Exmark Navigator User manual

Category
Lawnmowers
Type
User manual
ForSerialNos.
720,000&Higher
NAVIGATOR®
PlaceModelNo.andSerialNo.
LabelHere(IncludedintheLiterature
Pack)orFillinBelow
DatePurchased
EngineModelNo.andSpec.No.
ModelNo.EngineSerialNo.(E/No)
SerialNo.
PartNo.4500-212Rev.A
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.
Important:Whenthemowerisusedoroperated
onanyCaliforniaforest,brushorgrasscovered
land,aworkingsparkarrestermustbeattached
tothemufer.Ifnot,theoperatorisviolating
statelaw,Section4442PublicResourceCode.To
acquireasparkarresterforyourunit,seeyour
EngineServiceDealer.
ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada
TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.
KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2005–2007—ExmarkMfg.Co.,Inc.
IndustrialParkBox808
Beatrice,NE68310
2
Contactusatwww.Exmark.com.
PrintedintheUSA.
AllRightsReserved
EXMARK PARTS PLUS
®
PROGRAM
EFFECTIVE DATE: September 1, 1995
Program
If your Exmark dealer does not have the Exmark part in stock, Exmark will
get the parts to the dealer the next business day or the part will be FREE*
Guaranteed!!
How the Program Works
1. If dealer does not have part in stock for a "down" unit at the time of request by customer, the dealer contacts his distributor
by 1:00 p.m., local time, and requests Exmark Parts Plus
®
shipment of six (6) line items or less.
2. Distributor ships part(s) to dealer or customer, as requested by dealer, same day, overnight UPS Distributor bills dealer for
part and freight charges where applicable.
3. If distributor does not have the part(s) in stock to satisfy Exmark Parts Plus
®
order, he contacts Exmark by 3:00 p.m., central
time, with an Exmark Parts Plus
®
order of six (6) line items or less.
4. If order is received by 3:00 p.m. central time, Exmark ships part(s) direct to dealer or customer, as requested by distributor,
same day, overnight UPS, Exmark bills the distributor for parts and shipping charges, where applicable.
5. The customer pays for the part and freight if it is shipped under the Exmark Parts Plus
®
and if it arrives in accordance to the
program.
6. Who pays for the part and freight if it fails to arrive overnight in accordance to the program?
A. Under any circumstance the customer does not pay.
B. If the part does not arrive overnight due to:
1. The dealer not submitting the Exmark Parts Plus
®
order to his Exmark distributor by 1:00 p.m., the dealer
pays for the part and freight.
2. The Distributor being unable to ship the part the same day or not submitting the Exmark Parts Plus
®
order
to Exmark by 3:00 p.m., central time, the Distributor pays for the part and freight.
3. Exmark being unable to ship the part and the Exmark parts order is received by 3:00 p.m., central time,
Exmark pays for the part and freight.
4. If the part does not arrive overnight due to the shipper (UPS), the shipper pays for the freight and Exmark
pays for the part.
* The following restrictions apply -- The Exmark Parts Plus
®
Program is available only through participating Exmark
Dealers and applies only to orders submitted on this program Monday through Thursday. Parts Plus service is available only in
the 48 contiguous United States. UPS has initiated a Saturday delivery program to many areas of the continental United States
and can be requested for an overnight shipment on Friday to be delivered Saturday. The next day air charge, plus the Saturday
delivery fee will be the responsibility of the purchaser. Exmark Mfg. will assume no responsibility for Saturday delivery
shipments. To qualify, all Exmark Parts Plus
®
orders must be received by Exmark by 3:00 p.m., central time. Orders must be
six (6) line items or less. Exclusions from the Exmark Parts Plus
®
Program are: Any wholegood or accessory in its entirety,
engines and engine replacement parts, 5-speed Peerless transmissions and 5-speed transaxles, hydraulic or hydrostatic wheel
motors, cutter decks and engine decks or any item exceeding United Parcel Service size and weight restrictions.
Due to UPS restrictions, aerosol spray paint is considered a hazardous material and cannot be shipped via UPS next day or
Second Day Air.
Exmark Manufacturing stocks a limited supply of parts for transaxles, pumps and wheel motors. These parts can be ordered
for Next Day Air shipment but will not be guaranteed per the Parts Plus Program.
3
Introduction
CONGRATULATIONSonthepurchaseofyour
ExmarkMower.Thisproducthasbeencarefully
designedandmanufacturedtogiveyouamaximum
amountofdependabilityandyearsoftrouble-free
operation.
Thismanualcontainsoperating,maintenance,
adjustment,andsafetyinstructionsforyourExmark
mower.
BEFOREOPERATINGYOURMOWER,
CAREFULLYREADTHISMANUALINITS
ENTIRETY.
Byfollowingtheoperating,maintenance,andsafety
instructions,youwillprolongthelifeofyourmower,
maintainitsmaximumefciency,andpromotesafe
operation.
Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
AllExmarkequipmentdealersanddistributorsare
keptinformedofthelatestmethodsofservicing
andareequippedtoprovidepromptandefcient
serviceintheeldorattheirservicestations.They
carryamplestockofservicepartsorcansecurethem
promptlyforyoufromthefactory.
AllExmarkpartsarethoroughlytestedandinspected
beforeleavingthefactory,however,attentionis
requiredonyourpartifyouaretoobtainthefullest
measureofsatisfactionandperformance.
Wheneveryouneedservice,genuineExmarkparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorExmarkCustomerServiceandhave
themodelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
4
Contents
Introduction...........................................................4
Safety.....................................................................6
SafetyAlertSymbol.........................................6
SafeOperatingPractices..................................6
SafetyandInstructionalDecals.....................11
Specications.......................................................14
ModelNumbers............................................14
Systems.........................................................14
Dimensions...................................................15
TorqueRequirements....................................16
ProductOverview................................................16
Operation.............................................................17
Controls........................................................17
Pre-Start........................................................18
OperatingInstructions..................................18
Transporting.................................................20
Maintenance.........................................................22
RecommendedMaintenanceSchedule(s)...........22
PeriodicMaintenance.......................................23
CheckEngineOilLevel.................................23
CheckBatteryCharge....................................23
CheckSafetyInterlockSystem.......................24
CheckforLooseHardware............................24
ServiceAirCleaner........................................24
ChangeEngineOil........................................24
CheckHydraulicOilLevel.............................25
CheckTirePressures.....................................25
CheckConditionOfBelts..............................25
LubricateGreaseFittings...............................25
LubricateRearCasterWheelHubs.................26
LubricateBrakeHandlePivot........................27
LubricateBrakeRodBushings.......................27
LubricateSteeringLinkageRodEnds.............27
LubricateHopperActuator............................27
CheckSparkPlugs.........................................27
ChangeHydraulicSystemFilter.....................28
CheckWheelHubLocknuts..........................28
CheckWheelLugNuts..................................28
ThreadLockingAdhesives.............................28
DielectricGrease...........................................28
Adjustments.....................................................29
PTODriveBeltTension................................29
PumpDriveBeltTension...............................29
PTOBeltReplacement..................................29
PumpDriveBeltReplacement......................29
BeltGuideAdjustment..................................30
AdjustSafetySwitch......................................30
BrakeAdjustment..........................................30
AdjustSpeedControlLeverTension..............31
SpeedControlLinkageAdjustment................31
SteeringControlLeverResponse
Adjustment...............................................33
TrackingAdjustment.....................................33
PTODrivePulleyAlignment.........................33
PumpDrivePulleyAlignment........................34
RearCasterPivotBearingsPre-Load
Adjustment...............................................34
HopperDoorAdjustment.............................34
PTOBrakeSpringAdjustment......................35
Cleaning...........................................................35
RemoveAccumulatedDebrisfrom
Engine......................................................35
RemoveEngineShroudsandCleanCooling
Fins...........................................................35
WasteDisposal..............................................36
Troubleshooting...................................................37
Schematics...........................................................39
5
Safety
Safety
SafetyAlertSymbol
ThisSafetyAlertSymbol(Figure2)isusedbothin
thismanualandonthemachinetoidentifyimportant
safetymessageswhichmustbefollowedtoavoid
accidents
Thissymbolmeans:ATTENTION!BECOME
ALERT!YOURSAFETYISINVOLVED!
Figure2
1.Safetyalertsymbol
Thesafetyalertsymbolappearsaboveinformation
whichalertsyoutounsafeactionsorsituations
andwillbefollowedbythewordDANGER,
WARNING,orCAUTION.
DANGER:Whitelettering/Redbackground.
Indicatesanimminentlyhazardoussituationwhich,if
notavoided,Willresultindeathorseriousinjury.
WARNING:Blacklettering/Orangebackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Couldresultindeathorseriousinjury.
CAUTION:Blacklettering/Yellowbackground.
Indicatesapotentiallyhazardoussituationwhich,if
notavoided,Mayresultinminorormoderateinjury.
Thismanualusestwootherwordstohighlight
information.Importantcallsattentiontospecial
mechanicalinformationandNoteemphasizes
generalinformationworthyofspecialattention.
SafeOperatingPractices
Training
ReadtheOperator’sManualandothertraining
material.Iftheoperator(s)ormechanic(s)can
notreadEnglishitistheowner’sresponsibilityto
explainthismaterialtothem.
Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
Alloperatorsandmechanicsshouldbetrained.
Theownerisresponsiblefortrainingtheusers.
Neverletchildrenoruntrainedpeopleoperate
orservicetheequipment.Localregulationsmay
restricttheageoftheoperator.
Theowner/usercanpreventandisresponsible
foraccidentsorinjuriesoccurringtohimselfor
herself,otherpeopleorproperty.
Preparation
Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbyExmark.
Wearappropriateclothingincludingsafetyglasses,
substantialfootwear,longtrousers,andhearing
protection.DoNotoperatewhenbarefootor
whenwearingopensandals.Longhair,loose
clothingorjewelrymaygettangledinmoving
parts.
CAUTION
Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.
Wearhearingprotectionwhenoperatingthis
machine.
Inspecttheareawheretheequipmentistobe
usedandremoveallrocks,toys,sticks,wires,
bones,andotherforeignobjectswhichcanbe
thrownbythemachineandmaycausepersonal
injurytotheoperatororbystanders.
6
Safety
DANGER
Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.
Fillthefueltankoutdoorsinanopen
area,whentheengineiscold.Wipeup
anygasolinethatspills.
Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.
DoNotllthefueltankcompletely
full.Addgasolinetothefueltankuntil
thelevelis1/4to1/2inch(6–13mm)
belowthebottomofthellerneck.This
emptyspaceinthetankallowsgasoline
toexpand.
Neversmokewhenhandlinggasoline,
andstayawayfromanopenameor
wheregasolinefumesmaybeignitedby
spark.
Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.
Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.
Iffuelisspilled,DoNotattempttostart
theengine.Moveawayfromtheareaof
thespillandavoidcreatinganysourceof
ignitionuntilfuelvaporshavedissipated.
DoNotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.
DANGER
Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitegasolinevapors.Areor
explosionfromgasolinecanburnyouand
othersandcausepropertydamage.
Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.
DoNotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.
Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelson
theground.
Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.
Ifagasolinedispensernozzlemustbe
used,keepthenozzleincontactwiththe
rimofthefueltankorcontaineropening
atalltimesuntilfuelingiscomplete.
WARNING
Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
Avoidprolongedbreathingofvapors.
Keepfaceawayfromnozzleandgas
tank/containeropening.
Keepawayfromeyesandskin.
Neversiphonbymouth.
7
Safety
Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
Operation
WARNING
Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.
Allowengineparts,especiallythemufer,
tocoolbeforetouching.
Removeaccumulateddebrisfrommufer
andenginearea.
Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.
DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.
WARNING
OperatingaNavigatortractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofoperator
entanglementindrivewheelsorforwardtip
over.Entanglementortip-overcouldcause
seriousinjuryordeath.
WhenoperatingaNavigatortractor
withoutanapprovedExmarkfrontmount
attachment,observethefollowing:
Keepfeetandclothingawayfromtires.
Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.
Minimizespeedanduseextremecaution.
Onlyoperateonaatlevelsurface.
Donotoperateupordownatrailerramp.
Avoidsuddenaccelerationordeceleration.
Operateonlyindaylightorgoodarticiallight,
keepingawayfromholesandhiddenhazards.
Besurealldrivesareinneutralandparkingbrake
isengagedbeforestartingengine.
Neverraisedeckwithbladesrunning.
Neveroperatethemowerwithdamagedguards,
shields,orcovers.Alwayshavesafetyshields,
guards,switchesandotherdevicesinplaceandin
properworkingcondition.
Nevermowunlessthereisagrasscollection
systemormulchkitinplaceandworkingproperly.
DoNotchangetheenginegovernorsettingor
overspeedtheengine.
Stopengine,waitforallmovingpartstostop,
removekeyandengageparkingbrake:
Beforechecking,cleaningorworkingonthe
mower.
Afterstrikingaforeignobjectorabnormal
vibrationoccurs(inspectthemowerfor
damageandmakerepairsbeforerestarting
andoperatingthemower).
Beforeclearingblockages.
Wheneveryouleavethemower.
8
Safety
Stopengine,waitforallmovingpartstostop,and
engageparkingbrake:
Beforerefueling.
Beforedumpingthegrasscatcher.
WARNING
Hands,feet,hair,clothing,oraccessoriescan
becomeentangledinrotatingparts.Contact
withtherotatingpartscancausetraumatic
amputationorseverelacerations.
DoNotoperatethemachinewithout
guards,shields,andsafetydevicesin
placeandworkingproperly.
Keephands,feet,hair,jewelry,orclothing
awayfromrotatingparts.
NEVERcarrypassengers.DONOToperate
themowerwhenpeople,especiallychildren,or
petsareinthearea.
Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebefore
changingdirections.
Stoptheblades,slowdown,andusecautionwhen
crossingsurfacesotherthangrassandwhen
transportingthemowertoandfromtheareato
bemowed.
Beawareofthemowerdischargepathanddirect
dischargeawayfromothers.
DoNotoperatethemowerundertheinuence
ofalcoholordrugs.
Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.
Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.
SlopeOperation
UseExtremecautionwhenmowingand/orturning
onslopesaslossoftractionand/ortip-overcould
occur.Theoperatorisresponsibleforsafeoperation
onslopes.
DANGER
Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.Wheels
droppingoveredges,ditches,steepbanks,or
watercancauserollovers,whichmayresult
inseriousinjury,deathordrowning.
DoNotmowslopeswhengrassiswet.
DoNotmowneardrop-offsornearwater.
DoNotmowslopesgreaterthan15
degrees.
Reducespeedanduseextremecaution
onslopes.
Avoidsuddenturnsorrapidspeed
changes.
Seeinsidethebackcovertodeterminethe
approximateslopeangleoftheareatobemowed.
Useawalkbehindmowerand/orahandtrimmer
neardrop-offs,ditches,steepbanksorwater.
(Figure3).
Figure3
1.SafeZone-Usethemowerhereonslopeslessthan15
degrees
2.DangerZone-Useawalkbehindmowerand/orhand
trimmerneardrop-offsandwater.
3.Water
Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
9
Safety
Avoidsuddenstartswhenmowingdownhill.
Mowermaytipforwards.
Beawarethatlossoftractionmayoccurgoing
uphill.Weighttransfertotherearwheelmay
causedrivewheelstoslipandcauselossof
brakingandsteering.
Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
Useextremecarewithattachments.Thesecan
changethestabilityofthemachineandcauseloss
ofcontrol.
MaintenanceandStorage
Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.
Keepengine,enginearea,andpumpdrivebelt
compartmentfreefromaccumulationofgrass,
leaves,excessivegreaseoroil,andotherdebris
whichcanaccumulateintheseareas.These
materialscanbecomecombustibleandmayresult
inare.
Letenginecoolbeforestoringanddonotstore
nearameoranyenclosedareawhereopenpilot
lightsorheatappliancesarepresent.
Shutofffuelwhilestoringortransporting.Do
Notstorefuelnearamesordrainindoors.
Parkmachineonlevelground.Neverallow
untrainedpersonneltoservicemachine.
Usejackstandstosupportcomponentswhen
required.
Carefullyreleasepressurefromcomponentswith
storedenergy.
Disconnectbatteryorremovesparkplugwire
beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Reconnectpositiverstandnegativelast.
Usecarewhencheckingblades.Wraptheblade(s)
orweargloves,andusecautionwhenservicing
them.Onlyreplaceblades.Neverstraightenor
weldthem.
Keephandsandfeetawayfrommovingparts.
Ifpossible,donotmakeadjustmentswiththe
enginerunning.
Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugcharger
beforeconnectingordisconnectingfrombattery.
Wearprotectiveclothinganduseinsulatedtools.
Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
Checkallboltsfrequentlytomaintainproper
tightness.
Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
Allreplacementpartsmustbethesameas
orequivalenttothepartssuppliedasoriginal
equipment.
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.
Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.
Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
Usecardboardorpaper,notyourhands,
tondhydraulicleaks.
Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.
10
Safety
SafetyandInstructionalDecals
Keepallsafetysignslegible.Removeallgrease,
dirtanddebrisfromsafetysignsandinstructional
labels.
Replaceallworn,damaged,ormissingsafety
signs.
Whenreplacementcomponentsareinstalled,be
surethatcurrentsafetysignsareafxedtothe
replacedcomponents.
Ifanattachmentoraccessoryhasbeeninstalled,
makesurecurrentsafetysignsarevisible.
Newsafetysignsmaybeobtainedfrom
yourauthorizedExmarkequipmentdealeror
distributororfromExmarkMfg.Co.Inc.
Safetysignsmaybeafxedbypeelingoffthe
backingtoexposetheadhesivesurface.Apply
onlytoaclean,drysurface.Smoothtoremove
anyairbubbles.
Familiarizeyourselfwiththefollowingsafetysigns
andinstructionlabels.Theyarecriticaltothesafe
operationofyourExmarkcommercialmower.
1–513747
1–523552
65–2690
98–4361
98–5954
103–8425
103–8444
103–8451
103–8495
11
Safety
103–8611
103–9032
103–9034
103–9724
109–4273
12
Safety
109–4638
109–7318
MoldedinLHConsole
MoldedintoFrontofHopper
13
Specications
Specications
ModelNumbers
SerialNos:720,000andHigher
NAV20KC;NAV27KC
Systems
Engine
EngineSpecications:SeeyourEngineOwner’s
Manual
RPM:FullSpeed:3600±50RPM(NoLoad)
Idle:1500RPM
FuelSystem
Capacity:7.5gal.(28L)
TypeofFuel:Regularunleadedgasoline,87
octaneorhigher.
FuelFilter:In-line30MicronKohlerP/N
2405010.
FuelShut-OffValve:1/4turnincrementsin-line
valvebyfuellter.
ElectricalSystem
ChargingSystem:FlywheelAlternator
ChargingCapacity:15amps
BatteryType:BCIGroupU1
BatteryVoltage:12Volt
Polarity:NegativeGround
Fuses:Two20ampandone30ampbladetype
SafetyInterlockSystem:
PTOmustbedisengaged,brakeengaged,and
speedcontrolleverinneutralpositiontostart
engine.(Itisnotnecessaryfortheoperatorto
beintheseattostarttheengine.)
OperatormustbeinseatwhenPTOis
engaged,brakeisdisengaged,orspeedcontrol
leverismovedoutofneutralorenginewill
stop.
Enginewillstopinthefollowingconditions:
Ifthespeedcontrolleverismovedfrom
neutralpositionwhilebrakeisengaged.
IfthePTOisengagedwhilethehopper
istiltedup.
OperatorControls
SteeringandMotionControl:
SpeedControllever,locatedonRHconsole,
setsmaximumforwardspeed.
Steeringlevers,centeredinfrontoftheseat,
controlthespeedanddirectionoftravelof
therespectivedrivewheels.
Movingspeedcontrolleverrearwardtothe
neutralpositionplacesthedrivesystemin
neutral.
Note:Theunitmaybemovedinreverse
whilethespeedcontrolisintheneutral
positionbypullingbackonthesteeringlevers.
PTOEngagementLever:EngagesdrivetoPTO
(mowerdeck)andblower.
ParkingBrakeLever:Pullbacktoengageparking
brake.
Seat
Type:Standardseatwithhighback,foampadded
(internalsuspension).
Mounting:Seatishingedtotiltupforaccessto
hydraulicpumpsandothercomponents.Theseat
isheldinthetiltedpositionwithalink.
Armrests:None.
SeatSafetySwitch:Internaltothebottomseat
cushion,nonserviceable.Timedelaymodule
incorporatedintotheSafetyInterlockSystem
eliminatesroughgroundcut-outs.
HydrostaticGroundDriveSystem
HydrostaticPumps:TwoHydroGearvariable
displacementpistonpumps.
WheelMotors:HydroGearplanetaryreduction
motors.
HydraulicOilType:UseMobil115W-50
Syntheticmotoroil.
HydraulicOilCapacity:4.0qt.(3.8L)
14
Specications
HydraulicFilter:Replaceablecartridgetype.
Summeruseabove32°F(0°C):
P/N109-0071:25microns,10psibypass
Winterusebelow32°F(0°C):
P/N1-523541:40microns,18psibypass
Speeds:
0-7.0mph(11.3km/hr)forward.
0-5.5mph(8.6km/hr)reverse.
Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
Tires&Wheels
Drive
Front
Caster
RearCaster
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
(Soldseparately)
ModelNumbers:
CD42CD
CD48CD
CuttingWidth:
42inchDeck:42inch(106.7cm)
48inchDeck:48inch(121.9cm)
Discharge:Center
BladeSize:(2ea.)
w/42inchDeck:22.00inches(55.9cm)
w/48inchDeck:25.00inches(63.5cm)
DeckDrive:
Clutchingbeltonhorizontalengineshaft.
Dual Asectionhexagonbeltwithspring
tensionedidlertojackshaftandblower.
Heavy-dutycastiron,spiralbevelgearboxis
naldrivetoblades.
Deck:
Fulloatingdeckisattachedtoout-frontsupport
frame.Deckdesignallowsforbaggingor
mulching.
DeckDepth:
42inchDeck:45/8inches(11.7cm)
48inchDeck:45/8inches(11.7cm)
Dimensions
OverallWidth:
WithoutDeck42inchDeck48inchDeck
42.6inches
(108.2cm)
43.2inches
(109.7cm)
49.2inches
(125.0cm)
OverallLength:
WithoutDeck42inchDeck48inchDeck
67.3inches
(170.9cm)
91.8inches
(233.2cm)
94.5inches
(240.0cm)
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)
WheelBase:(CenterofDriveWheel
toCenterofRearCasterWheel)
42inchDeck48inchDeck
44.2inches(112.3cm)44.2inches(112.3cm)
15
ProductOverview
CurbWeight:
42inchDeck48inchDeck
W/72inch
Deck
850lb(386kg)1145lb(519kg)1170lb(531kg)
TorqueRequirements
BoltLocation
Torque
BladeMountingBolt85-110ft-lb(115-149N-m)
EngineMountingBolts
30-35ft-lb(41-47N-m)
WheelLugNuts
90-95ft-lb(122-129N-m)
WheelMotorMounting
Bolts
72-77ft-lb(98-104N-m)
WheelHubLocknut210-250ft-lb
(285-339N-m)
ProductOverview
Figure4
1.SpeedControlLever4.SteeringLevers
2.Controls5.PTOEngagementLever
3.FuelCap
6.ParkingBrakeLever
16
Operation
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Controls
SteeringLevers
Locatedinthecenterinfrontoftheseat.
Pullingbackonthesteeringlevers,progressively
slows,thenreversesthedirectionoftravelofthe
respectivedrivewheels.
Bymovingbothsteeringleversanequalamountback,
themachinecanbesloweddownortravelbackward
inastraightline.
Steeringiscontrolledbyvaryingthepositionofthe
steeringleversrelativetoeachother.
SpeedControlLever
Locatedonrighthandconsole.
Thespeedcontrolleversetsmaximumforwardspeed.
Movingspeedcontrolleverrearwardtotheneutral
positionplacesthedrivesysteminneutral.
ChokeControl
Locatedonrighthandconsole.
Thechokeisusedtoaidinstartingacoldengine.
Movingthechokeleverforwardwillputthechokein
the“ON”positionandmovingthechokelevertothe
rearwillputthechokeinthe“OFF”position.DO
NOTrunawarmenginewithchokeinthe“ON”
position.
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
thenextpositiontoengagethestarter(keymustbe
heldagainstspringpressureinthisposition).
Note:Brakemustbeengaged,speedcontrollever
rearward(neutralposition)andPTOdisengagedto
startengine.(Itisnotnecessaryfortheoperatorto
beintheseattostarttheengine.)
HourMeter
Locatedontherighthandconsole.
Thehourmeterisconnectedtoapressureswitch
installedintheengineblockanditrecordsthe
numberofhoursthattheenginehasrun.Ifthe
ignitionswitchisleftonwithoutenginerunning,
hourmeterwillnotrun.
Note:Thisswitchisnotalowoilsensorandwillnot
alerttheoperatoriftheengineoilislow.
FuelShut-OffValve
Locatedinfuellinebyfueltankandfuellter
(accessiblebyraisingthehopper).
Thefuelshut-offvalveisusedtoshutoffthefuel
whenthemachinewillnotbeusedforafewdays,
duringtransporttoandfromthejobsite,andwhen
parkedinsideabuilding.
Rotatethevalve1/4turnclockwisetoshutoffthe
fuel.rotatethevalve1/4turncounterclockwiseto
turnonthefuel.
17
Operation
DriveWheelReleaseValves
Locatedonthetopleftfrontcornerofhydrostatic
pumps.
Drivewheelreleasevalvesareusedtoreleasethe
hydrostaticdrivesystemtoallowthemachinetobe
pushedwithouttheenginerunning.Tiltseatupto
gainaccesstopumps.
Witha7/16wrench,turnbothvalvesoneturn
counterclockwisetoreleasedrivesystem.Turn
clockwisetoresetsystem.DoNotovertighten.Do
Nottowmachine.
TrackingAdjustmentKnob
Locatedundertheseatontheleftpumpcontrollink.
Rotatingthisknoballowsnetuningadjustmentsso
thatthemachinetracksstraightwiththedrivelevers
inthefullforwardposition.
Rununitat3/4speedforatleast5minutesto
bringhydraulicoiluptooperatingtemperature.
Stopmachineandwaitforallmovingpartstostop.
Engageparkbrake.Tiltseatforwardtogainaccess
tothetrackingknob.Rotatetheknobtowardsthe
righttosteerrightandrotatetowardstheleftto
steerleft.Adjustin1/8turnincrementsuntilthe
machinetracksstraight.Checkthatthemachine
doesnotcreepwheninneutralwiththeparkbrakes
disengaged.
Important:DoNotrotatetheknobtoofar,as
thismaycausethemachinetocreepinneutral.
RefertotheMotionControlLinkageAdjustment
sectioninMaintenance.
PTOEngagementLever
Locatedimmediatelyleftoftheleftconsole.
Levermustbemoveduptothe“ROTATE”position
toengagethePTOandblowerdrives.Leverismoved
downtothe“STOP”positiontostopthedrives.
EngineOilTemperatureLightand
Buzzer
Locatedontherightconsole.
Theengineoiltemperaturelightmonitorsthe
temperatureoftheengineoil.Anilluminatedengine
oiltemperaturelightandintermittentbuzzingsound
signalstheengineisoverheating.
Pre-Start
Fillfueltanks.Forbestresultsuseonlyclean,fresh
regulargradeunleadedgasolinewithanoctanerating
of87orhigher.Regulargradeleadedgasolinemay
alsobeused;however,combustionchamberand
cylinderheadwillrequiremorefrequentservice.See
EngineOwner’sManual.
DoNotaddoiltogasoline.
DoNotoverllfueltank.Neverllthefueltankso
thatthefuellevelrisesabovealevelthatis1/2inch
(13mm)belowthebottomofthellernecktoallow
forfuelexpansionandpreventfuelspillage.
Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.
RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.
OperatingInstructions
OpentheFuelShut-OffValve
Thefuelshut-offvalveislocatedontherightsideof
unitinfuellinenexttothefuellter.Raisethehopper
toaccess.Rotatethevalve1/4counterclockwiseto
turnonfuel.
StartingtheEngine
1.Movethespeedcontrollevertotheneutral
position.
2.Pullupandbackontheparkingbrakeleverto
engagetheparkingbrake.
3.PushthePTOengagementleverdowntothe
“STOP”position.
Note:Itisnotnecessaryfortheoperatortobe
intheseattostarttheengine.
4.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.
5.Onacoldengine,pushthechokeleverforward
intothe“ON”position.
Onawarmengine,leavethechokeinthe“OFF”
position.
6.Turnignitionswitchtothe“START”position.
Releasetheswitchassoonastheenginestarts.
18
Operation
Important:DoNotcranktheengine
continuouslyformorethantensecondsata
time.Iftheenginedoesnotstart,allowa60
secondcool-downperiodbetweenstarting
attempts.Failuretofollowtheseguidelines
canburnoutthestartermotor.
7.Ifthechokeisinthe“ON”position,gradually
returnchoketothe“OFF”positionastheengine
warmsup.
EngagingthePTO
DANGER
Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.
DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.
DANGER
Anuncovereddischargeopeningwillallow
objectstobethrowninanoperator’sor
bystander’sdirection.Also,contactwiththe
blowerbladescouldoccur.Thrownobjects
orbladecontactcancauseseriousinjuryor
death.
Neveroperatethemowerwiththehopper
orhopperdoorraised,removed,oraltered
unlessthereisamulchkitinplaceand
workingproperly.
ThePTOleverengagesthePTOandblower.Besure
thatthehopperisdown,thehopperdoorissecurely
closed,andallpersonsareclearofthemowerdeck
anddischargeareabeforeengagingPTO.
Important:Operatormustbeinseatbeforethe
PTOcanbeengaged.
1.Setthethrottletothe“MIDWAY”position.
2.PullthePTOleverupwarduntillockedover
center.
3.Placethethrottleinthe“FAST”positiontobegin
mowing.
DisengagingthePTO
1.Setthethrottletothe“MIDWAY”position.
2.PushPTOleverdowntothe“STOP”position
stoppingthePTOandblower.
StoppingtheEngine
1.Bringtheunittoafullstop.
2.DisengagethePTO.
3.Movespeedcontrollevertotheneutralposition.
4.Engagetheparkingbrake.
5.Placethethrottlemidwaybetweenthe“SLOW”
and“FAST”positions.
6.Allowtheenginetorunforaminimumof15
seconds,thenturntheignitionswitchtothe
“OFF”positiontostoptheengine.
7.Removethekeytopreventchildrenorother
unauthorizedpersonsfromstartingengine.
8.Closethefuelshut-offvalvewhenthemachine
willnotbeinuseforafewdays,when
transporting,orwhentheunitisparkedinside
abuilding.
DrivingtheMachine
CAUTION
Machinecanspinveryrapidlybypositioning
onelevertoomuchaheadoftheother.
Operatormaylosecontrolofthemachine,
whichmaycausedamagetothemachine
orinjury.
Usecautionwhenmakingturns.
Slowthemachinedownbeforemaking
sharpturns.
Important:Tobeginmovement(forwardor
backward)theoperatormustbeintheseat,the
brakelevermustbedisengaged(pusheddown)
beforethespeedcontrollevercanbemoved
forwardortheenginewillstop.
DrivingForward
1.Starttheengine.
2.Releasetheparkingbrake.
3.Tomoveforwardinastraightlinemovethespeed
controlleverforward.
19
Operation
Toturnleftorright,pulloneofthesteeringlevers
backtowardneutralinthedirectiondesired.
Themachinewillmovefasterthefartherthe
speedcontrolleverismovedawayfromneutral.
4.Tostop,pullthespeedcontrolleverbacktothe
neutralposition.
DrivinginReverse
1.Tomoverearwardinastraightlineapplyingequal
pressurepullbothsteeringleversrearward.
Toturnleftorright,releasepressureonthe
steeringlevertowardthedirectiondesired.
2.Tostop,releasethesteeringleverstotheneutral
position.
EmptyingHopper
1.Afullhopperisindicatedbyabuzzerlocated
behindtheoperatorinthehopper.Emptyhopper
whenbuzzersoundstopreventcloggingofthe
blowerordeck.
2.DisengagePTO,movespeedcontroltoneutral,
setparkbrakeanddismountunittodumphopper.
3.Makesureunitisonadrylevelsurface.
4.Liftthereardoorupandallowittorestontop
ofhopper.
5.Dumphopperbyrmlygraspingoneofthe
hopperhandlesoneithersideoftheunitand
liftingthehopper.
ClearingHopperScreen
Screenmayberemovedbyrmlyliftingscreen
handles(seeFigure5).
Pullscreentowardsthebacktoremove.Gentlytap
debrisfromthescreenasneeded.
Excessivebuild-uponthescreencancausethe
blowertoplug.
Note:Inconditionswherethescreenclogsquickly,
thefrontremovablescreenpanelcanbeturnedand
reinstalledundertheprimaryscreentoallowfreeair
owfromthehopper.
Figure5
1.Frontremovablescreen
canberotatedand
storedforwetcondtions
3.Primaryscreen
2.Frontremovablescreen4.Handles.
Transporting
TransportingaUnit
Useaheavy-dutytrailerortrucktotransportthe
machine.Lockbrakeandblockwheels.Securely
fastenthemachinetothetrailerortruckwithstraps,
chains,cable,orropes.Besurethatthetrailerortruck
hasallnecessarylightingandmarkingasrequiredby
law .Secureatrailerwithasafetychain.
CAUTION
Thisunitdoesnothaveproperturn
signals,lights,reectivemarkings,ora
slowmovingvehicleemblem.Drivingona
streetorroadwaywithoutsuchequipment
isdangerousandcanleadtoaccidents
causingpersonalinjury.Drivingonastreet
orroadwaywithoutsuchequipmentmayalso
beaviolationofStatelawsandtheoperator
maybesubjecttotrafcticketsand/ornes.
DoNotdriveaunitonapublicstreetor
roadway.
20
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Exmark Navigator User manual

Category
Lawnmowers
Type
User manual

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