NA VIGATOR®
ForSerialNos.
850,000&Higher
PartNo.4500-628Rev.B
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,or
otherreproductiveharm.
Important:Theengineinthisproductisnot
equippedwithasparkarrestermufer.Itisa
violationofCaliforniaPublicResourceCode
(CPRC)Section4442touseoroperatethis
engineonanyforest-covered,brush-covered,or
grass-coveredlandasdenedinCPRC4126.
Otherstatesorfederalareasmayhavesimilar
laws.
ThissparkignitionsystemcomplieswithCanadian
ICES-002Cesystèmed’allumageparètincellede
vèhiculeestconformeàlanormeNMB-002du
Canada
TheenclosedEngineOwner’sManualis
suppliedforinformationregardingTheU.S.
EnvironmentalProtectionAgency(EPA)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenanceandwarranty.
KeepthisengineOwner’sManualwithyourunit.
ShouldthisengineOwner’sManualbecome
damagedorillegible,replaceimmediately.
Replacementsmaybeorderedthroughthe
enginemanufacturer.
Exmarkreservestherighttomakechangesor
addimprovementstoitsproductsatanytime
withoutincurringanyobligationtomakesuch
changestoproductsmanufacturedpreviously.
Exmark,oritsdistributorsanddealers,accept
noresponsibilityforvariationswhichmaybe
evidentintheactualspecicationsofitsproducts
andthestatementsanddescriptionscontained
inthispublication.
©2010—ExmarkMfg.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.
Ifadditionalinformationisneeded,orshouldyou
requiretrainedmechanicservice,contactyour
authorizedExmarkequipmentdealerordistributor.
Exmarkpartsmanualsareavailableonlineat
http://www.exmark.com/manuals.htm.
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.......................................................14
ModelNumbers............................................14
Systems.........................................................14
Dimensions...................................................15
TorqueRequirements....................................16
ProductOverview................................................16
Operation.............................................................17
Controls........................................................17
Pre-Start........................................................18
OperatingInstructions..................................18
Transporting.................................................20
Maintenance.........................................................22
RecommendedMaintenanceSchedule(s)...........22
PeriodicMaintenance.......................................23
CheckEngineOilLevel.................................23
CheckBatteryCharge....................................23
CheckSafetyInterlockSystem.......................24
CheckforLooseHardware............................25
ServiceAirCleaner........................................25
ChangeEngineOil........................................25
CheckHydraulicOilLevel.............................26
CheckTirePressures.....................................26
CheckConditionOfBelts..............................26
LubricateGreaseFittings...............................26
LubricateRearCasterWheelHubs.................27
LubricateBrakeHandlePivot........................28
LubricateBrakeRodBushings.......................28
LubricateSteeringLinkageRodEnds.............28
LubricateHopperActuator............................28
CheckSparkPlugs.........................................28
ChangeHydraulicSystemFilter.....................29
CheckWheelHubLocknuts..........................29
CheckWheelLugNuts..................................29
ThreadLockingAdhesives.............................29
DielectricGrease...........................................30
Adjustments.....................................................30
PTODriveBeltTension................................30
PumpDriveBeltTension...............................30
PTOBeltReplacement..................................30
PumpDriveBeltReplacement......................31
BeltGuideAdjustment..................................31
AdjustSafetySwitch......................................32
BrakeAdjustment..........................................32
AdjustSpeedControlLeverTension..............32
SpeedControlLinkageAdjustment................33
SteeringControlLeverResponse
Adjustment...............................................34
TrackingAdjustment.....................................35
PTODrivePulleyAlignment.........................35
PumpDrivePulleyAlignment........................35
RearCasterPivotBearingsPre-Load
Adjustment...............................................36
HopperDoorAdjustment.............................36
PTOBrakeSpringAdjustment......................36
Cleaning...........................................................37
CleanEngineandExhaustSystem
Area..........................................................37
RemoveEngineShroudsandCleanCooling
Fins...........................................................37
CleanDebrisFromMachine..........................37
WasteDisposal..............................................37
Troubleshooting...................................................38
Schematics...........................................................40
4
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.
•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,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.
5
Safety
DANGER
Incertainconditionsgasolineisextremely
ammableandvaporsareexplosive.
Areorexplosionfromgasolinecanburn
you,others,andcausepropertydamage.
•Fillthefueltankoutdoorsonlevel
ground,inanopenarea,whentheengine
iscold.Wipeupanygasolinethatspills.
•Neverrellthefueltankordrainthe
machineindoorsorinsideanenclosed
trailer.
•DoNotllthefueltankcompletelyfull.
Fillthefueltanktothebottomoftheller
neck.Theemptyspaceinthetankallows
gasolinetoexpand.Overllingmayresult
infuelleakageordamagetotheengine
oremissionsystem(ifequipped).
•Neversmokewhenhandlinggasoline,
andstayawayfromanopenameor
wheregasolinefumesmaybeignitedby
spark.
•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.
•Addfuelbeforestartingtheengine.
Neverremovethecapofthefueltankor
addfuelwhenengineisrunningorwhen
theengineishot.
•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.
WARNING
Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporshascaused
cancerinlaboratoryanimals.Failuretouse
cautionmaycauseseriousinjuryorillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgas
tank/containeropening.
•Keepawayfromeyesandskin.
•Neversiphonbymouth.
6
Safety
•Checkthattheoperator’spresencecontrols,
safetyswitches,andshieldsareattachedand
functioningproperly.DoNotoperateunlessthey
arefunctioningproperly.
Operation
WARNING
Operatingengineparts,especiallythe
mufer,becomeextremelyhot.Severeburns
canoccuroncontactanddebris,suchas
leaves,grass,brush,etc.cancatchre.
•Allowengineparts,especiallythemufer,
tocoolbeforetouching.
•Removeaccumulateddebrisfrommufer
andenginearea.
•Installandmaintaininworkingordera
sparkarresterbeforeusingequipment
onforest-covered,grass-covered,or
brush-coveredunimprovedland.
WARNING
Engineexhaustcontainscarbonmonoxide,
whichisanodorlessdeadlypoisonthatcan
killyou.
DoNotrunengineindoorsorinasmall
connedareawheredangerouscarbon
monoxidefumescancollect.
WARNING
OperatingaNavigatortractorwithoutan
approvedExmarkfrontmountattachment
increasesthepossibilityofoperator
entanglementindrivewheelsorforwardtip
over.Entanglementortip-overcouldcause
seriousinjuryordeath.
WhenoperatingaNavigatortractor
withoutanapprovedExmarkfrontmount
attachment,observethefollowing:
•Keepfeetandclothingawayfromtires.
•Limitoperationtominimumrequiredto
installadifferentfrontmountattachment.
•Minimizespeedanduseextremecaution.
•Onlyoperateonaatlevelsurface.
•Donotoperateupordownatrailerramp.
•Avoidsuddenaccelerationordeceleration.
•Operateonlyindaylightorgoodarticiallight,
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.
7
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.
•DoNotoperatethemowerundertheinuence
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
trimmeronslopesgreaterthan15degrees,near
drop-offsandwater.
3.Water
•Removeormarkobstaclessuchasrocks,tree
limbs,etc.fromthemowingarea.Tallgrasscan
hideobstacles.
•Watchforditches,holes,rocks,dipsandrisesthat
changetheoperatingangle,asroughterraincould
overturnthemachine.
8
Safety
•Avoidsuddenstartswhenmowingdownhill.
Mowermaytipforwards.
•Beawarethatoperatingonwetgrass,acrosssteep
slopesordownhillmaycausethemowertolose
traction.Lossoftractiontothedrivewheelsmay
resultinslidingandalossofbrakingandsteering.
•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagetheblades
andproceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprove
stability.
•Useextremecarewithattachments.Thesecan
changethestabilityofthemachineandcauseloss
ofcontrol.
Note:A2–postfoldableROPS(RolloverProtection
System)isavailablefortheNavigatorasanaccessory.
AROPSisrecommendedifyouwillbemowing
nexttodrop-offs,nearwater,oronsteepbanks
whichcouldresultinarollover.Themodelnumber
fortheROPSattachmentisFRPSNA V .Contactan
AuthorizedExmarkServiceDealerformoredetails.
MaintenanceandStorage
•Disengagedrives,lowerimplement,setparking
brake,stopengineandremovekeyordisconnect
sparkplugwire.Waitforallmovementtostop
beforeadjusting,cleaningorrepairing.
•Keepengine,enginearea,andpumpdrivebelt
compartmentfreefromaccumulationofgrass,
leaves,excessivegreaseoroil,andotherdebris
whichcanaccumulateintheseareas.These
materialscanbecomecombustibleandmayresult
inare.
•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.
9
Safety
CAUTION
Iftheignitionisinthe“ON”positionthere
ispotentialforsparksandengagement
ofcomponents.Sparkscouldcausean
explosionormovingpartscouldaccidentally
engagecausingpersonalinjury
Besureignitionswitchisinthe“OFF”
positionbeforechargingthebattery.
•Keepallguards,shieldsandallsafetydevicesin
placeandinsafeworkingcondition.
•Checkallboltsfrequentlytomaintainproper
tightness.
•Frequentlycheckforwornordeteriorating
componentsthatcouldcreateahazard.
WARNING
Removingstandardoriginalequipment
parts,orusingnon-Exmarkreplacement
partsandaccessoriesmayalterthewarranty,
traction,andsafetyofthemachine.Failure
touseoriginalExmarkpartscouldcause
seriousinjuryordeath.
Replaceallpartsincluding,butnotlimited
to,tires,belts,andbladeswithoriginal
Exmarkparts.
WARNING
Hydraulicuidescapingunderpressure
canpenetrateskinandcauseinjury.Fluid
accidentallyinjectedintotheskinmustbe
surgicallyremovedwithinafewhoursbya
doctorfamiliarwiththisformofinjuryor
gangrenemayresult.
•Makesureallhydraulicuidhoses
andlinesareingoodconditionand
allhydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.
•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.
•Usecardboardorpaper,notyourhands,
tondhydraulicleaks.
•Safelyrelieveallpressureinthehydraulic
systembyplacingthemotioncontrol
leversinneutralandshuttingoffthe
enginebeforeperforminganyworkon
thehydraulicsystem.
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.
1-513747
65-2690
98-4361
98-5954
103-8425
103-8444
103-8451
103-8495
103-8611
11
Safety
103-9034
103-9724
109-4273
109-4638
109-7318
116-0404
12
Safety
116-1175
117–2718
MoldedinLHConsole
MoldedintoFrontofHopper
13
Specications
Specications
ModelNumbers
SerialNos:850,000andHigher
NAV20KC;NA V27KC
Systems
Engine
•EngineSpecications:SeeyourEngineOwner’s
Manual
•RPM:FullSpeed:3600±50RPM(NoLoad)
Idle:1500RPM
FuelSystem
•Capacity:7.5gal.(28L)
•TypeofFuel:Regularunleadedgasoline,87
octaneorhigher;containingnomorethan10%
methanolorethanol.
•FuelFilter:In-line30MicronKohlerP/N
2405010.
•FuelShut-OffValve:1/4turnincrementsin-line
valvebyfuellter.
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.
14
Specications
•HydraulicOilType:UseExmarkPremiumHydro
oil.
•HydraulicOilCapacity:4.0qt.(3.8L)
•HydraulicFilter:Replaceablecartridgetype.
–Summeruseabove32°F(0°C):
P/N109-0071:25microns,10psibypass
–Winterusebelow32°F(0°C):
P/N1-523541:40microns,18psibypass
•Speeds:
–0-7.0mph(11.3km/hr)forward.
–0-5.5mph(8.6km/hr)reverse.
•Drivewheelreleasevalvesallowmachinetobe
movedwhenengineisnotrunning.
Tires&Wheels
Drive
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“A ”sectionhexagonbeltwithspring
tensionedidlertojackshaftandblower.
–Heavy-dutycastiron,spiralbevelgearboxis
naldrivetoblades.
•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:
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
850lb(386kg)1145lb(519kg)
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
Locatedinfuellinebyfueltankandfuellter
(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.
Rotatingthisknoballowsnetuningadjustmentsso
thatthemachinetracksstraightwiththedrivelevers
inthefullforwardposition.
Rununitat3/4speedforatleast5minutesto
bringhydraulicoiluptooperatingtemperature.
Stopmachineandwaitforallmovingpartstostop.
Engageparkbrake.Tiltseatforwardtogainaccess
tothetrackingknob.Rotatetheknobtowardsthe
righttosteerrightandrotatetowardstheleftto
steerleft.Adjustin1/8turnincrementsuntilthe
machinetracksstraight.Checkthatthemachine
doesnotcreepwheninneutralwiththeparkbrakes
disengaged.
Important:DoNotrotatetheknobtoofar,as
thismaycausethemachinetocreepinneutral.
RefertotheMotionControlLinkageAdjustment
sectioninMaintenance.
PTOEngagementLever
Locatedimmediatelyleftoftheleftconsole.
Levermustbemoveduptothe“ROTATE”position
toengagethePTOandblowerdrives.Leverismoved
downtothe“STOP”positiontostopthedrives.
EngineOilTemperatureLightand
Buzzer
Locatedontherightconsole.
Theengineoiltemperaturelightmonitorsthe
temperatureoftheengineoil.Anilluminatedengine
oiltemperaturelightandintermittentbuzzingsound
signalstheengineisoverheating.
Pre-Start
Fillfueltanks.Forbestresultsuseonlyclean,fresh
regulargradeunleadedgasolinewithanoctanerating
of87orhigher.
Important:Neverusemethanol,gasoline
containingmethanol,gasoholcontainingmore
than10%ethanol,premiumgasoline,orwhite
gasbecausethefuelsystemcouldbedamaged.
DoNotaddoiltogasoline.
DoNotoverllfueltank.Fillthefueltanktothe
bottomofthellerneck.Theemptyspaceinthe
tankallowsgasolinetoexpand.Overllingmayresult
infuelleakageordamagetotheengineoremission
system(ifequipped).
Makesureyouunderstandthecontrols,their
locations,theirfunctions,andtheirsafety
requirements.
RefertotheMaintenancesectionandperformallthe
necessaryinspectionandmaintenancesteps.
OperatingInstructions
OpentheFuelShut-OffValve
Thefuelshut-offvalveislocatedontherightsideof
unitinfuellinenexttothefuellter.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.
18
Operation
6.Turnignitionswitchtothe“START”position.
Releasetheswitchassoonastheenginestarts.
Important:DoNotcranktheengine
continuouslyformorethantensecondsata
time.Iftheenginedoesnotstart,allowa60
secondcool-downperiodbetweenstarting
attempts.Failuretofollowtheseguidelines
canburnoutthestartermotor.
7.Ifthechokeisinthe“ON”position,gradually
returnchoketothe“OFF”positionastheengine
warmsup.
EngagingthePTO
DANGER
Therotatingbladesunderthemowerdeck
aredangerous.Bladecontactcancause
seriousinjuryorkillyou.
DoNotputhandsorfeetunderthemower
ormowerdeckwhenthebladesareengaged.
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.Dumphopperbyrmlygraspingoneofthe
hopperhandlesoneithersideoftheunitand
liftingthehopper.
ClearingHopperScreen
Screenmayberemovedbyrmlyliftingscreen
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,reectivemarkings,ora
slowmovingvehicleemblem.Drivingona
streetorroadwaywithoutsuchequipment
isdangerousandcanleadtoaccidents
causingpersonalinjury.Drivingonastreet
orroadwaywithoutsuchequipmentmayalso
beaviolationofStatelawsandtheoperator
maybesubjecttotrafcticketsand/ornes.
DoNotdriveaunitonapublicstreetor
roadway.
20
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