NA VIGATOR®
ForSerialNos.
316,000,000&Higher
PartNo.4502-722Rev.A
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemical
orchemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:Theengineinthisproductisnot
equippedwithasparkarrestermufer.Itisa
violationofCaliforniaPublicResourceCode
(CPRC)Section4442touseoroperatethis
engineonanyforest-covered,brush-covered,
orgrass-coveredlandasdenedinCPRC4126.
Otherstatesorfederalareasmayhavesimilar
laws.
Toacquireasparkarresterforyourunit,seeyour
EngineServiceDealer.
Thissparkignitionsystemcomplieswiththe
CanadianstandardICES-002.Cesystèmed’allumage
parètincelledevèhiculeestconformeàlanorme
NMB-002duCanada.
TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.
KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.
Labeledpowerratingsaresuppliedbytheengine
manufacturerinaccordancewithSAEtesting
andgross/netpowerratingstandards(J1940,
J1995,J1349).
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2015ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
2
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,
maintainitsmaximumefciency,andpromotesafe
operation.
Important:Tomaximizesafety,performance,
andproperoperationofthismachine,itis
essentialthatalloperatorscarefullyreadand
fullyunderstandthecontentsoftheOperator’s
manualprovidedwiththeproduct.Safe
operationofExmarkequipmentisessential.
Failuretocomplywiththeoperatinginstructions
orreceivepropertrainingmayresultininjury.
Gotohttp://www.Exmark.comforadditional
safeoperationinformation,suchassafetytips,
trainingmaterials,andOperator’smanuals.
Ifadditionalinformationisneeded,orshould
yourequiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
3
Contents
Introduction...........................................................3
Safety.....................................................................5
SafetyAlertSymbol.........................................5
SafeOperatingPractices..................................5
SafetyandInstructionalDecals......................11
Specications........................................................17
Systems..........................................................17
Dimensions....................................................18
TorqueRequirements.....................................19
ProductOverview.................................................19
Operation..............................................................20
Controls.........................................................20
Pre-Start.........................................................22
OperatingInstructions...................................22
Transporting..................................................28
Maintenance..........................................................30
RecommendedMaintenanceSchedule(s)............30
PeriodicMaintenance........................................31
CheckEngineOilLevel..................................31
CheckMowerBlades......................................33
CheckSafetyInterlockSystem........................34
CheckforLooseHardware.............................34
ServiceAirCleaner.........................................34
ChangeEngineOil.........................................34
CheckHydraulicOilLevel..............................35
CheckTirePressures......................................35
CheckConditionOfBelts...............................35
ChangeGearboxOil.......................................36
CheckGearboxOil.........................................36
LubricateGreaseFittings................................36
LubricateRearCasterWheelHubs..................37
LubricateBrakeHandlePivot.........................38
LubricateBrakeRodBushings........................38
LubricateSteeringLinkageRodEnds..............38
LubricateHopperSwitchActuator..................38
CheckSparkPlugs..........................................38
ChangeHydraulicSystemFilterand
Fluid..........................................................38
CheckWheelHubLocknuts...........................39
CheckWheelLugNuts...................................39
ThreadLockingAdhesives..............................39
DielectricGrease............................................39
Adjustments......................................................40
DeckLeveling................................................40
PTODriveBeltTension.................................40
PumpDriveBeltTension................................40
PTOBeltReplacement...................................40
PumpDriveBeltReplacement.......................41
BeltGuideAdjustment...................................41
AdjustSafetySwitch.......................................42
ParkingBrakeAdjustment..............................42
ReverseStopRodAdjustment.........................43
AdjustSpeedControlLeverTension...............44
SpeedControlLinkageAdjustment.................44
TrackingAdjustment......................................45
PTODrivePulleyAlignment..........................45
PumpDrivePulleyAlignment.........................46
CasterPivotBearingsPre-Load
Adjustment................................................46
HopperDoorAdjustment..............................46
PTOBrakeSpringAdjustment.......................47
DeckLockingPinStopAdjustment................47
Cleaning............................................................48
CleanEngineandExhaustSystem
Area...........................................................48
RemoveEngineShroudsandClean
CoolingFins...............................................48
CleanDebrisFromMachine...........................48
CleanDebrisFromCuttingDeck....................48
CleanGrassBuild-UpUnderDeck.................48
WasteDisposal...............................................48
Troubleshooting....................................................50
Schematics............................................................52
4
Safety
Safety
SafetyAlertSymbol
ThislawnmowercompliestotheB71.4-2012
specicationoftheAmericanNationalStandards
InstitutewiththeadditionoftheoptionalROPS
accessory.
Exmarkdesignedandtestedthislawnmowertooffer
reasonablysafeservice;however,failuretocomply
withthefollowinginstructionsmayresultinpersonal
injury.
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents.
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
SafetyAlertSymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Indicatesanimminentlyhazardous
situationwhich,ifnotavoided,Willresultindeathor
seriousinjury.
WARNING:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Couldresultindeath
orseriousinjury.
CAUTION:Indicatesapotentiallyhazardous
situationwhich,ifnotavoided,Mayresultinminor
ormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
•ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)cannot
readthismanual,itistheowner’sresponsibilityto
explainthismaterialtothem;otherlanguagesmay
beavailableonourwebsite.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
•Onlyadultsandmatureteenagersshouldoperate
amower,andevenmatureteenagersshouldhave
adultsupervision.Besureateenager:
1.hasreadandunderstandstheOperator's
Manualandrecognizestherisksinvolved;
2.issufcientlymaturetousecaution;and
3.isofsufcientsizeandweighttooperate
thecontrolscomfortablyandtomanagethe
mowerwithouttakingrisks.
•Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
•Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,andhearingprotection.Do
Notoperatewhenbarefootorwhenwearingopen
sandals.Longhair,looseclothingorjewelrymay
gettangledinmovingparts.
CAUTION
Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause
hearinglossthroughextendedperiodsof
exposure.
Wearhearingprotectionwhenoperatingthis
machine.
5
Safety
•Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
DANGER
Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.
•Fillthefueltankoutdoorsonlevelground,
inanopenarea,whentheengineiscold.
Wipeupanygasolinethatspills.
•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.
•DoNotllthefueltankcompletelyfull.
Fillthefueltanktothebottomoftheller
neck.Theemptyspaceinthetankallows
gasolinetoexpand.Overllingmayresult
infuelleakageordamagetotheengine
oremissionsystem.
•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyspark.
•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.
•Addfuelbeforestartingtheengine.Never
removethecapofthefueltankoradd
fuelwhenengineisrunningorwhenthe
engineishot.
•Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
•DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
DANGER
Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.
•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.
•DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.
•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.
•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.
•Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.Do
Notuseanozzlelockopendevice.
WARNING
Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgas
tank/containeropening.
•Keepawayfromeyesandskin.
•Neversiphonbymouth.
•Checkthattheoperatorpresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
6
Safety
Operation
WARNING
Operatingengineparts,especiallythemufer,
becomeextremelyhot.Severeburnscanoccur
oncontactanddebris,suchasleaves,grass,
brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,to
coolbeforetouching.
•Removeaccumulateddebrisfrommuferand
enginearea.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcankill
you.
DoNotrunengineindoorsorinasmallconned
areawheredangerouscarbonmonoxidefumes
cancollect.
WARNING
OperatingaNavigatortractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofoperatorentanglement
indrivewheelsorforwardtipover.Entanglement
ortip-overcouldcauseseriousinjuryordeath.
WhenoperatingaNavigatortractorwithout
anapprovedExmarkfrontmountattachment,
observethefollowing:
•Keepfeetandclothingawayfromtires.
•Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.
•Minimizespeedanduseextremecaution.
•Onlyoperateonaatlevelsurface.
•DoNotoperateupordownatrailerramp.
•Avoidsuddenaccelerationordeceleration.
•Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
•Lightningcancausesevereinjuryordeath.If
lightningisseenorthunderisheardinthearea,
DoNotoperatethemachine;seekshelter.
•Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.
•Neverraisedeckwithbladesrunning.
•Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
•Nevermowunlessthereisagrasscollection
systemormulchkitinplaceandworkingproperly.
•DoNotchangetheenginegovernorsettingor
overspeedtheengine.
•Parkmachineonlevelground.Stopengine,wait
forallmovingpartstostop,removekeyand
engageparkingbrake:
–Beforechecking,cleaningorworkingonthe
mower.
–Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
–Beforeclearingblockages.
–Wheneveryouleavethemower.
•Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:
–Beforerefueling.
–Beforedumpingthegrasscatcher.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
•DoNotoperatethemachinewithout
guards,shields,andsafetydevicesinplace
andworkingproperly.
•Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
•NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.
•Bealert,slowdownandusecautionwhen
makingturns.Lookbehindandtothesidebefore
changingdirections.
•Stoptheblades,slowdown,andusecaution
whencrossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
•Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
7
Safety
•DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
DANGER
Operatingonwetgrassorsteepslopescancause
slidingandlossofcontrol.Wheelsdroppingover
edges,ditches,steepbanks,orwatercancause
rollovers,whichmayresultinseriousinjury,
deathordrowning.
•DoNotmowslopeswhengrassiswet.
•DoNotmowneardrop-offsornearwater.
•DoNotmowslopesgreaterthan15degrees.
•Reducespeedanduseextremecautionon
slopes.
•Avoidsuddenturnsorrapidspeedchanges.
•Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
•Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.
(Figure3).
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.
•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.
AROPSisrecommendedifyouwillbemowingnext
todrop-offs,nearwater,oronsteepbankswhich
couldresultinarollover.ContactanAuthorized
ExmarkServiceDealerformoredetails.
8
Safety
TheCaliforniaCodeofRegulationsrequiresROPS
andseatbelt(ifequipped)onallcommercialmowers
effectiveMarch1,2011.BecauseallNavigatorswere
designedwithanoptionalROPSaccessory,theyare
subjecttothisregulationandmustberetrottedwith
ROPS.
MaintenanceandStorage
•Disengagedrives,setparkingbrake,stopengine
andremovekeyordisconnectsparkplugwire.
Waitforallmovementtostopbeforeadjusting,
cleaningorrepairing.
•Keepengineandengineareafreefrom
accumulationofgrass,leaves,excessivegrease
oroil,andotherdebriswhichcanaccumulate
intheseareas.Thesematerialscanbecome
combustibleandmayresultinare.
•LetenginecoolbeforestoringandDoNotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
•Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.
•Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen
required.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplacedamagedblades.Never
straightenorweldthem.
•Keephandsandfeetawayfrommovingparts.
Ifpossible,DoNotmakeadjustmentswiththe
enginerunning.
•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
DANGER
Chargingorjumpstartingthebatterymay
produceexplosivegases.Batterygasescan
explodecausingseriousinjury.
•Keepsparks,ames,orcigarettesaway
frombattery.
•Ventilatewhenchargingorusingbattery
inanenclosedspace.
•Makesureventingpathofbatteryis
alwaysopenoncebatteryislledwith
acid.
•Alwaysshieldeyesandfacefrombattery.
DANGER
Batteryelectrolytecontainssulfuricacid,
whichispoisonousandcancausesevere
burns.Swallowingelectrolytecanbefatalor
ifittouchesskincancausesevereburns.
•Wearsafetyglassestoshieldeyes,and
rubberglovestoprotectskinandclothing
whenhandlingelectrolyte.
•DoNotswallowelectrolyte.
•Intheeventofanaccident,ushwith
waterandcalladoctorimmediately.
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagementof
components.Sparkscouldcauseanexplosion
ormovingpartscouldaccidentallyengage
causingpersonalinjury.
Besureignitionswitchisinthe“OFF”
positionbeforechargingthebattery.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
9
Safety
WARNING
Removalormodicationoforiginalequipment,
partsand/oraccessoriesmayalterthewarranty,
controllability,andsafetyofthemachine.
Unauthorizedmodicationstotheoriginal
equipmentorfailuretouseoriginalExmark
partscouldleadtoseriousinjuryordeath.
Unauthorizedchangestothemachine,engine,
fuelorventingsystem,mayviolateapplicable
safetystandardssuchas:ANSI,OSHAand
NFPAand/orgovernmentregulationssuchas
EPAandCARB.
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbyadoctor
familiarwiththisformofinjuryorgangrenemay
result.
•Ifequipped,makesureallhydraulicuid
hosesandlinesareingoodconditionandall
hydraulicconnectionsandttingsaretight
beforeapplyingpressuretohydraulicsystem.
•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpaper,notyourhands,to
ndhydraulicleaks.
•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrollevers
inneutralandshuttingofftheenginebefore
performinganyworkonthehydraulicsystem.
ForKohlerEFI(ElectronicFuelInjection)Units:
WARNING
Fuelsystemcomponentsareunderhigh
pressure.Theuseofimpropercomponentscan
resultinsystemfailure,gasolineleakageand
possibleexplosion.
Useonlyapprovedfuellinesandfuelltersfor
highpressuresystems.
10
Safety
SafetyandInstructionalDecals
•Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
•Replaceallworn,damaged,ormissingsafety
signs.
•Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
•Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
•Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
•Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
•Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
93-6696
1.Storedenergyhazard-Removethespringfromthe
tractorsectiononly.SeeOperator’smanualfor
disassemblyprocedure.
93-7818
1.Warning-readtheOperator’smanualforinstructionson
torquingthebladebolt/nutto115–149N-m(85–110
ft-lb).
98-1977
1.Entanglementhazard,belt—stayawayfrommoving
parts.
106-5517
1.Warning—donottouchthehotsurface.
112-8760
1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.
2.Cutting/dismembermentofhandorfoot—stayaway
frommovingparts.
112-9028
1.Warning—stayawayfrommovingparts;keepallguards
inplace.
11
Safety
115-4212
1.Hydraulicoillevel3.Warning—donottouch
thehotsurface.
2.ReadtheOperator's
Manual.
116-8934
1.Warning-Disengage
bladeclutch,shutoff
engine,andremove
keybeforemaking
adjustments,servicing,
orcleaningdeck.
2.Heightofcut.
116-8935
1.Warningfoldingdeckhazard-Lockthepivotjointby
pushinginwardandrotatingtowardsthefrontofthe
deck.
116-8936
1.Danger-DoNotoperatewithdeckintilt-upposition.
116-8941
116-8943
1.Rotatingbladeshazard-DisengagePTO,movespeed
controlleverinneutral,engageparkingbrake,stop
engine,andremovekeybeforeleavingtheoperator’s
position.Readtheinstructionsbeforeservicingor
performingmaintenance.
2.Danger-Donotoperatewithmowerhopperinraised
position
12
Safety
116-8946
1.Rotatecounterclockwise
torelease
3.Unlocktopushmachine
2.Rotateclockwisetolock4.Readtheinstructions
beforeservicingor
performingmaintenance.
116-9049
1.Rotatingdrivelinehazard-Keepalldrivelinesshieldsin
place.Securelyattachbothendsofthedriveline.
116-9357
EFIUnits
1.Neutral
4.Slow
2.Reverse5.Hopperdown
3.Fast6.Hopperup
116-9375
AllUnitsExceptEFI
1.Neutral3.Fast
2.Reverse
4.Slow
116-9470
AllUnitsExceptEFI
1.Choke-on2.Choke-off
117–2718
13
Safety
120-0625
1.Pinchpoint,hand-keephandsaway.
126-4207
1.RefertotheOperator’smanualforadjustment
procedure.WhenPTOisengaged,idlerarmposition
mustbeinhatchedareaoradjustmentisrequired.
126-7425
EFIUnits
1.Fast4.Neutral
2.Machinespeed5.Engineoiltemperature
light
3.Slow6.Checkengine
126-7442
AllUnitsExceptEFI
1.Fast4.Neutral
2.Machinespeed5.Engineoiltemperature
light
3.Slow
MoldedinLHConsole
1.PTO-disengage
3.Parkbrake-release
2.PTO-engage
4.Parkbrake-engage
14
Safety
MessageDisplay
1.Hopperupindicator5.Parkingbrake
2.Battery6.Neutral
3.Hourmeter
7.Operatorpresence
switch
4.PTO
116-9044
1.ReadtheOperator’sManualbeforeperformingany
maintenance.
8.Greasedecklockmechanismevery100hours.
2.Checkengineoilevery8hours.9.Greasedeckpivotsevery100hours.
3.Greasefrontcasterwheelbearingsevery8hours.10.Checkgearboxoilevery100hours(useonlyMobil1
75W-90gearoil).
4.Checkhydraulicoillevelevery40hours(onlyuse
recommendedhydrooil).
11.Greasefrontcasterpivotsevery500hours.
5.Checktirepressureevery40hours.12.Greaserearcasterpivotevery500hours.
6.GreasedeckdrivePTOevery40hours.13.Greaserearcasterwheelevery500hours.
7.Checkaircleanerevery40hours.14.Greasebeltidlersevery500hours.
15
Safety
MoldedintoFrontofHopper
1.Warning-ReadtheOperator’sManual.DoNotoperatethis
machineunlessyouaretrained.Wearhearingprotection.
5.Warning-Stayawayfrommovingparts;keepallguards
inplace.Stopengineandremovekeybeforeadjusting,
servicing,orcleaning.
2.Sliding,tippinghazard-DoNotusethemachinenear
drop-offswithslopesgreaterthan15degrees,usethe
machineasafedistanceformdrop-offsonslopesless
than15degrees;DoNotturnsharplywhiletravelingfast,
driveslowlywhenturning.
6.Warning-DisengagePTO,movespeedcontrolleverto
neutralposition,engageparkingbrake,andstopengine
beforeleavingtheoperator’sposition.
3.Warning-DoNotusedualramps,useonepieceramps
whentransportingmachine;DoNotuserampswith
inclinationgreaterthan15degrees.
7.Thrownobjecthazard-Pickupobjectsthatcouldbethrown
bymower.DoNotoperatewhenpeopleandpetsarein
thearea.Keepdeectorinplace.
4.Arollbarisavailableanditsuseisrecommendedforareas
wherethereareslopes,drop-offs,orwater
8.Crushing/dismembermenthazardofbystanders-DoNot
carrypassengers,lookforwardanddownwhenoperating
themachine,lookbehindanddownwhenreversing.
16
Specications
Specications
Systems
Engine
•EngineSpecications:SeeyourEngineOwner’s
Manual
•EngineOilType:Exmark4–CyclePremium
EngineOil
•RPM:FullSpeed:3600±50RPM(NoLoad)Idle:
1500RPM
FuelSystem
•Capacity:7.5gal.(28L)
•FuelRecommendations:
–Forbestresults,useonlyclean,fresh,unleaded
gasolinewithanoctaneratingof87orhigher
((R+M)/2ratingmethod).
–Oxygenatedfuelwithupto10%ethanolor
15%MTBEbyvolumeisacceptable.
–DoNotuseethanolblendsofgasoline(such
asE15orE85)withmorethan10%ethanol
byvolume.Performanceproblemsand/or
enginedamagemayresultwhichmaynotbe
coveredunderwarranty.
–DoNotusegasolinecontainingmethanol.
–DoNotstorefueleitherinthefueltankor
fuelcontainersoverthewinterunlessafuel
stabilizerisused.
–DoNotaddoiltogasoline.
•FuelFilter:
Allunits:KohlerP/N2405013
ElectricalSystem
•ChargingSystem:FlywheelAlternator
•ChargingCapacity:
–AllunitsexceptKohlerEFI:15amps
–KohlerEFI:20amps
•BatteryType:BCIGroupU1
•BatteryVoltage:12Volt
•Polarity:NegativeGround
•Fuses:Two25ampandone15ampbladetype
SafetyInterlockSystem
•LCDindicatorsappearforthePTO,parkbrake,
drivelevers,andoperatorpresenceinthemessage
displayontheRHcontrolpanel.
•PTOmustbedisengaged,brakeengaged,and
speedcontrolleverinneutraltostartengine.(It
isnotnecessaryfortheoperatortobeintheseat
tostarttheengine.)
•OperatormustbeinseatwhenPTOisengaged,
brakeisdisengaged,orspeedcontrolleveris
movedoutofneutralorenginewillstop.
•Enginewillstopifthehopperisraisedwhilethe
PTOisengaged.
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:Internaltothebottom
seatcushion,serviceable.Timedelaymodule
incorporatedintotheSafetyInterlockSystem
eliminatesroughgroundcut-outs.
HydrostaticGroundDriveSystem
•HydrostaticPumps:TwoHydroGearvariable
displacementpistonpumps.
17
Specications
•WheelMotors:HydroGearplanetaryreduction
motors.
•HydraulicOilType:UseExmarkPremiumHydro
oil.
•HydraulicOilCapacity:6.0qt.(5.7L)
•HydraulicFilter:Replaceablecartridgetype.
–Summeruseabove32°F(0°C):
P/N109-4180:25microns,10psibypass
–Winterusebelow32°F(0°C):
P/N1-523541:40microns,18psibypass
•Speeds:
–0-7.0mph(11.3km/hr)forward.
–0-4.5mph(7.2km/hr)reverse.
•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
Tires&Wheels
Drive
Front
Caster
Rear
Caster
Pneumatic
(Air-Filled)
Semi-
Pneumatic
Semi-
Pneumatic
Quantity
221
Tread
“Multi-Trac
C/S”
SmoothSmooth
Size
18x
10.50-10
8x3.00-413x8.00-6
PlyRating
4
Pressure
15psi(103
kPa)
CuttingDeck
•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:
–Clutchingbeltonhorizontalengineshaft.
Dual“A ”sectionhexagonbeltwithspring
tensionedidlertojackshaftandblower.
–Heavy-dutycastiron,spiralbevelgearboxis
naldrivetoblades.
–GearboxOilType:MobilSHC(synthetic)
75W-90gearlube.
•Deck:
Fulloatingdeckisattachedtoout-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)
OverallLength:
WithoutDeck
67.3inches(170.9cm)
DeckDown
42inchDeck48inchDeck
91.8inches(233.2cm)94.5inches(240.0cm)
DeckUp
42inchDeck48inchDeck
82.4inches(209.3cm)81.8inches(207.6cm)
OverallHeight:
WithoutDeck42inchDeck48inchDeck
51.2inches
(130.0cm)
51.2inches
(130.0cm)
51.2inches
(130.0cm)
TreadWidth:(CentertoCenterof
Tires,Widthwise)
42inchDeck48inchDeck
DriveWheels32.7inches
(83.1cm)
32.7inches
(83.1cm)
18
ProductOverview
WheelBase:(CenterofDriveWheel
toCenterofRearCasterWheel)
42inchDeck48inchDeck
44.2inches(112.3cm)44.2inches(112.3cm)
CurbWeight:
42inchDeck48inchDeck
1140lb(517kg)1170lb(531kg)
TorqueRequirements
BoltLocation
Torque
BladeMountingBolt85-110ft-lb(115-149
N-m)
EngineMountingBolts
30-35ft-lb(41-47N-m)
WheelLugNuts
85-105ft-lb(122-129
N-m)
WheelMotorMounting
Bolts
72-77ft-lb(115-142N-m)
WheelHubLocknut275-350ft-lb
(373-475N-m)
BladeDriverShearBolts80-100in-lb
(922-1130N-cm)
ProductOverview
Figure4
1.SpeedControlLever4.SteeringLevers
2.Controls5.PTOEngagementLever
3.FuelCap
6.ParkingBrakeLever
19
Operation
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
SteeringLevers
Locatedinthecenterinfrontoftheseat.
Pullingbackonthesteeringlevers,progressively
slows,thenreversesthedirectionoftravelofthe
respectivedrivewheels.
Bymovingbothsteeringleversanequalamountback,
themachinecanbesloweddownortravelbackward
inastraightline.
Steeringiscontrolledbyvaryingthepositionofthe
steeringleversrelativetoeachother.
SpeedControlLever
Locatedonrighthandconsole.
Thespeedcontrolleversetsmaximumforwardspeed.
Movingspeedcontrolleverrearwardtotheneutral
positionplacesthedrivesysteminneutral.
ChokeControl(AllUnitsExcept
KohlerEFI)
Locatedonthecontrolconsolefrontrighthandside.
Chokeisusedtoaidinstartingacoldengine.The
chokecontrolispulledouttobeinthe“ON”position
andpushedintobeinthe“OFF”position.DoNot
runawarmenginewithchokeinthe“ON”position.
Figure5
1.Ignitionswitch5.Throttle
2.Hopperswitch6.Engineoiltemperature
lightandbuzzer
3.Messagedisplay
7.Checkenginelight(EFI
UnitsOnly)
4.Choke(AllUnitsExcept
EFI)
ThrottleControl
Locatedonrighthandconsole.
Thethrottleisusedtocontrolenginespeed.Moving
throttleleverforwardwillincreaseenginespeedand
movingthrottlelevertotherearwilldecreaseengine
speed.
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
20
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