Clean all debris from around engine drive belts and exhaust system area Remove Engine Shrouds and Clean Cooling Fins Service Interval Every 80 hours 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Remove cooling shroud clean out covers from engine and clean cooling fins Also clean dust dirt and oil from external surfaces of engine which can cause improper cooling Make sure cooling shroud clean out covers are reinstalled Operating the engine without cooling shroud clean out covers will cause engine damage due to overheating For 27HP Kohler units Swing out the fuel tank and remove debris from around the oil cooler positioned at right front corner of engine Important Do Not use water to clean engine Use low pressure compressed air See Engine Owner s Manual Clean Debris From Machine Service Interval Before each use or daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake Clean off any oil debris ot grass build up on the machine especially around the fuel tank around engine and exhaust area Waste Disposal Motor Oil Disposal Engine oil and hydraulic oil are both pollutants to the environment Dispose of used oil at a certified recycling center or according to your state and local regulations Battery Disposal A DANGER Battery electrolyte contains sulfuri
61. s all necessaty lighting and marking as required by law Secure a trailer with a safety chain A CAUTION This unit does not have proper turn signals lights reflective markings slow moving vehicle emblem Driving on a street or roadway without such equipment is dangerous and can lead to accidents causing personal injury Driving on a street or roadway without such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and or fines Do Not drive a unit on a public street or roadway 20 Operation A WARNING Loading a unit on a trailer or truck increases the possibility of tip over Tip over could cause serious injury or death Use extreme caution when operating a unit on a ramp Use only a single full width ramp Do Not use individual ramps for each side of the unit If individual ramps must be used use enough ramps to create an unbroken ramp surface wider than the unit Do Not exceed a 15 angle between ramp and ground or between ramp and trailer ot truck Avoid sudden acceleration while driving unit on a ramp Loading a Unit Use extreme caution when loading units on trailers or trucks One full width ramp is required If it is not possible to use one full width ramp use enough individual ramps to simulate a full width continuous ramp Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer
62. sibility for variations which may be evident in the actual specifications of its products and the statements and descriptions contained in this publication 2010 Exmark Mfg Co Inc Industrial Park Box 808 Beatrice NE 68310 PARTS OVERNIGHT FREE If your Exmark dealer does not have the Exmatk part in stock Exmark will get the parts to the dealer the next business day or the part will be FREE Guaranteed Some restrictions apply See your participating Exmark Dealer for details Contact us at www Exmark com Printed in the USA Rights Reserved Introduction CONGRATULATIONS on the purchase of your Exmark Mower This product has been carefully designed and manufactured to give you a maximum amount of dependability and years of trouble free operation This manual contains operating maintenance adjustment and safety instructions for your Exmark mowet BEFORE OPERATING YOUR MOWER CAREFULLY READ THIS MANUAL IN ITS ENTIRETY By following the operating maintenance and safety instructions you will prolong the life of your mower maintain its maximum efficiency and promote safe operation If additional information is needed or should you require trained mechanic service contact yout authorized Exmatk equipment dealer or distributor Exmark parts manuals are available online at http www exmark com manuals htm All Exmark equipment dealers and distributors are kept informed of the latest meth
63. skin and clothing when handling electrolyte Do Not swallow electrolyte In the event of an accident flush with water and call a doctor immediately Safety A CAUTION If the ignition is in the ON position there is potential for sparks and engagement of components Sparks could cause an explosion ot moving parts could accidentally engage causing personal injury Be sure ignition switch is the OFF position before charging the battery Keep all guards shields and all safety devices in place and in safe working condition Check all bolts frequently to maintain proper tightness Frequently check for worn or deteriorating components that could create a hazard A WARNING Removing standard original equipment parts using non Exmark replacement parts and accessories may alter the warranty traction and safety of the machine Failure to use original Exmark parts could cause serious injury or death Replace all parts including but not limited to tires belts and blades with original Exmark parts A WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings ate tight before applying pre
64. ssure to hydraulic system Keep body and hands away from pinhole leaks or nozzles that eject high pressure hydraulic fluid Use cardboard or paper not your hands to find hydraulic leaks Safely relieve all pressure in the hydraulic system by placing the motion control levers in neutral and shutting off the engine before performing any work on the hydraulic system Safety Safety and Instructional Decals Keep all safety signs legible Remove all grease dirt and debris from safety signs and instructional labels Replace all worn damaged or missing safety signs When replacement components are installed be sure that current safety signs are affixed to the replaced components e Ifan attachment or accessory has been installed make sure current safety signs are visible FEE A WARNING INTAINS SULFURIC ACID AVOID CONTACT OR USE BOOSTER CABLES OR ADJUST POST CONNECT 5 SHIEI FACE FROM BATTERY CIGARETTES FLAMES OR SPARKS ACCIDENT FLUSH WITH WATER AND CALL A PHYSICIAN COULD CAUSE BATTERY TO EXPLODE DO NOT CHARGE IMMEDIATELY KEEP OUT OF REACH OF CHILDREN 1 513747 WARNING New safety signs may be obtained from your authorized Exmark equipment dealer or distributor or from Exmark Mfg Co Inc Safety signs may be affixed by peeling off the backing to expose the adhesive surface Apply only to a clean dry surface Smooth to remove any ait bubbles Familiarize yourself
65. t control the speed and direction of travel of the respective drive wheels Moving speed control lever rearward to the neutral position places the drive system in neutral Note The unit may be moved in reverse while the speed control is in the neutral position by pulling back the steering levers PTO Engagement Lever Engages drive to mower deck and blower e Parking Brake Lever Pull back to engage parking brake Seat Standard seat with high back foam padded internal suspension Mounting Seat is hinged to tilt up for access to hydraulic pumps and other components The seat is held in the tilted position with a link e Armrests None Seat Safety Switch Internal to the bottom seat cushion non serviceable Time delay module incorporated into the Safety Interlock System eliminates rough ground cut outs Hydrostatic Ground Drive System Hydrostatic Pumps Two Hydro Gear variable displacement piston pumps Wheel Motors Hydro Gear planetary reduction motots 14 Specifications Hydraulic Oil Type Use Exmark Premium Hydro Clutching belt on horizontal engine shaft oil Dual section hexagon belt with spring Hydraulic Capacity 4 0 qt 3 8 L tensioned idler to jackshaft and blower Hydraulic Filter Replaceable cartridge type cast iron spiral bevel gearbox is Summer use above 32 F 0 C D P N 109 0071 25 microns 10 psi
66. ter hose between the hopper and hopper door see Figure 23 Close door and push tight against hopper Tighten hinge hardware Open hopper door and remove rubber strip Figure 23 2 Place a piece of 3 8 inch 9 5 mm rubber on this surface 1 Loosen door hinge nuts three per side PTO Brake Spring Adjustment PTO brake spring adjustment is only necessary if the blower has been removed or replaced or if the PTO drive idler arm has been disassembled 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Locate the brake spring and thread the two jam nuts out to the end of the brake spring rod see Figure 24 3 Tighten jam nuts together at end of brake spring rod Figure 24 1 Tighten jam nuts here 2 PTO Brake spring assembly Maintenance Cleaning Clean Engine and Exhaust System Area Service Interval Before each use or daily May be required more often in dry or dirty conditions A CAUTION Excessive debris around the engine cooling ait intake and inside of the pump drive belt compartment and damaged or missing rubber baffles can cause the engine and hydraulic system to overheat which can create a fire hazard Clean all debris from inside of pump drive belt compartment daily 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Clean all debris from rotating engine air intake screen and from a
67. tor without an approved Exmark front mount attachment increases the possibility of operator entanglement in drive wheels or forward tip over Entanglement or tip over could cause serious injury death When operating a Navigator tractor without an approved Exmark front mount attachment observe the following Keep feet and clothing away from tires Limit operation to minimum required to install a different front mount attachment Minimize speed and use extreme caution Only operate on a flat level surface Do not operate up or down a trailer ramp Avoid sudden acceleration or deceleration Operate only in daylight or good artificial light keeping away from holes and hidden hazards Be sure all drives are in neutral and parking brake is engaged before starting engine Never raise deck with blades running Never operate the mower with damaged guards shields or covers Always have safety shields guards switches and other devices in place and in proper working condition Never mow unless there is a grass collection system or mulch kit in place and working properly Do Not change the engine governor setting or overspeed the engine Stop engine wait for all moving parts to stop remove key and engage parking brake Before checking cleaning or working on the mower After striking a foreign object or abnormal vibration occurs inspect the mower for damage and make repairs before restarting and ope
68. understand the controls their locations their functions and their safety requirements Refer to the Maintenance section and perform all the necessary inspection and maintenance steps Operating Instructions Open the Fuel Shut Off Valve The fuel shut off valve is located on the right side of unit in fuel line next to the fuel filter Raise the hopper to access Rotate the valve 1 4 counterclockwise to turn on fuel Starting the Engine 1 Move the speed control lever to the neutral position 2 Pull up and back on the parking brake lever to engage the parking brake 3 Push the PTO engagement lever down to the STOP position Note It is not necessary for the operator to be in the seat to start the engine 4 Place the throttle midway between the SLOW and FAST positions 5 Ona cold engine push the choke lever forward into the position On a warm engine leave the choke in the OFF position 18 Operation 6 Turn ignition switch to the START position Release the switch as soon as the engine starts Important Do Not crank the engine continuously for more than ten seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the choke is in the ON position gradually return choke to the OFF position as the engine warms up Engagin
69. veness hook pump control sprints directly on anchor bolt To decrease steering responsiveness hook pump control springs on anchor tabs as shown Tracking Adjustment See Motion Control Linkage Adjustment section PTO Drive Pulley Alignment PTO drive pulley alignment is necessary for any of the following conditions The blower has been removed or replaced The engine mounting bolts have been loosened ot the engine has been moved or replaced The jackshaft mounting bolts have been loosened ot the jackshaft has been moved or replaced 1 Stop engine wait for all moving parts to stop and remove key Engage parking brake 2 Move the speed control lever to the neutral position 3 Disengage the PTO lever 4 Remove fuel tank mounting nuts and swing out fuel tank 5 Verify that the blower is installed and secured tightly Loosen the 4 engine mounting bolts Unhook the pump belt tension spring Loosen the 4 jackshaft mounting bolts 59 00 c gs Measuring from the blower pulley as a baseline move the engine and jackshaft until the rear surface of all 3 pulleys are aligned within 1 32 35 inch to 1 16 inch 0 8 1 6 mm Use a straight edge to align all three surfaces see Figure 21 Figure 21 Align three pump drive pulley surfaces shown with this pattern within 1 32 inch to 1 16 inch 0 8 1 6 mm 2 Align three PTO drive pulley surfaces shown with this pattern within 1 32 inch to 1 16 in

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